Hydromethanation Process Eliminates Gas Recycle Loops
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Solution Overview
Problem
Current hydromethanation processes are complex and costly due to gas recycle loops and inefficient steam generation, leading to increased engineering complexity and reduced system efficiency in producing methane from carbonaceous feedstocks.
Innovation Solution
A process that minimizes gas recycle loops by using a syngas generator to produce a hydrogen and carbon monoxide stream, which, along with a hydromethanation catalyst and steam, is used in a hydromethanation reactor to convert carbonaceous feedstocks into a methane-enriched product stream, with in situ heat generation and process heat recovery to meet thermal and syngas balance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas recycle loops are used in conventional hydromethanation processes, then syngas balance can be maintained, but engineering complexity and process cost increase
Solution Approach 1:
The patent extracts and eliminates the gas recycle loop from the conventional hydromethanation process. Instead of recycling syngas back to the reactor, the process uses a syngas generator to produce fresh syngas that is fed directly to the hydromethanation reactor, thereby removing the complexity of recycle loops while maintaining syngas supply
Solution Approach 2:
The patent introduces a syngas generator as an intermediary device between the carbonaceous feedstock and the hydromethanation reactor. This mediator converts carbonaceous materials into syngas, which then supplies the hydromethanation reactor, replacing the need for recycle loops while ensuring adequate syngas balance
2Quantity of substance
If external superheaters are used for steam generation, then steam supply is ensured, but process cost and system complexity increase
Solution Approach 1:
The patent merges the steam generation function with the syngas generator. The syngas generator simultaneously produces syngas and generates steam as a byproduct, eliminating the need for separate external superheaters. This integration reduces system complexity while ensuring adequate steam supply for the hydromethanation process
Solution Approach 2:
The syngas generator is designed to perform multiple functions: it generates syngas for the hydromethanation reactor and simultaneously produces steam through the gasification process. This multi-functionality eliminates the need for dedicated steam generation equipment, reducing overall system complexity
3Manufacturing precision
If multiple gas cooling and scrubbing processes are used, then product purity is improved, but process complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates multiple sequential cooling and scrubbing stages from the conventional process. Instead, a single integrated cooling and scrubbing step is employed that achieves the necessary product purity, thereby reducing process complexity while maintaining manufacturing precision
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 simplifies the production process, reduces costs, and enhances efficiency by eliminating the need for external superheaters and recycle gas loops, while ensuring thermal and syngas balance, resulting in a more cost-effective and efficient method for generating methane.
Implementation Method 1
The catalytic gasification of such materials to produce methane and other value-added gases
Implementation Method 2
Steam carbon: C+H2O→CO+H2
Implementation Method 3
CO Methanation: CO+3H2→CH4+H2O
Implementation Method 4
2H2+C→CH4
Implementation Method 5
The overall reaction is essentially thermally balanced; however, due to process heat losses and other energy requirements
Implementation Method 6
in situ heat generation and process heat recovery to meet thermal and syngas balance requirements
Data Source
AI summary
The present invention relates to processes for preparing gaseous products, and in particular methane, via the catalytic hydromethanation of a carbonaceous feedstock in the presence of steam, syngas and an oxygen-rich gas stream.