Membrane and PSA Synthesis Gas H2/CO Ratio Control
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Solution Overview
Problem
Existing methods for producing synthesis gas with an adjustable hydrogen-carbon monoxide ratio and pure hydrogen stream are inefficient, requiring costly and complex processes such as cryogenic gas separation and multiple stages of processing, which limits flexibility and increases investment costs.
Innovation Solution
A method involving partial oxidation or steam reforming of hydrocarbons, followed by partial CO conversion, acidic gas separation, and a combination of membrane separation and pressure swing adsorption to achieve the desired H2/CO ratio and produce a synthesis gas product stream suitable for oxo synthesis and pure hydrogen, minimizing the need for costly separation operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (cryogenic gas separation, multiple processing stages) are used to produce synthesis gas with adjustable H2/CO ratio and pure hydrogen, then the desired product purity and ratio adjustment are achieved, but the investment costs and operational complexity increase significantly
Solution Approach 1:
The patent changes the fundamental separation parameter from cryogenic temperature-based separation to membrane permeability-based separation. The hydrogen-selective membrane allows H2 to pass through while retaining CO, enabling continuous ratio adjustment by controlling the extent of membrane separation without requiring complex cryogenic equipment or multiple processing stages.
Solution Approach 2:
The patent extracts hydrogen from the synthesis gas mixture using a hydrogen-selective membrane, separating H2 from CO in a single step. This extraction approach eliminates the need for complex cryogenic gas separation equipment and multiple processing stages, achieving both high purity hydrogen production and flexible H2/CO ratio adjustment.
2Manufacturing precision
If conventional methods are used to produce synthesis gas with adjustable H2/CO ratio, then the desired product composition is achieved, but the investment costs increase due to costly separation operations
Solution Approach 1:
The patent replaces mechanical cryogenic separation systems with a membrane-based separation system. The hydrogen-selective membrane provides continuous separation without moving parts, eliminating the need for expensive cryogenic equipment, compressors, and multiple processing units, thereby significantly reducing investment costs while maintaining precise H2/CO ratio control.
3Manufacturing precision
If multiple stages of processing are used to produce pure hydrogen and synthesis gas, then high product purity is achieved, but the operational complexity and processing time increase
Solution Approach 1:
The patent combines hydrogen separation and H2/CO ratio adjustment into a single membrane separation step. The hydrogen-selective membrane simultaneously achieves high-purity hydrogen production and flexible synthesis gas composition control in one continuous process, eliminating the need for multiple sequential processing stages and significantly improving operational 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 allows for flexible adjustment of the H2/CO ratio and high-purity hydrogen production with reduced investment costs and operational complexity, enhancing the efficiency and availability of the synthesis gas product.
Implementation Method 1
a) in a membrane separation unit, separating a hydrogen-enriched permeate stream and a hydrogen-depleted retentate stream from the deacidified synthesis gas stream
Implementation Method 2
b) in a pressure swing adsorption system, separating a high-purity hydrogen stream and a carbon monoxide-containing residual gas stream from the permeate
Implementation Method 3
The carbon monoxide content of the raw synthesis gas is converted, in a CO conversion plant, partially or completely into hydrogen
Data Source
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AI summary
A process and a plant for producing a synthesis gas product stream with an adjustable H₂/CO ratio and a pure hydrogen stream are proposed. According to the invention, a partial stream of a deacidified synthesis gas stream is fed to a membrane separation plant equipped with a hydrogen-selective membrane, and the remaining partial stream is fed to a pressure swing adsorption plant, from which a pure hydrogen stream and a fuel gas stream are obtained. The hydrogen-enriched permeate stream obtained from the membrane separation is also fed to the pressure swing adsorption plant, thereby increasing the yield of pure hydrogen. The hydrogen-depleted retentate stream obtained from the membrane separation is discharged as a synthesis gas product stream and, with a suitable composition, can be used as oxogas.