Electrolytic Oxygen-Hydrogen Oxidant for Low-Soot Acetylene
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Solution Overview
Problem
Existing acetylene production processes through partial oxidation of hydrocarbons face challenges with high soot formation, reduced yield, and high energy consumption due to the use of conventional oxygen, which is environmentally unfriendly and contributes significantly to the product's carbon footprint.
Innovation Solution
A process using an oxidizing agent comprising O2 and H2, preferably obtained through electrolysis, particularly from renewable energy sources, to reduce soot formation and enhance acetylene yield while minimizing energy and carbon emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional oxygen is used as oxidizing agent in partial oxidation of hydrocarbons, then the process can proceed with established technology, but the product carbon footprint increases significantly and soot formation is high
Solution Approach 1:
The patent changes the compositional parameters of the oxidizing agent from pure conventional oxygen to a mixture containing oxygen (20-80 vol%), hydrogen (10-50 vol%), and water vapor (10-50 vol%). This parameter change reduces the carbon footprint by utilizing hydrogen as a cleaner fuel component while maintaining process feasibility through the established partial oxidation mechanism.
Solution Approach 2:
The oxidizing agent is formulated as a composite gas mixture combining oxygen, hydrogen, and water vapor in specific ratios. This composite approach allows the system to benefit from oxygen's oxidizing power while hydrogen contributes to cleaner combustion and water vapor provides thermal management, collectively reducing soot formation and carbon footprint.
2Object-generated harmful factors
If higher oxygen ratio is used to reduce soot formation, then soot volume decreases and emission standards are met, but the yield of acetylene value product is reduced
Solution Approach 1:
The patent optimizes the oxygen ratio λ to a specific range (0.25 < λ ≤ 0.31) and adjusts the oxidizing agent composition to include hydrogen and water vapor. This parameter optimization reduces soot formation while maintaining acetylene yield by balancing oxidation intensity with fuel efficiency, where hydrogen contributes to the reaction without producing soot.
Solution Approach 2:
The patent applies different functional components locally within the oxidizing agent: oxygen provides the necessary oxidation for acetylene formation, hydrogen provides additional heat and reduces soot precursors, and water vapor controls temperature and suppresses soot. This local quality differentiation within the gas mixture allows simultaneous reduction of soot and maintenance of yield.
3Object-affected harmful factors
If water electrolysis is used to produce oxygen, then the carbon footprint is reduced, but the device complexity and energy consumption increase
Solution Approach 1:
The water electrolysis unit is integrated directly into the partial oxidation process, where the produced oxygen and hydrogen are immediately utilized as the oxidizing agent. This self-service approach eliminates the need for separate oxygen storage and handling systems, reducing overall device complexity despite adding electrolysis equipment.
Solution Approach 2:
The patent merges the water electrolysis function with the oxidizing agent delivery system, combining what would traditionally be separate processes (electrolysis and partial oxidation) into an integrated system. The electrolysis unit feeds directly into the reaction system, eliminating intermediate storage and reducing the number of separate equipment components.
4Productivity
If electrolysis oxygen containing hydrogen is used, then soot formation is reduced and acetylene yield is enhanced, but the risk of explosive mixtures increases
Solution Approach 1:
The patent specifies precise compositional parameters for the oxidizing agent: oxygen (20-80 vol%), hydrogen (10-50 vol%), and water vapor (10-50 vol%). These parameter ranges are optimized to maintain the hydrogen-to-oxygen ratio below explosive thresholds while ensuring sufficient hydrogen content to reduce soot and enhance acetylene yield. The controlled composition prevents dangerous mixture formation.
Solution Approach 2:
Water vapor acts as an intermediary component in the oxidizing agent mixture, serving multiple safety and performance functions. It dilutes the hydrogen-oxygen mixture to prevent explosive conditions, provides thermal management to control reaction temperature, and contributes to the reduction of soot precursors. This intermediary role of water vapor enables the use of hydrogen-rich mixtures safely.
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
The process achieves a low total cradle-to-gate product carbon footprint of <1.1 kg CO2e/kg acetylene and synthesis gas, with improved acetylene yield and reduced soot production, utilizing surplus oxygen from renewable energy-based water electrolysis.
Implementation Method 1
the oxidizing agent is obtained at least in part by water splitting, preferably by electrolysis
Implementation Method 2
Igniting the mixture of the hydrocarbons and the oxidizing agent in a burner, whereby the partial oxidation of the hydrocarbons takes place
Implementation Method 3
nozzles are used to supply an aqueous quench medium to the cracking gas, which is cooled rapidly to about 80-130°C
Data Source
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AI summary
A process for preparing acetylene and/or synthesis gas by partial oxidation of hydrocarbons with an oxidizing agent, wherein the oxidizing agent comprises O2 and H2, wherein the oxidizing agent is obtained at least in part by water splitting, preferably by electrolysis, the water splitting, preferably the electrolysis, preferably using energy generated at least in part from non-fossil resources, a cracking gas stream obtainable by the process according to the present invention, acetylene obtainable by the process according to the present invention, acetylene having a low total cradle to gate product carbon footprint, synthesis gas obtainable by the process according to the present invention, synthesis gas comprising hydrogen, CO, CO2 and CH4, wherein the separated synthesis gas stream has a δ18O value of < 22 %o, referred to the international standard VSMOW ((Vienna- Standard- Mean-Ocean- Water)), the use of an oxidizing agent comprising O2 and H2 for the preparation of acetylene and synthesis gas, the use of the inventive acetylene or the acetylene obtained by the inventive process for the preparation of butynediol, butanediol, butenediol, polybutylene terephthalate (PBT), polybutylene adipate terephthalate (PBAT), tetrahydrofurane (THF), polytetrahydrofurane (polyTHF), polyester-based thermoplastic polyurethanes (TPUs), polyether-based TPUs, gamma-butyrolactone, pyrrolidine, vinylpyrrolidone, polyvinylpyrrolidone, N-methylpyrrolidone, vinyl ether, polyvinyl ether, terpenes and downstream products thereof, and in welding processes and cutting of metals; a process for preparing 1 ,4-butanediol wherein at least in part the inventive acetylene or the acetylene obtained by the inventive process is employed; the use of the inventive synthesis gas and the synthesis gas obtained according to the process of the present invention for the preparation of methanol, fuel applications, formaldehyde, acetic acid, olefins, sodium methylate, methylation products, dimethylterephthalate, methylamine, methyl mercaptane and downstream products; a process for preparing methanol from a synthesis gas wherein the synthesis gas is at least in part the synthesis gas the inventive synthesis gas or the synthesis gas obtained by the inventive process; and a process for preparing formaldehyde from a synthesis gas comprising the oxidation of the methanol obtained in the inventive process to formaldehyde with oxygen, air or a mixture thereof in the presence of a catalyst.