Hydromethanation Reactor Pressure Segmentation
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Solution Overview
Problem
The hydromethanation process faces inefficiencies in acid gas removal due to suboptimal pressure conditions, affecting the economic viability and capital intensity of the overall system, as the operating conditions of the hydromethanation reactor do not align with the optimal conditions for acid gas treatment systems.
Innovation Solution
A process is developed to separately control the pressure conditions of the hydromethanation reactor and acid gas removal system, involving steps such as preparing a carbonaceous feedstock, introducing it into a hydromethanation reactor with a catalyst, reacting to produce a methane-enriched raw product gas, and then compressing and dehydrating this gas to optimize acid gas removal by adjusting pressure and removing carbon dioxide and hydrogen sulfide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the hydromethanation reactor operates at moderately-elevated temperatures and pressures, then the conversion of carbonaceous feedstock to methane-enriched synthesis gas is achieved, but the acid gas removal treatment efficiency is reduced due to suboptimal pressure conditions
Solution Approach 1:
The process is divided into two distinct pressure zones: the hydromethanation reactor operates at moderately-elevated pressures (first pressure condition) for optimal methane production, while the acid gas removal system operates at higher pressures (second pressure condition) for optimal acid gas treatment. This segmentation allows each unit to operate at its optimal pressure condition independently.
Solution Approach 2:
The system dynamically adjusts pressure conditions between different process units. The carbonaceous feedstock is compressed to a second pressure condition (higher than the first) before acid gas removal, allowing the acid gas treatment system to operate at optimal high pressure while the hydromethanation reactor maintains its moderately-elevated pressure for efficient methane production.
2Object-generated harmful factors
If higher pressure conditions are applied to improve acid gas removal efficiency, then the acid gas treatment is optimized, but the capital intensity of the system increases
Solution Approach 1:
The system uses a dynamic compression strategy where only the carbonaceous feedstock is compressed to the second (higher) pressure condition before acid gas removal. This selective compression approach allows the acid gas removal system to operate at optimal high pressure without requiring the entire system to operate at elevated pressures, thereby reducing overall capital intensity while maintaining acid gas treatment efficiency.
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 the efficiency of producing higher-value products while reducing capital intensity by optimizing the operating conditions for both the hydromethanation reactor and acid gas removal system, leading to improved economic viability.
Implementation Method 1
reacting the carbonaceous feedstock in the hydromethanation reactor at a first pressure condition in the presence of carbon monoxide, hydrogen, steam and hydromethanation catalyst to produce a methane-enriched raw product gas
Implementation Method 2
compressing the dehydrated raw product stream to a second pressure condition to generate a compressed dehydrated raw product stream, wherein the second pressure condition is higher than the first pressure condition
Implementation Method 3
removing a substantial portion of the carbon dioxide and a substantial portion of the hydrogen sulfide from the compressed dehydrated raw product stream to produce the sweetened gas stream
Data Source
AI summary
The present invention relates to processes for hydromethanating a carbonaceous feedstock to an acid gas-depleted methane-enriched synthesis gas, with improved efficiency of the acid gas removal treatment.