Hydrocarbon Synthesis Gas CO2 Dissolution Process
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Solution Overview
Problem
Existing processes for producing gasoline from synthesis gas require separate removal of carbon dioxide, which is inefficient and costly, and do not effectively utilize CO2 present in the synthesis gas feed stream.
Innovation Solution
A process that maintains carbon dioxide in the synthesis gas feed stream and dissolves it in the liquid phase during oxygenate synthesis, allowing for easier separation and subsequent sequestration without the need for upstream CO2 removal, using catalysts like copper, zinc, and zeolites to convert synthesis gas into gasoline products at high pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 is removed from synthesis gas feed stream and intermediate oxygenate synthesis product, then process efficiency is improved, but device complexity and operational cost increase due to requirement of separate CO2 removal systems
Solution Approach 1:
The invention extracts CO2 from the synthesis gas feed stream and intermediate oxygenate synthesis product by dissolving it in the liquid phase under pressure. This extraction is achieved by maintaining CO2 in the liquid phase during oxygenate synthesis, allowing for easier separation and subsequent sequestration without upstream CO2 removal equipment.
Solution Approach 2:
The invention changes the pressure parameter to maintain CO2 in the liquid phase during oxygenate synthesis. By operating at elevated pressures (at least 3 MPa), CO2 remains dissolved in the liquid phase rather than forming a separate gas phase, which simplifies the overall process by eliminating the need for separate CO2 removal systems while maintaining process efficiency.
2Use of energy by moving object
If CO2 is removed from synthesis gas and oxygenate product, then energy consumption is reduced, but additional equipment and operational steps are required
Solution Approach 1:
The invention merges the CO2 dissolution step with the oxygenate synthesis process by maintaining CO2 in the liquid phase during synthesis. This combination eliminates the need for separate CO2 removal equipment and operational steps, thereby reducing both energy consumption and equipment requirements while achieving effective CO2 management.
3Productivity
If CO2 is separated from gaseous phase, then separation efficiency is improved, but energy consumption increases due to compression requirements
Solution Approach 1:
The invention changes the phase state of CO2 from gaseous to liquid by operating at elevated pressures (at least 3 MPa). This parameter change allows CO2 to be separated from the gaseous phase more efficiently while avoiding the energy-intensive compression step that would otherwise be required to achieve high-pressure CO2 sequestration.
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 enables efficient production of gasoline with reduced energy consumption and CO2 recycling at elevated pressure, facilitating sequestration without additional compression, and enhances conversion efficiency by leveraging CO-rich conditions.
Implementation Method 1
cooling the reaction mixture to obtain a liquid phase with the amounts of methanol, dimethyl ether and water and simultaneously dissolving carbon dioxide in the liquid phase
Implementation Method 2
reacting at least part of the synthesis gas to an oxygenate mixture comprising methanol and dimethyl ether in presence of one or more catalysts which together catalyse a reaction of hydrogen and carbon monoxide to oxygenates
Implementation Method 3
evaporating and reacting the liquid phase being withdrawn from step (d) in presence of a catalyst being active in the conversion of oxygenates to higher hydrocarbons
Implementation Method 4
conversion of synthesis gas to oxygenates involves heat development in that both the conversion of synthesis gas to oxygenate and the further conversion of oxygenate to gasoline product are exothermic processes
Data Source
AI summary
A process for the preparation of hydrocarbon products comprising the steps of a) providing a synthesis gas comprising hydrogen, carbon monoxide and carbon dioxide; (b) reacting at least part of the synthesis gas to an oxygenate mixture comprising methanol and dimethyl ether in presence of one or more catalysts which together catalyse a reaction of hydrogen and carbon monoxide to oxygenates at a pressure of at least 3 MPa; (c) withdrawing from step (b) a reaction mixture comprising amounts of methanol, dimethyl ether, carbon dioxide and water together with unreacted synthesis gas and cooling the reaction mixture to obtain a liquid phase with the amounts of methanol, dimethyl ether and water and simultaneously dissolving carbon dioxide in the liquid phase; (d) separating the carbon dioxide containing liquid phase from a remaining gaseous phase comprising hydrogen and carbon monoxide; (e) evaporating and reacting the liquid phase being withdrawn from step (d) in presence of a catalyst being active in the conversion of oxygenates to higher hydrocarbons and a tail gas comprising carbon dioxide; (f) separating tail gas from a liquid phase with the higher hydrocarbons; and wherein pressure employed in step (c) to step (f) is substantially the same as employed in step (b).