Hydrogen Production With Integrated Gas-Heated and Autothermal Reforming
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Solution Overview
Problem
Existing hydrogen production methods from natural gas, particularly for the transport sector, are inefficient and costly, requiring substantial electrical power and CO2 storage infrastructure, which contributes to greenhouse gas emissions and is limited by scale and location.
Innovation Solution
Integrate a gas-heated reformer (GHR) with an autothermal reformer (ATR) to produce hydrogen, utilizing the hot autothermal reformate to heat the GHR, followed by a shift reactor and efficient separation of hydrogen and CO2, with optional integration into methanol synthesis processes to enhance efficiency and reduce CO2 emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydrogen is produced by electrolysis of water, then hydrogen can be produced with high purity, but the process is expensive and requires substantial electrical power
Solution Approach 1:
The patent replaces the electrical energy-based electrolysis process with a thermal/chemical reforming process. Instead of using electrical power to split water, the invention uses natural gas reforming with steam and oxygen to produce hydrogen, substituting the energy input mechanism from electrical to thermal/chemical domain
Solution Approach 2:
The patent changes the fundamental operating parameters of hydrogen production from electrical potential and water splitting to thermal conditions and hydrocarbon reforming. By altering the input energy form and chemical reactions involved, the process achieves lower operational costs while maintaining hydrogen production capability
2Ease of manufacture
If hydrogen is produced by reforming natural gas, then production cost is lower than electrolysis, but the process requires CO2 storage infrastructure and contributes to greenhouse gas emissions
Solution Approach 1:
The patent converts the harmful CO2 byproduct of natural gas reforming into a useful resource. By capturing the CO2 produced during reforming and utilizing it in subsequent chemical processes (such as methanol synthesis or chemical feedstock production), the invention transforms the harmful emission into a beneficial product, reducing net CO2 releases while maintaining cost-effective hydrogen production
Solution Approach 2:
The patent creates a multi-functional system where the CO2 from hydrogen production serves multiple purposes: it can be stored, utilized in chemical synthesis, or processed further. This universal approach allows the same reforming process to serve both hydrogen production and CO2 management functions, reducing overall environmental impact
3Adaptability or versatility
If hydrogen production facilities are made small to meet limited demand, then location flexibility is improved, but production efficiency decreases
Solution Approach 1:
The patent enables segmentation of the hydrogen production system into modular units that can be deployed at different scales. By designing the reforming process with flexible configuration options, the system can be scaled up or down based on local demand, allowing both small distributed units for location flexibility and larger centralized units for production efficiency
4Object-generated harmful factors
If CO2 is stored in offshore underground reservoirs, then carbon emissions are reduced, but the process requires substantial infrastructure and capital investment
Solution Approach 1:
The patent implements a self-service approach where the CO2 captured during hydrogen production is utilized on-site for chemical processes or stored in existing geological formations without requiring external infrastructure. The system serves its own CO2 management needs by integrating capture, utilization, or storage functions directly into the hydrogen production process, reducing dependency on separate infrastructure
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
Significantly reduces natural gas consumption, lowers CO2 capture needs, enhances energy efficiency, and allows flexible production to meet demand fluctuations, while minimizing greenhouse gas emissions.
Implementation Method 1
an autothermal reforming process, with heat generated by the autothermal reforming process supplied to the gas-heated reforming process
Implementation Method 2
a gas-heated reforming process... utilizing the hot autothermal reformate to heat the GHR
Implementation Method 3
followed by a shift reactor and efficient separation of hydrogen and CO2
Data Source
Figure 1~2
Figure 3
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AI summary
Disclosed herein is a method of producing hydrogen, the method comprising: receiving a feed gas comprising hydrocarbons; and performing reforming processes so as to generate hydrogen in dependence on the feed gas; wherein the reforming processes comprise both a gas-heated reforming process and an autothermal reforming process; and heat generated by the autothermal reforming process is supplied to the gas-heated reforming process; wherein the method is performed in a hydrogen production plant that is integrated with one or more further processing plants.