Electrically Heated RWGS Reactor for On-Demand CO Production
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Solution Overview
Problem
Small-scale synthesis gas production is challenging due to energy-intensive reactions and the toxicity of carbon monoxide, making storage difficult and posing safety risks, while there is a need for on-demand production using a simple setup with minimal operator input and easily storable reactants, particularly for processes like the reverse water gas shift reaction to capture and utilize carbon dioxide.
Innovation Solution
A reactor system using a structured catalyst with electrically conductive material and catalytically active material, heated by electrical conductors to facilitate both reverse water gas shift and methanation reactions, allowing for rapid temperature increase from 200°C to over 800°C, enabling efficient conversion of CO2 and H2 to CO with minimal carbon formation and methane concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional large-scale chemical plants are used for synthesis gas production, then production capacity is sufficient, but the setup becomes complex and energy consumption increases
Solution Approach 1:
The patent divides the synthesis gas production process into modular reactor units that can be operated independently. Each reactor contains structured catalyst elements that can be electrically heated separately, allowing small-scale distributed production rather than requiring one large centralized plant. This segmentation enables production capacity to be achieved through parallel operation of multiple simple units rather than a single complex facility.
Solution Approach 2:
The patent replaces conventional thermal heating systems with electrical heating of structured catalyst elements. Instead of using large-scale furnaces or heat exchangers that require complex mechanical systems, the invention uses direct electrical resistance heating through conductive catalyst supports (such as FeCrAl or SiC). This substitution dramatically simplifies the plant setup while maintaining production capacity.
2Adaptability or versatility
If synthesis gas is produced and stored for later use, then on-demand supply is enabled, but storage becomes difficult due to carbon monoxide toxicity and safety risks increase
Solution Approach 1:
The patent implements preliminary action by pre-heating the structured catalyst elements to reaction temperature using electrical heating before feedstock is introduced. This allows the reactor to be quickly activated when synthesis gas is needed, enabling on-demand production without requiring storage. The catalyst elements are maintained in a ready state, so production can start immediately when required.
Solution Approach 2:
The patent rushes through the heating-up phase by using direct electrical heating of catalyst elements, which can reach operating temperature much faster than conventional thermal systems. This rapid heating capability allows the system to quickly transition from standby to full production, eliminating the need for storage and reducing the time synthesis gas is present in the system, thereby minimizing safety risks.
3Temperature
If conventional thermal heating is used for endothermic reactions, then reaction temperature is achieved, but energy consumption increases and heating speed decreases
Solution Approach 1:
The patent substitutes conventional indirect thermal heating with direct electrical resistance heating of the catalyst elements. The conductive support materials (FeCrAl, SiC) serve as both structural support and heating elements. When electrical current passes through these materials, they generate heat directly at the catalyst sites, eliminating the need for external furnaces, heat exchangers, and complex thermal management systems. This dramatically reduces energy consumption and heating time.
Solution Approach 2:
The structured catalyst elements serve themselves by being both the catalytic medium and the heating element. The conductive support materials generate their own heat through electrical resistance, eliminating the need for separate heating systems. This self-service approach reduces overall energy consumption by eliminating heat transfer losses and enabling direct heating at the reaction sites.
4Productivity
If conventional catalysts are used for reverse water gas shift reaction, then CO production is achieved, but carbon formation and methane concentration increase
Solution Approach 1:
The patent uses composite structured catalyst elements combining conductive support materials (FeCrAl or SiC) with catalytically active materials. The FeCrAl forms a protective Al2O3 layer at high temperatures that serves as a support for the washcoat containing catalytically active material. This composite structure provides both the electrical heating capability and the catalytic function, while the controlled temperature profile from electrical heating prevents excessive carbon formation and methane generation by maintaining optimal reaction conditions.
Solution Approach 2:
The patent changes the temperature parameter through precise electrical heating control, maintaining the catalyst at optimal temperatures for the reverse water gas shift reaction (typically 700-1300°C). By controlling the temperature profile through electrical power adjustment, the system achieves high CO production rates while preventing the temperature excursions that lead to excessive carbon formation and methane generation. The ability to rapidly adjust temperature allows operation at the optimal point on the reaction rate vs. side reaction suppression curve.
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
Enables on-demand synthesis gas production in compact, safe, and efficient chemical plants, reducing the need for gas storage and handling risks, and utilizing renewable energy sources effectively.
Implementation Method 1
at least two conductors electrically connected to said structured catalyst and to an electrical power supply placed outside said pressure shell, wherein said electrical power supply is dimensioned to heat at least part of said structured catalyst to a temperature of at least 500°C by passing an electrical current through said macroscopic structure
Implementation Method 2
a structured catalyst comprising a macroscopic structure of an electrically conductive material and a catalytically active material capable of catalysing both the reverse water gas shift reaction and a methanation reaction
Implementation Method 3
a heat insulation layer between said structured catalyst and said pressure shell
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A reactor system and a process for carrying out reverse water gas shift reaction of a feedstock comprising C02 and H2 to a first product gas comprising CO are provided, where a methanation reaction take place in parallel to the reverse water gas shift reaction, and where the heat for the endothermic reverse water gas shift reaction is provided by resistance heating. Ø