Integrated Steam Generation and Gasification Reactor
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Solution Overview
Problem
The existing methods for catalytic gasification of carbonaceous materials to produce synthetic natural gas require additional fuel sources for steam generation, resulting in a significant carbon footprint due to carbon dioxide emissions.
Innovation Solution
A process that generates steam and gaseous products from carbonaceous feedstocks while capturing and recovering carbon dioxide, using the heat energy from combusting a first carbonaceous feedstock to produce steam, which is then used in a gasifier with an alkali metal catalyst to form methane and other gaseous products, thereby reducing the carbon footprint by capturing carbon dioxide emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coal-fired boilers are used to generate steam for catalytic gasification, then steam is produced to react with carbon to generate methane, but additional fuel sources are required and carbon dioxide emissions increase the carbon footprint
Solution Approach 1:
The patent combines the steam generation function and the gasification function into a single integrated reactor system. The reactor simultaneously performs partial combustion of carbonaceous material to generate heat and steam, and catalytic gasification to produce methane, eliminating the need for separate coal-fired boilers and reducing overall carbon dioxide emissions.
Solution Approach 2:
The reactor is designed as a multi-functional device that performs multiple operations: combustion of carbonaceous material, steam generation, and catalytic gasification all within the same system. This universal reactor eliminates the need for dedicated steam boilers and reduces the overall carbon footprint by integrating functions that previously required separate fuel sources.
2Quantity of substance
If additional fuel sources are used for steam generation, then steam is produced for the gasification process, but the overall fuel efficiency decreases and energy costs increase
Solution Approach 1:
The patent merges the steam generation process with the gasification process in a single reactor system. The carbonaceous material serves dual purposes: as fuel for combustion to generate steam and as feedstock for gasification to produce methane. This eliminates the need for additional fuel sources and improves overall fuel efficiency.
Solution Approach 2:
The system uses the carbonaceous material itself to generate the steam required for its own gasification process. The partial combustion of the feedstock provides the necessary heat and steam, making the system self-sufficient and eliminating external fuel requirements for steam generation.
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 process achieves a low or near-zero carbon footprint by capturing carbon dioxide produced during the catalytic gasification of carbonaceous materials, efficiently utilizing fuel sources and reducing environmental impact.
Implementation Method 1
at least partially combusting the first carbonaceous feedstock in the reactor to generate (i) heat energy and (ii) a first gas stream comprising carbon dioxide
Implementation Method 2
utilizing the heat energy to generate steam
Implementation Method 3
reacting the second carbonaceous feedstock in the gasifier in the presence of the steam and the alkali metal gasification catalyst
Implementation Method 4
reacting the second carbonaceous feedstock in the gasifier in the presence of the steam and the alkali metal gasification catalyst and under suitable temperature and pressure to form a second gas stream comprising a plurality of gaseous products comprising methane, carbon dioxide and at least one or more of hydrogen, carbon monoxide, hydrogen sulfide, ammonia and other higher hydrocarbons
Data Source
AI summary
Processes for the generation of steam are provided for use in an integrated catalytic gasification process for converting carbonaceous materials to combustible gases, such as methane. Generally, the exhaust gas from a steam generating reactor is provided along with steam, a carbonaceous feedstock, and a gasification catalyst, to a catalytic gasifier, wherein under appropriate temperature and pressure conditions, the carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, and carbon dioxide. As substantially all the carbon dioxide produced from the steam generation process and the gasification process are subsequently directed though gas purification and separation processes, substantially all the carbon dioxide may be recovered, yielding a process having a near zero carbon footprint.