Electrically Heated Structured Catalyst for On-Demand Syngas
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Solution Overview
Problem
Small-scale synthesis gas production is challenging due to energy-intensive reactions and the toxicity of carbon monoxide, making storage difficult and posing safety risks, while there is a need for on-demand production using a simple setup with minimal operator input and easily storable reactants.
Innovation Solution
A reactor system utilizing an electrically heated structured catalyst with a macroscopic conductive material and catalytically active material, allowing for rapid temperature control to facilitate reverse water gas shift and methanation reactions, enabling on-demand synthesis gas production without carbon formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large chemical plants are used for synthesis gas production, then production capacity is sufficient, but plant size and complexity increase
Solution Approach 1:
The patent divides the synthesis gas production process into modular reactor units that can be operated independently. Each reactor contains a structured catalyst with electric heating elements, creating a self-contained module that can be scaled by replication rather than requiring a single large complex plant
Solution Approach 2:
The patent replaces traditional thermal heating systems with electric heating elements integrated into the catalyst structure. This substitution enables precise temperature control and rapid startup/shutdown, allowing small-scale on-demand production without the infrastructure of large chemical plants
2Stability of the object's composition
If synthesis gas is produced and stored, then supply stability is improved, but safety risks increase due to CO toxicity
Solution Approach 1:
The patent implements dynamic on-demand production capability where synthesis gas is produced only when needed through electrically controlled heating of the catalyst. This eliminates the need for large storage facilities while maintaining supply stability through controlled production rates that match demand
Solution Approach 2:
The patent extracts the essential function of synthesis gas supply from large-scale storage systems and replaces it with distributed on-demand production units. This removes the harmful association between large quantities of stored CO and safety risks while preserving the benefit of reliable supply
3Use of energy by moving object
If traditional heating methods are used for the reactor, then energy supply is sufficient, but temperature control precision and response time are insufficient
Solution Approach 1:
The patent substitutes traditional external thermal heating with electric heating elements directly integrated into the catalyst structure. This provides superior temperature control precision and rapid response time because electrical heating can be modulated instantly and localized exactly where needed within the catalyst pores
Solution Approach 2:
The structured catalyst contains self-contained heating elements within its macroscopic structure, allowing each catalyst unit to regulate its own temperature independently. This self-service capability enables precise temperature control without requiring complex external heating systems or infrastructure
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 enables efficient, on-demand synthesis gas production in compact plants with minimal storage needs, reducing handling risks and utilizing renewable energy sources, while maintaining high CO yield and low methane concentration.
Implementation Method 1
electrical power supply is dimensioned to heat at least part of said structured catalyst to a temperature of at least 500°C by passing an electrical current through said macroscopic structure
Implementation Method 2
a catalytically active material capable of catalysing both the reverse water gas shift reaction and a methanation reaction
Implementation Method 3
a heat insulation layer between said structured catalyst and said pressure shell
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A reactor system and a process for carrying out reverse water gas shift reaction of a feedstock comprising CO2 and H2 to a first product gas comprising CO are provided, where a methanation reaction take place in parallel to the reverse water gas shift reaction, and where the heat for the endothermic reverse water gas shift reaction is provided by resistance heating.