Hydrogen Production With Integrated CO2 Capture And Process Heat
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Solution Overview
Problem
Current hydrogen production methods, such as steam methane reforming, generate carbon dioxide as a byproduct that requires costly and inefficient removal processes, reducing overall process efficiency and increasing materials costs.
Innovation Solution
The use of oxy-fuel combustion systems that integrate carbon dioxide capture and recycling, utilizing a CO2 convective reformer (CCR) and oxygen secondary reformer (OSR) to produce hydrogen with enhanced efficiency by using combustion gases for process heat and minimizing the need for separate carbon dioxide removal systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam methane reforming is used to produce hydrogen, then hydrogen is generated, but carbon dioxide is produced as a byproduct requiring costly removal processes
Solution Approach 1:
The patent converts the harmful carbon dioxide byproduct into a useful heating medium by combusting it to generate high-temperature flue gas, which then serves as the heat source for driving the endothermic reforming reactions in the reformer reactor, thereby eliminating the need for separate fuel combustion systems and reducing overall carbon emissions
Solution Approach 2:
The patent merges the carbon dioxide removal function with the heat generation function by integrating the combustion of captured carbon dioxide directly into the reforming process, where the combustion flue gas provides both heat for reforming and the driving force for the reaction, combining multiple functions into a single integrated system
2Object-generated harmful factors
If separate carbon dioxide removal systems are implemented, then carbon dioxide capture is achieved, but process complexity and materials costs increase
Solution Approach 1:
The patent combines the carbon dioxide capture system with the reforming heat supply system, where the captured carbon dioxide is combusted to provide process heat, merging two separate functions (CO2 capture and heat generation) into one integrated process that reduces equipment complexity and material costs
Solution Approach 2:
The combustion flue gas serves multiple functions simultaneously: it acts as a heating medium for the endothermic reforming reaction, provides the driving force for the reforming process, and serves as the source of high-temperature heat for steam generation, demonstrating multi-functionality that reduces overall system complexity
3Productivity
If conventional radiant furnaces with thick-walled tubes are used for reforming, then reforming reactions occur, but heat transfer efficiency is reduced
Solution Approach 1:
The patent replaces the conventional radiant furnace heat transfer system with a direct contact combustion system where flue gas flows through the reformer reactor, enabling more efficient convective and direct heat transfer to the reforming catalyst and reactants, eliminating the thermal resistance of thick tube walls
Solution Approach 2:
The patent uses combustion flue gas as an intermediary heat transfer medium that directly contacts the reforming reaction zone, facilitating more efficient energy transfer from the combustion process to the reforming reactions compared to indirect heat transfer through thick-walled furnace tubes
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 enhances hydrogen production efficiency and reduces materials costs by integrating carbon dioxide capture and recycling, achieving increased purity and reduced energy consumption.
Implementation Method 1
CO2 convective reformer (CCR)
Implementation Method 2
combustion gases for process heat
Implementation Method 3
water gas shift (WSG) reactors, where the carbon monoxide reacts with water in the presence of a catalyst
Data Source
AI summary
The present disclosure provides systems and methods for hydrogen production as well as apparatuses useful in such systems and methods, including steam generation systems and methods. Hydrogen is produced by reforming of a hydrocarbon in a plurality of reformers to achieve improved reforming efficiency. A CO2 convective reformer (CCR) and an oxygen secondary reformer (OSR) are used in series to convert hydrocarbon and steam to synthesis gas with substantially complete carbon capture. Steam generation is provided along separate pathways to provide separate steam streams of different composition.