Methanol Production Using Hydrogen-Rich Off Gas

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Solution Overview

Problem

Conventional methanol production methods are inefficient in utilizing off gas streams rich in hydrogen, leading to increased greenhouse gas emissions and suboptimal natural gas consumption.

Innovation Solution

Integrating an off gas stream containing 70 to 100 mole percent hydrogen with a CO2 stream into the methanol production process, allowing for the formation of synthesis gas to enhance methanol production while reducing natural gas consumption and emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If off gas stream rich in hydrogen is burned as fuel in the chemical production system, then energy needs are met, but valuable hydrogen is wasted and greenhouse gas emissions increase

Engineering Contradiction:

Improvehydrogen utilization efficiencyVSAvoidgreenhouse gas emissions

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful waste stream (off gas containing hydrogen) into a beneficial resource by routing it to the methanol synthesis unit where it serves as a feedstock. This transforms what was previously burned as fuel (causing CO2 emissions) into a valuable chemical原料, simultaneously reducing emissions and improving hydrogen utilization efficiency.

Inventive Principle:

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

Solution Approach 2:

The patent changes the destination and usage parameter of the off gas stream from combustion (energy production) to chemical synthesis (methanol production). This parameter change enables the hydrogen-rich off gas to contribute to both methanol production and reduced natural gas consumption in the synthesis gas generation process.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional methanol production methods are used, then methanol is produced, but natural gas consumption is higher and greenhouse gas emissions increase

Engineering Contradiction:

Improvemethanol production efficiencyVSAvoidnatural gas consumption

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent merges the off gas stream from the chemical production system with the methanol synthesis process. By integrating these two previously separate streams, the system achieves improved methanol production efficiency while reducing natural gas consumption, as the off gas provides additional hydrogen and carbon sources for methanol synthesis.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The off gas stream serves multiple functions simultaneously: it acts as a feedstock for methanol synthesis, a source of hydrogen for synthesis gas generation, and a means to reduce natural gas consumption. This multi-functionality improves overall system efficiency and reduces waste.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If off gas stream is utilized for methanol production, then methanol production increases and natural gas consumption decreases, but process complexity increases

Engineering Contradiction:

Improvemethanol production outputVSAvoidprocess integration complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The chemical production system's off gas stream serves the methanol production unit, creating a self-service arrangement where waste from one process becomes feedstock for another. This internal resource circulation improves methanol output and reduces external natural gas requirements without requiring complex external supply chains.

Inventive Principle:

Principle #25Self-service

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 valorizes the off gas stream, increases methanol production, and decreases overall greenhouse gas emissions, including CO2 and NOx, compared to traditional methods.

Implementation Method 1

reacting the synthesis gas stream and the CO2 stream in the methanol production assembly to produce methanol, wherein the method further includes reacting the off gas stream with the synthesis gas stream and the CO2 stream in the methanol production assembly to produce methanol

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS20240400481A1Use of an off gas comprising hydrogen for methanol production

Publication Date: 2024.12.05 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A method for producing methanol includes feeding a synthesis gas stream to a methanol production assembly; feeding an off gas stream including hydrogen to the methanol production assembly; feeding a CO2 stream to the methanol production assembly; and reacting the synthesis gas stream and the CO2 stream in the methanol production assembly to produce methanol, wherein the method further includes reacting the off gas stream with the synthesis gas stream and the CO2 stream in the methanol production assembly to produce methanol, or feeding a reforming feed stream and the off gas stream including hydrogen to a reforming portion of the methanol production assembly to form the synthesis gas stream.