Methanization Reactor for CO2 Recovery in C/C Preform Production
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Solution Overview
Problem
The challenge lies in effectively capturing and managing CO2 emissions from small point sources in the carbon/carbon (C/C) preform production process, as existing technologies are costly and inefficient for such applications.
Innovation Solution
A system utilizing a methanization reactor to convert CO2 and hydrogen (H2) into methane (CH4), with H2 being separated from off-gases and potentially supplemented with green H2, and the produced CH4 being reused in the C/C preform production process or for heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If CO2 capture technologies are implemented for small point sources, then CO2 emission management is achieved, but the cost becomes prohibitively expensive and the system becomes overly complex
Solution Approach 1:
The patent converts harmful CO2 emissions from the C/C preform production process into useful methane fuel through a methanization reactor. The CO2 captured from off-gases is combined with hydrogen to produce methane, which can be reused as fuel in the same production process or sold as a energy product, thereby eliminating waste and creating value
Solution Approach 2:
The system uses the CO2 produced internally by the C/C preform production process itself as feedstock for the methanization reactor. The methane generated is then fed back into the production process as fuel, creating a self-sufficient circular system that manages its own emissions without requiring external infrastructure
2Object-affected harmful factors
If pipeline infrastructure is installed for CO2 sequestration, then CO2 storage is achieved, but the cost increases and the system becomes impractical for small emission sources
Solution Approach 1:
Instead of storing CO2 as a waste product, the system converts it into valuable methane fuel through chemical transformation. This eliminates the need for storage infrastructure while creating a useful energy carrier that can be immediately utilized or commercialized
Solution Approach 2:
The system changes the chemical composition and energy state of CO2 by converting it into methane through the methanization reaction (CO2 + 4H2 → CH4 + 2H2O). This parameter transformation converts a harmful greenhouse gas into a useful energy carrier, fundamentally changing its utility and value
3Ease of operation
If CO2 emissions are released without capture, then operational simplicity is maintained, but environmental impact increases and sustainability goals are not met
Solution Approach 1:
The patent merges the CO2 capture function with the existing production process by integrating the methanization reactor into the workflow. The CO2 from off-gases is captured and converted in-situ, and the resulting methane is fed back into the process, creating a unified system that maintains operational simplicity while achieving emission management
Solution Approach 2:
The system performs multiple functions simultaneously: it captures CO2 emissions, converts them to methane fuel, provides heat generation for the production process, and potentially generates revenue from excess methane. This multi-functionality achieves sustainability goals without significantly complicating operations
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 enables efficient CO2 emission recovery and conversion into usable products, reducing the environmental impact and operational costs associated with managing CO2 emissions from small point sources.
Implementation Method 1
The methanization reactor is configured to convert the CO2 and supplied hydrogen (H2) via methanization to produce methane (CH4)
Implementation Method 2
the supplied H2 is separated by the H2 separator from the one or more off gases produced from the C/C preform production process
Implementation Method 3
the condenser condenses the steam to water (H2O) which is supplied to the burner/steam generator
Implementation Method 4
the burner/steam generator generates at least the CO2 that is used by the methanization reactor
Data Source
AI summary
A system is provided for carbon dioxide (CO2) emission recovery. The system includes a methanization reactor. The methanization reactor is configured to receive CO2 separated from one or more off gases of a brake manufacturing process, convert the CO2 and supplied hydrogen (H2) via methanization to produce methane (CH4); and supply the produced CH4 to at least one of a carbon/carbon (C/C) preform production process or another system for heat generation.