Fuel Synthesis Device CH4 Oxidation Recycling
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Solution Overview
Problem
The existing fuel synthesis techniques, such as the FT method and Direct-FT, generate methane (CH4) as a side product with low reactivity, leading to inefficient carbon chain growth and high Global Warming Potential, necessitating effective utilization of CH4 within the fuel synthesis system.
Innovation Solution
A fuel synthesis device that includes a CH4 oxidation catalyst to partially oxidize CH4, using a switching valve controlled by a CH4 density detector to return the produced CO as a feedstock to the fuel synthesis catalyst, thereby enhancing carbon chain growth and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CH4 is circulated in the reaction system to increase carbon chain growth, then the amount of C1-4 hydrocarbon increases, but CH4 has low reactivity and cannot effectively contribute to carbon chain growth
Solution Approach 1:
The patent changes the chemical state of CH4 by introducing oxygen to create a reducing atmosphere, transforming unreactive CH4 into reactive carbon species that can effectively participate in carbon chain growth reactions
Solution Approach 2:
The patent uses carbon black as an intermediary substance that forms under oxygen-limited conditions, serving as a reactive intermediate that facilitates carbon chain growth from CH4 more effectively than direct CH4 reaction
2Object-affected harmful factors
If CH4 is released into the atmosphere to reduce environmental impact, then Global Warming Potential decreases, but CH4 cannot be effectively utilized
Solution Approach 1:
The patent converts the harmful effect of CH4 emissions into a beneficial process by using controlled oxygen introduction to transform CH4 into reactive carbon species that drive fuel synthesis, turning an environmental problem into a resource utilization opportunity
3Loss of substance
If CO is supplied to the reforming reactor to convert CH4, then CH4 utilization improves, but the amount of C in the reforming reactor continues to increase requiring separate C supply to FT synthesis reactor
Solution Approach 1:
The patent merges the reforming reactor and FT synthesis reactor into an integrated system where carbon from CH4 conversion is directly utilized in the FT synthesis zone, eliminating the need for separate carbon supply lines and reducing system complexity
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 device effectively utilizes CH4 as a feedstock to synthesize hydrocarbons of C5+ by partially oxidizing it and recycling the produced CO, thereby improving carbon chain growth and reducing the environmental impact of CH4 within the fuel synthesis system.
Implementation Method 1
a bypass path configured to bypass, and merge downstream of, the return path, and including a CH4 separator to separate the CH4 and a CH4 oxidation catalyst to oxidize the CH4 separated by the CH4 separator
Implementation Method 2
a CH4 oxidation catalyst to oxidize the CH4 separated by the CH4 separator
Implementation Method 3
a fuel synthesis catalyst located downstream of the supplier and configured to chemically react the CO2 gas and the H2 gas to synthesize fuel
Implementation Method 4
The synthesis of hydrocarbon with the FT method is a kind of polymerization reaction in which carbon chain grows through the reaction
Implementation Method 5
a gas-liquid separator arranged downstream of the fuel synthesis catalyst and configured to liquefy the fuel into liquid and separate the liquid from a gas containing the CO2 gas and the H2 gas
Data Source
AI summary
A fuel synthesis device includes: a supplier to supply CO2 and H2 gasses; a fuel synthesis catalyst to chemically react the CO2 and H2 gasses to synthesize fuel; a gas-liquid separator to liquefy the fuel into liquid and separate the liquid from a gas containing unreacted CO2 and H2 gasses, and CH4 gas as a side product; a return path to return the separated gas to a point between the supplier and the fuel synthesis catalyst; a bypass path to bypass, and merge downstream of, the return path, and to include a CH4 separator to separate the CH4 and a CH4 oxidation catalyst to oxidize the CH4; and a switching valve to selectively switch between communication with the return path and communication with the bypass path, wherein whether the switching valve communicates with the return path or bypass path is controlled based on the density of CH4.