Integrated Hydrocracking and CO2 Hydrogenation for Methanol Production

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Solution Overview

Problem

Traditionally, waste hydrogen from refining processes could not be economically utilized for the hydrogenation of CO2 to produce methanol due to its low partial pressure, making it impractical to separate from other waste gases.

Innovation Solution

A process and system that generate hydrogen gas and carbon dioxide, hydroprocess a hydrocarbon feedstock to produce hydrocarbon products and waste hydrogen, and then contact the waste hydrogen with carbon dioxide in a hydrogenation unit to produce methanol and product hydrogen gas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If waste hydrogen is used for CO2 hydrogenation to produce methanol, then resource utilization is improved and CO2 emissions are reduced, but the low partial pressure of waste hydrogen makes separation from other waste gases economically infeasible

Engineering Contradiction:

Improvewaste hydrogen utilizationVSAvoidseparation feasibility

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent combines the CO2 hydrogenation unit with the hydroprocessing unit, allowing waste hydrogen to be directly utilized without requiring separate separation infrastructure. The integrated system merges multiple functions (hydroprocessing and CO2 hydrogenation) into a single operational framework, eliminating the need for complex gas separation while achieving waste hydrogen utilization.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydroprocessing unit serves multiple functions: it processes hydrocarbon feedstock to produce desired products while simultaneously generating waste hydrogen that is immediately utilized by the integrated CO2 hydrogenation unit. This multi-functionality allows the system to convert what would be waste into a valuable resource (methanol) without requiring additional separation steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If waste hydrogen is separated from other waste gases for methanol production, then hydrogen utilization is improved, but the separation process becomes economically infeasible due to low partial pressure

Engineering Contradiction:

Improvemethanol productionVSAvoidseparation cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent merges the CO2 hydrogenation function with the hydroprocessing operation, allowing waste hydrogen to be utilized in-situ without requiring separate separation equipment or processes. This integration eliminates the economic barrier of separation while maintaining methanol production capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydroprocessing unit effectively serves itself by providing the hydrogen needed for its own operations and simultaneously generating waste hydrogen that is self-utilized by the integrated CO2 hydrogenation unit. This self-service approach eliminates the need for external separation and purification infrastructure.

Inventive Principle:

Principle #25Self-service

3Productivity

If traditional hydroprocessing is used, then hydrocarbon products are produced, but hydrogen gas is expel as waste stream

Engineering Contradiction:

Improvehydrocarbon product yieldVSAvoidhydrogen waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent converts the harmful waste stream (excess hydrogen) into a beneficial resource by integrating a CO2 hydrogenation unit that uses the waste hydrogen to produce methanol. This transforms what was previously a loss into a valuable product, simultaneously reducing waste and producing additional revenue-generating chemicals.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Instead of discarding the excess hydrogen from hydroprocessing, the system recovers it by feeding it into the CO2 hydrogenation unit. This recovery process converts waste hydrogen into methanol, a valuable chemical product, thereby eliminating the loss of substance while maintaining hydrocarbon production efficiency.

Inventive Principle:

Principle #34Discarding and recovering

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 allows for the economical utilization of waste hydrogen to produce methanol and hydrocarbon products, effectively utilizing a previously wasted resource and reducing CO2 emissions.

Implementation Method 1

contacting the waste hydrogen gas with the carbon dioxide in a hydrogenation unit, thereby producing methanol and product hydrogen gas

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS12331253B2Integrated hydrocracking and carbon dioxide hydrogenation to produce oxygenated and hydrocarbon fuels

Publication Date: 2025.06.17 SAUDI ARABIAN OIL CO

AI summary

In accordance with one or more embodiments of the present disclosure, a process for producing methanol and hydrocarbon products comprises: generating hydrogen gas and carbon dioxide in a hydrogen production unit; hydroprocessing a hydrocarbon feedstock stream using the hydrogen gas, thereby producing hydrocarbon products and waste hydrogen gas; and contacting the waste hydrogen gas with the carbon dioxide in a hydrogenation unit, thereby producing methanol and product hydrogen gas.