Methanation Installation for CO2-Rich Gas Processing
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Solution Overview
Problem
Existing technologies for converting CO2 rich gases from biogas units into methane rich gases are inefficient and not compatible with renewable energy sources with fluctuating availability.
Innovation Solution
An installation comprising an electrolysis unit, a gasification unit, a catalytic methanation unit, and a steam generation unit, which processes CO2 rich gas and organic wastes to produce methane rich gas, while switching between operating modes to utilize renewable energy and grid power effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methanation processes use syngas from gasification of solid or liquid feedstocks, then continuous treatment of large gas flows is achieved, but compatibility with renewable energy with fluctuating availability is lost
Solution Approach 1:
The methanation process is designed to dynamically adapt its operation to the fluctuating availability of renewable energy. The system can modulate its gasification and methanation rates to match variable power input from renewable sources, transforming a static continuous process into a dynamic one that responds to changing energy supply conditions.
Solution Approach 2:
The process operates at atmospheric pressure and employs temperature variations (200-750°C) to optimize methanation efficiency under different operating conditions. By adjusting operational parameters like temperature and pressure, the system maintains productivity while adapting to renewable energy fluctuations.
2Ease of manufacture
If biogas units separate and discharge biogenic CO2 to the atmosphere, then biomethane production is simplified, but methane production yield remains low due to 40-50 vol.% CO2 content
Solution Approach 1:
The process converts the harmful CO2 emission into a valuable resource by feeding it to the methanation unit where it is transformed into additional methane. This turns the waste stream that limited productivity into a feedstock that enhances it, achieving both environmental benefit and increased methane yield.
Solution Approach 2:
The system merges the biogas upgrading process with a methanation process that uses the CO2-rich gas as feedstock. By combining these previously separate operations, the system simultaneously achieves biomethane production and CO2 utilization, eliminating the need for CO2 separation and discharge.
3Object-generated harmful factors
If CO2 rich gas is discharged to the atmosphere, then environmental impact is negative, but no additional processing cost is incurred
Solution Approach 1:
The methanation unit serves multiple functions: it processes CO2-rich gas from biogas units, converts it to methane, and can operate with variable renewable energy input. This multi-functionality allows the system to address CO2 emissions while maintaining operational flexibility and avoiding the need for separate dedicated CO2 capture and storage facilities.
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
The installation efficiently converts CO2 rich gas into methane rich gas in a thermally efficient manner, utilizing renewable energy with fluctuating availability, and increases methane production yield by 150% compared to standalone biogas units, while reducing CO2 emissions and waste disposal issues.
Implementation Method 1
an electrolysis unit adapted for receiving power and steam, and for producing a hydrogen rich gas
Implementation Method 2
a gasification unit adapted for receiving the wastes, an oxygen rich gas and boiler feed water, and for producing syngas
Implementation Method 3
a catalytic methanation unit adapted for receiving said CO2 rich gas, said hydrogen rich gas and said syngas, and for producing said methane rich gas
Implementation Method 4
CO and CO2 methanation is a mature process that converts carbon and hydrogen atoms to produce Synthetic Natural Gas (SNG)
Implementation Method 5
a steam generation unit adapted for receiving water and heat, and for producing said steam received by the electrolysis unit
Data Source
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AI summary
An installation (10) comprising: - an electrolysis unit (24) for receiving power (26) and steam (28), and for producing a hydrogen rich gas (30), - a gasification unit (34) for receiving wastes (16) containing organic matter, and an oxygen rich gas (32B), and for producing syngas (38), - a catalytic methanation unit (44) for receiving a CO2 rich gas (14), said hydrogen rich gas and said syngas, and for producing a methane rich gas (18), - a steam generation unit (50) for receiving heat (54) from the catalytic methanation unit (44), and producing said steam. The installation is adapted for switching at least between a first operating mode, in which said power is intended to be fully renewable, and a second operating mode, in which said power is at a lower level and is intended to be renewable and/or from an electricity grid (58).