Methanation Reactor Using Hydrogen Combustion Heat

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Solution Overview

Problem

Existing methods for producing methane from exhaust gases containing carbon dioxide and oxygen require prior removal of oxygen, which complicates the manufacturing process and increases energy costs.

Innovation Solution

A method and system for producing methane that involves supplying a raw material gas containing hydrogen, oxygen, and carbon dioxide to a reactor with a catalyst, where a methanation reaction is initiated and sustained using heat from catalyst combustion of hydrogen, without prior removal of oxygen.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If oxygen removal step is added to the methanation process, then catalyst deactivation is prevented, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecatalyst stabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention converts the harmful effect of oxygen (which causes catalyst deactivation) into a beneficial effect by using oxygen to combust hydrogen and generate heat. This combustion heat is then utilized to drive the methanation reaction, eliminating the need for separate oxygen removal equipment while maintaining catalyst stability through controlled conditions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention merges the oxygen removal function with the heat generation function by allowing oxygen to react with hydrogen in a controlled combustion process. Instead of removing oxygen before methanation, the system combines oxygen consumption with heat production, thereby simplifying the overall process flow and reducing equipment requirements.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If external heating is used to start the methanation reaction, then reaction initiation is achieved, but energy costs increase

Engineering Contradiction:

Improvereaction initiationVSAvoidenergy cost

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system achieves self-heating by utilizing the combustion of hydrogen with oxygen to generate the necessary heat for initiating and sustaining the methanation reaction. This eliminates the need for external heating sources, as the reaction system itself provides the required thermal energy through the exothermic combustion process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The previously harmful presence of oxygen is converted into a beneficial heat source. The oxygen that would normally require removal is instead used to combust hydrogen and generate the heat needed for reaction initiation, thereby eliminating external heating requirements and reducing energy costs.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If oxygen is present in the raw material gas, then the process is simplified, but catalyst deactivation occurs

Engineering Contradiction:

Improveprocess simplificationVSAvoidcatalyst stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention transforms the harmful presence of oxygen into a beneficial element by using it for hydrogen combustion to generate heat. This allows the process to remain simplified without oxygen removal equipment while the catalyst remains stable due to the controlled combustion process that consumes oxygen before it can cause deactivation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Device complexity

If hydrogen combustion is used to generate heat, then external heating equipment is eliminated, but oxygen must be controlled precisely

Engineering Contradiction:

Improveheating equipmentVSAvoidoxygen control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The system employs feedback control mechanisms to monitor and adjust the oxygen concentration in the raw material gas, ensuring that the hydrogen combustion proceeds safely and efficiently. This control system maintains oxygen levels within optimal ranges, preventing both incomplete combustion and excessive heat generation that could damage the catalyst.

Inventive Principle:

Principle #23Feedback

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 efficient methane production without the need for oxygen removal, thereby simplifying the process and reducing energy costs associated with heating.

Implementation Method 1

heat including reaction heat due to catalyst combustion of the hydrogen gas

Methodology Applied

Scientific EffectCatalyst combustion: Combustion

Implementation Method 2

a catalyst functioning as a catalyst for both a methanation reaction and combustion of the hydrogen gas

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

a reaction called a methanation reaction for producing methane and water from carbon dioxide and hydrogen

Methodology Applied

Scientific EffectMethanation reaction: Catalysis

Data Source

PatentUS12319633B2Methane producing method and production system

Publication Date: 2025.06.03 NAT UNIV CORP SHIZUOKA UNIV

AI summary

A method for producing methane that includes supplying a raw material gas containing hydrogen gas, oxygen gas, and carbon dioxide gas to a reactor provided with a catalyst, thereby starting a methanation reaction using heat including reaction heat due to catalyst combustion of the hydrogen gas; and continuing the methanation reaction.