GTL Co-Processing Renewable Fuels Hydrogen Integration
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Solution Overview
Problem
The processing of renewable feedstocks into fuels and chemicals is hindered by the high demand for hydrogen and the complexity of integrating these materials into Gas to Liquids (GTL) processes, particularly due to the limited availability and high infrastructure costs associated with hydrogen production and the contamination of synthesis gas from biomass sources.
Innovation Solution
The integration of renewable feedstocks with a GTL process, leveraging excess hydrogen from natural gas reforming, recycling waste products to enhance synthesis gas production, and utilizing existing GTL infrastructure to reduce carbon footprint and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If renewable feedstocks are processed into fuels and chemicals, then renewable product output increases, but hydrogen demand increases significantly
Solution Approach 1:
The patent combines renewable feedstock processing with natural gas reforming in a single integrated system. The reforming unit produces synthesis gas (CO and H2) that serves dual purposes: providing hydrogen for renewable feedstock conversion and generating CO that can be converted to additional hydrocarbons via Fischer-Tropsch synthesis, thereby reducing overall hydrogen demand from external sources
Solution Approach 2:
The reforming unit serves multiple functions: (1) producing hydrogen for renewable feedstock hydroprocessing, (2) generating synthesis gas for Fischer-Tropsch conversion, and (3) providing a source of CO that can be adjusted to match H2:CO ratios required by downstream processes, eliminating the need for separate hydrogen production facilities
2Quantity of substance
If biomass sources are used to produce synthesis gas, then renewable feedstock availability increases, but synthesis gas contamination occurs
Solution Approach 1:
The patent introduces a gas cleaning section as an intermediary between the reforming unit and downstream processing. This section removes contaminants (tar, particulates, sulfur compounds) from the synthesis gas produced by natural gas reforming, ensuring the gas is suitable for Fischer-Tropsch catalysts while maintaining high CO and H2 concentrations
Solution Approach 2:
The reforming process operates at controlled temperatures (700-900°C) and pressures to optimize synthesis gas composition while minimizing contaminant formation. The cleaning section further adjusts gas parameters by removing specific contaminants, ensuring the synthesis gas meets the strict requirements of Fischer-Tropsch catalysts
3Ease of manufacture
If GTL infrastructure is utilized for co-processing, then operational costs decrease, but process complexity increases
Solution Approach 1:
The integrated process is divided into distinct functional sections: (1) reforming unit for synthesis gas production, (2) gas cleaning section for contaminant removal, (3) Fischer-Tropsch conversion unit for hydrocarbon synthesis, and (4) hydroprocessing unit for renewable feedstock conversion. This segmentation allows each unit to be optimized independently while sharing common infrastructure, reducing overall complexity compared to fully integrated designs
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 efficiently utilizes hydrogen and infrastructure to increase renewable product output, achieving a reduced CO2 footprint and enhanced economic viability by recycling waste products and blending renewable and natural gas-derived hydrocarbons, potentially increasing renewable content in final products up to 80%.
Implementation Method 1
natural gas is reacted with steam and/or oxygen to produce synthesis gas comprising carbon monoxide and hydrogen. This is a high temperature reaction involving a complex series of reforming and combustion reactions
Implementation Method 2
The second step in the GTL process is conversion of the synthesis gas to hydrocarbon products. This is typically a Fischer Tropsch reaction carried out over an iron based or cobalt based catalyst
Implementation Method 3
These same renewable feedstocks can be converted to high quality fuels by processing with hydrogen over a catalyst
Data Source
AI summary
A gas to liquids process with a reduced CO2 footprint to convert natural gas and a renewable feed stock material into fuels or chemicals. In one non-limiting embodiment of the invention, a natural gas feed is converted into synthesis gas containing hydrogen and carbon monoxide. A minor portion of the hydrogen is thereafter extracted from the synthesis gas. The synthesis gas is converted to hydrocarbons in a Fischer Tropsch reaction. The Fischer Tropsch hydrocarbon product and a renewable feedstock are hydro processed with the extracted hydrogen in order to produce fuels and/or chemicals. Waste products from the renewable feed are recycled to produce additional synthesis gas for the Fischer Tropsch reaction.