Hydrogen Production Through Oxy-Fuel Reforming and CO2 Capture
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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.
Innovation Solution
Utilizing oxy-fuel combustion to produce hydrogen with integrated carbon dioxide capture, where combustion gases are used to heat reforming processes, and waste gases are recycled to enhance efficiency and reduce 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 can be generated from hydrocarbon fuels, but carbon dioxide is produced as a harmful byproduct that requires costly removal processes
Solution Approach 1:
The patent converts the harmful carbon dioxide byproduct into a useful heating medium by combusting it in a combustor to generate hot combustion gases. These gases then serve as the heating fluid in the heat exchanger to provide thermal energy for the endothermic reforming reactions, thereby eliminating the need for separate fuel combustion and reducing additional carbon dioxide emissions.
Solution Approach 2:
The patent merges the hydrogen production process with carbon dioxide capture and utilization by integrating the combustor and heat exchanger into the reforming system. The carbon dioxide removal system is combined with the heating system, allowing the same equipment to both remove carbon dioxide from the syngas and provide thermal energy for the reforming reactions.
2Object-generated harmful factors
If separate carbon dioxide removal processes are implemented, then carbon dioxide can be captured, but process efficiency is reduced and additional costs are incurred
Solution Approach 1:
The system serves itself by using the carbon dioxide produced during hydrogen reforming as the heating medium for the reforming reactions. The carbon dioxide-rich combustion gases generated in the combustor automatically circulate through the heat exchanger to provide thermal energy, eliminating the need for external fuel sources and reducing additional carbon dioxide emissions.
Solution Approach 2:
The heat exchanger serves multiple functions: it heats the reactant gases for reforming, cools the combustion gases to condense water, and facilitates heat recovery from the carbon dioxide-rich stream. The combustor simultaneously removes carbon dioxide from the syngas and generates thermal energy for the process.
3Loss of energy
If combustion gases are used to heat reforming processes, then energy efficiency is improved, but system complexity increases due to integration of multiple processes
Solution Approach 1:
The heat exchanger acts as an intermediary device that transfers thermal energy from the carbon dioxide-rich combustion gases to the reforming reactants. This intermediary allows the coupling of the combustion process and reforming process without direct mixing of gases, maintaining process control while achieving energy efficiency.
4Loss of energy
If waste gases are recycled to enhance efficiency, then process performance is improved, but additional processing steps are required
Solution Approach 1:
The system maintains continuous circulation of the carbon dioxide-rich combustion gases through the heat exchanger, providing continuous thermal energy for the reforming reactions. The water condensed from these gases is continuously removed and can be recycled, maintaining continuous operation without interruption.
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 method achieves increased hydrogen purity and process efficiency by integrating oxy-fuel combustion and carbon dioxide processing, reducing material costs and improving overall system performance.
Implementation Method 1
CO2 convective reformer heated by combustion of waste gases from hydrogen separation process
Implementation Method 2
combustion of waste gases from hydrogen separation process; oxy-fuel combustion
Implementation Method 3
catalytic steam methane reforming (SMR) reaction is endothermic
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.