Integrated Electrolysis and Gasification for Hydrogen Production
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Solution Overview
Problem
Current methods for hydrogen production from integrated water electrolysis cells and hydrocarbon gasification reactors are inefficient and costly, with high energy consumption and significant capital investment, limiting their application in refining processes.
Innovation Solution
An integrated process combining water electrolysis and hydrocarbon gasification using a membrane wall gasification reactor, where water is electrolyzed to produce oxygen, which is then used in the gasification reactor to produce hydrogen, with the generated electricity powering the electrolysis cell and increasing the hydrogen yield through a water-gas shift reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air separation units are used to provide oxygen for gasification, then oxygen supply is reliable, but capital investment and operating costs increase significantly
Solution Approach 1:
The patent extracts the oxygen production function from the conventional air separation unit and relocates it to an electrolysis cell that uses renewable electricity to split water into hydrogen and oxygen. This eliminates the need for expensive air separation equipment while providing reliable oxygen supply to the gasification reactor.
Solution Approach 2:
The electrolysis cell produces oxygen on-demand within the integrated system, serving the gasification reactor's oxygen needs without requiring external air separation infrastructure. The system generates its own oxygen from water, making it self-sufficient and eliminating capital-intensive external equipment.
2Productivity
If high temperatures are used in gasification reactor, then conversion efficiency improves, but energy consumption and equipment requirements increase
Solution Approach 1:
The patent merges the electrolysis cell and gasification reactor into an integrated system where the oxygen produced by electrolysis is directly fed to the gasification reactor. This combination enables efficient hydrocarbon conversion at optimized temperatures while using renewable electricity to drive the endothermic gasification reactions, reducing overall energy consumption.
Solution Approach 2:
The system changes the energy input parameter from conventional fossil fuel-based heating to renewable electricity-driven electrolysis. This allows precise control of oxygen supply to the gasification reactor, optimizing the temperature and conversion efficiency while reducing greenhouse gas emissions and energy costs.
3Strength
If refractory liners are used in gasification reactor, then reactor protection is adequate, but maintenance costs and downtime increase
Solution Approach 1:
The patent removes the refractory liner component from the gasification reactor design. Instead of using protective refractory coatings that require periodic replacement, the reactor operates without them, reducing maintenance requirements and downtime while the integrated electrolysis-gasification system maintains optimal operating conditions.
4Productivity
If electrolysis cell is powered by external electricity source, then hydrogen production is consistent, but operating costs are high
Solution Approach 1:
The integrated system generates its own oxygen through water electrolysis powered by renewable electricity, and uses the oxygen to drive hydrocarbon gasification that produces hydrogen. The system is self-sufficient, producing both oxygen and hydrogen without requiring external electricity purchases or fossil fuel inputs, thereby reducing operating costs while maintaining consistent production.
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 reduces energy costs, eliminates the need for costly air separation units, and enhances hydrogen production efficiency, making it economically viable for refining applications.
Implementation Method 1
introducing water into an electrolysis cell and operating the electrolysis cell with an external source of electricity to produce oxygen and hydrogen
Implementation Method 2
The gasification process uses partial oxidation to convert carbonaceous materials, such as coal, petroleum, biofuel, biomass and other hydrocarbon-containing materials with oxygen at high temperature
Implementation Method 3
Hot syngas 106 is cooled with boiler feed water 156 to produce cooled syngas 114 and steam
Implementation Method 4
another portion of the steam (steam 116) is consumed in the heat recovery steam generator 150
Data Source
AI summary
An integrated process for hydrogen gas production includes:a. operating a water electrolysis cell with an external source of electricity to produce oxygen and hydrogen;b. optionally operating an air separation unit to produce additional oxygen for the process;c. introducing a hydrocarbon feedstock into a membrane wall gasification reactor with an ash-forming material and steam, and oxygen from the electrolysis cell and, optionally, oxygen from the air separation unit to produce hot raw synthesis gas;d. passing the hot raw synthesis gas from the gasification reactor to a steam-generating heat exchanger to produce steam and a cooled raw synthesis gas;e. introducing the steam generated in the heat exchanger into a turbine to produce electricity to operate the electrolysis cell; andf. recovering the hydrogen gas from the water electrolysis cell and, optionally, subjecting the synthesis gas to a water-gas shift reaction to increase the hydrogen content and recovering the hydrogen.