FCCU Reformer-Electrolyzer-Purifier for CO2 Capture
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Solution Overview
Problem
Current methods for removing carbon dioxide from fluidized catalytic cracking unit (FCCU) flue gas are inefficient due to low CO2 purity, requiring high energy expenditure and reducing refinery production capabilities.
Innovation Solution
A system integrating a reformer-electrolyzer-purifier assembly with a carbon capture assembly, which produces a cathode exhaust stream with high CO2 purity, allowing for efficient separation and production of a gas stream comprising at least 90 mole % CO2, utilizing a molten carbonate electrolysis cell to regenerate catalysts and minimize excess oxygen output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If current methods are used to remove carbon dioxide from FCCU flue gas, then carbon dioxide can be captured, but high energy expenditure is required due to low CO2 purity in the flue gas
Solution Approach 1:
The patent combines the catalyst regenerator and CO2 capture system into an integrated unit. The regenerator uses CO2 from the flue gas as the gasifying agent instead of air, eliminating the need for separate CO2 separation equipment and reducing energy consumption while maintaining high CO2 purity in the output stream
Solution Approach 2:
The catalyst regenerator serves dual functions: it regenerates spent catalyst by gasifying deposited carbon and simultaneously produces high-purity CO2 stream. This multi-functionality eliminates the need for separate CO2 capture equipment and reduces overall energy expenditure
2Loss of energy
If current methods are used to remove carbon dioxide from FCCU flue gas, then carbon dioxide can be captured, but production capabilities of the refinery are reduced
Solution Approach 1:
By merging the catalyst regenerator and CO2 capture functions into a single integrated system, the patent eliminates equipment idle time and process interruptions associated with separate systems, thereby maintaining refinery production capabilities while capturing CO2 with reduced energy expenditure
3Quantity of substance
If air is used to regenerate catalyst in FCCU, then catalyst can be regenerated, but nitrogen is introduced into the flue gas reducing CO2 purity
Solution Approach 1:
The patent changes the composition parameter of the gasifying agent from air (containing nitrogen) to CO2-rich flue gas. This parameter change eliminates nitrogen contamination in the regenerator output while maintaining effective catalyst regeneration through the gasification of deposited carbon
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 system achieves a highly efficient and cost-effective capture of carbon dioxide, producing a highly pure CO2 flue gas while co-producing a pure hydrogen stream, enhancing refinery efficiency and reducing energy consumption.
Implementation Method 1
utilizing a molten carbonate electrolysis cell to regenerate catalysts and minimize excess oxygen output
Implementation Method 2
The carbon capture assembly is configured to condense and cool the flue gas and to remove the carbon dioxide contained in the flue gas
Implementation Method 3
The cathode section of the reformer-electrolyzer-purifier assembly is configured to produce a cathode exhaust stream comprising oxygen and carbon dioxide
Data Source
AI summary
A fluidized catalytic cracking unit system includes: a fluidized catalytic cracking unit assembly including a first catalyst regenerator and a cracking unit, the cracking unit configured to output spent catalyst to the first catalyst regenerator; and a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section.