Dry Reforming Catalyst CO2 Feed Control
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Solution Overview
Problem
The challenge in dry reforming of methane with carbon dioxide is the formation of solid carbon (coke) in the dry reformer reactor, which reduces catalyst effectiveness and can lead to reactor blockage, especially at higher pressures and lower temperatures.
Innovation Solution
Increasing the concentration of carbon dioxide in the feed to at least 66 volume percent to inhibit coke formation, and using a control system to dynamically adjust the CO2 flow rate in response to coke formation, while operating at elevated pressures (at least 20 bar) and lower temperatures (less than 900°C) to suppress solid-carbon formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the concentration of carbon dioxide in the feed is increased to at least 66 vol %, then solid-carbon formation is inhibited and catalyst effectiveness is maintained, but the complexity of feed composition control increases
Solution Approach 1:
The control system monitors operating conditions and dynamically adjusts the CO2 flow rate in response to detected coke formation, maintaining optimal CO2 concentration (at least 66 vol %) to prevent solid-carbon formation while adapting to changing process conditions
Solution Approach 2:
The system changes the concentration parameter of CO2 in the feed to at least 66 vol % and maintains this parameter through dynamic control, transforming the feed composition to suppress coke formation while managing the complexity through automated parameter adjustment
2Productivity
If the operating pressure is increased to at least 20 bar, then syngas production efficiency is improved, but solid-carbon formation is promoted
Solution Approach 1:
The system operates at elevated pressure (at least 20 bar) to improve syngas production efficiency while simultaneously adjusting the CO2 concentration parameter to at least 66 vol %, creating a new operating regime where high productivity is achieved without excessive coke formation
Solution Approach 2:
The control system detects early signs of coke formation and preemptively increases CO2 flow rate to suppress further solid-carbon formation, preventing catalyst deactivation before it significantly impacts productivity
3Use of energy by moving object
If the operating temperature is decreased to less than 900° C., then energy consumption is reduced, but solid-carbon formation is promoted
Solution Approach 1:
The system operates at lower temperature (less than 900° C.) to reduce energy consumption while compensating for the increased tendency toward coke formation by increasing CO2 concentration to at least 66 vol %, creating a new balance where energy efficiency is improved without sacrificing catalyst performance
Solution Approach 2:
CO2 acts as an intermediary substance that suppresses solid-carbon formation at lower operating temperatures, allowing the system to operate energy-efficiently while maintaining catalyst effectiveness through the mediating effect of high CO2 concentration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for stable operation of the dry reformer and reforming catalyst at higher pressures without significant coke formation, maintaining catalyst effectiveness and preventing reactor blockage, while converting methane and carbon dioxide into syngas efficiently.
Implementation Method 1
converting the methane and the carbon dioxide (e.g., reforming the methane with the carbon dioxide) via reforming catalyst in the dry reformer vessel into syngas
Data Source
AI summary
A system and method for dry reforming methane at elevated pressure in a dry reformer vessel, and increasing concentration of carbon dioxide in the feed to the dry reformer vessel in response to solid-carbon formation in the dry reformer vessel.