Hydrogen Membrane Unit for Synthesis Gas Production

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Solution Overview

Problem

Current hydrogen production systems for synthesis gas production are costly and unreliable, relying on hydrogen recycling methods like pressure swing adsorption or membrane separation, which require energy-intensive compression and maintenance-intensive compressors.

Innovation Solution

A hydrogen production system utilizing a hydrogen membrane unit with a hydrogen permeable membrane to recycle hydrogen directly into the hydrocarbon feed stream, eliminating the need for compressors and simplifying the process by leveraging the partial pressure difference across the membrane to facilitate hydrogen transfer from the reformed stream to the hydrocarbon feed stream.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydrogen is separated by pressure swing adsorption, temperature swing adsorption, or membrane followed by compression, then hydrogen can be recycled to the hydrocarbon feed stream, but energy consumption increases due to compression and system complexity increases

Engineering Contradiction:

Improvehydrogen recycling reliabilityVSAvoidenergy consumption for hydrogen compression

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention extracts and removes the compressor from the hydrogen recycling system, eliminating the energy-intensive compression step while maintaining hydrogen recycling functionality through direct membrane separation and feed stream injection

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical compression system with a membrane-based separation system that utilizes partial pressure differences to transfer hydrogen directly into the hydrocarbon feed stream, eliminating the need for mechanical compressors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If hydrogen is separated by pressure swing adsorption, temperature swing adsorption, or membrane followed by compression, then hydrogen can be recycled to the hydrocarbon feed stream, but maintenance requirements increase due to compressor operation

Engineering Contradiction:

Improvehydrogen recycling reliabilityVSAvoidcompressor maintenance requirements

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The invention extracts and removes the compressor from the hydrogen recycling system, eliminating the maintenance-intensive component while maintaining hydrogen recycling functionality through direct membrane separation and feed stream injection

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If hydrogen is recycled through compression, then hydrogen can be supplied to the reformer feed, but system complexity and cost increase

Engineering Contradiction:

Improvehydrogen production efficiencyVSAvoidsystem complexity for hydrogen recycling

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention extracts and removes the compressor and associated control systems from the hydrogen recycling loop, simplifying the overall system architecture while maintaining hydrogen recycling efficiency through direct membrane separation

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the complex mechanical compression and control system with a simpler membrane-based separation system that passively transfers hydrogen using partial pressure gradients, reducing both device complexity and operational costs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces energy and maintenance requirements, enhances system reliability, and provides a cheaper and more efficient method for hydrogen production by directly recycling hydrogen into the feed stream, improving the overall efficiency and cost-effectiveness of the process.

Implementation Method 1

a hydrogen membrane unit downstream the steam reformer unit, where the hydrogen membrane unit comprises a hydrogen permeable membrane and is arranged to allow at least a part of the reformed stream to pass on a first side of the hydrogen permeable membrane and a hydrocarbon feed stream to pass on a second side of the hydrogen permeable membrane. During operation of the system, hydrogen passes from the reformed stream on the first side into the hydrocarbon feed stream on the second side

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS11345593B2System and process for synthesis gas production

Publication Date: 2022.05.31 HALDOR TOPSOE AS

AI summary

A hydrogen production system including a steam reformer unit, a steam addition line arranged to add steam upstream the steam reformer unit, a hydrogen membrane unit comprising a hydrogen permeable membrane and being arranged to allow at least a part of a reformed stream and a hydrocarbon feed stream to pass on different sides of a hydrogen permeable membrane, so that hydrogen passes from the reformed stream into the hydrocarbon feed stream, thereby forming said hydrogen enriched hydrocarbon stream, and a separation unit downstream the first side of the hydrogen membrane unit, where the separation unit is arranged to separating the reformed stream exiting the first side of the hydrogen membrane unit into a hydrogen product gas and an off-gas.