Methanol Production via Oxygen-Enriched Reformer Combustion
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Solution Overview
Problem
Conventional methanol production methods are inefficient due to the use of excess air in reformer burners, leading to high energy consumption, excess hydrogen production, and costly importation of carbon dioxide, resulting in increased production costs and environmental concerns from vented carbon dioxide emissions.
Innovation Solution
The method involves in-situ formation of carbon dioxide using a high oxygen content oxidant in the reformer burner, which is then used as a raw material for methanol production, along with excess hydrogen, optimizing the process by reducing fuel consumption and utilizing nitrogen for ammonia and urea production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If excess air is used in reformer burners to combust natural gas, then the required energy for steam reforming is generated, but the burner flame temperatures are reduced and natural gas demand increases
Solution Approach 1:
The patent changes the composition parameter of the oxidant from excess air (containing nitrogen and oxygen) to pure oxygen or oxygen-enriched air. This parameter change eliminates nitrogen dilution, increases flame temperature, and reduces the amount of natural gas fuel required while maintaining the energy output needed for steam reforming.
Solution Approach 2:
The patent applies strong oxidants (pure oxygen or high-concentration oxygen) instead of excess air to accelerate combustion and increase flame temperature. This allows complete combustion of fuel with less oxidant volume, eliminating the cooling effect of excess air and reducing natural gas consumption while generating sufficient thermal energy for reforming.
2Use of energy by stationary object
If excess air is used in reformer burners, then combustion energy is generated, but a diluted carbon dioxide stream is produced that is difficult to process and must be vented
Solution Approach 1:
The patent changes the oxidant composition from excess air to pure oxygen, which fundamentally alters the combustion product composition. Instead of producing a diluted stream (5 wt% CO2, 80 wt% N2, 15 wt% O2), pure oxygen combustion produces a concentrated CO2 stream that is much easier to separate and process, eliminating the need for complex processing or venting.
Solution Approach 2:
The patent extracts nitrogen from the oxidant stream by using pure oxygen instead of air. This removal of nitrogen prevents the formation of diluted combustion products, yielding a concentrated CO2 stream that can be easily separated and utilized, avoiding the processing difficulties associated with nitrogen-containing flue gas.
3Productivity
If imported carbon dioxide is used to consume excess hydrogen, then methanol production is enabled, but production costs increase due to high import prices
Solution Approach 1:
The patent makes the system self-sufficient by producing its own carbon dioxide through pure oxygen combustion in the reformer burners. The CO2 generated from fuel combustion is captured and used as the carbon source for methanol synthesis, eliminating the need to import expensive carbon dioxide and reducing production costs while maintaining methanol productivity.
Solution Approach 2:
The patent merges the combustion function and carbon dioxide supply function into a single integrated process. The reformer burners serve dual purposes: generating combustion energy for steam reforming and producing carbon dioxide as a byproduct that is then fed to the methanol synthesis unit, eliminating the separate carbon dioxide import requirement.
4Use of energy by moving object
If pure oxygen or high oxygen content oxidant is used in reformer burners, then fuel consumption is reduced and synthesis gas production increases, but an air separation unit is required to produce the oxidant
Solution Approach 1:
The patent applies multi-functionality by using the air separation unit to simultaneously provide pure oxygen for combustion (reducing fuel consumption and increasing flame temperature) and to separate nitrogen for potential use in other process areas. The added complexity of the ASU is offset by multiple benefits including reduced fuel demand, improved synthesis gas production, and concentrated CO2 generation.
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 significantly reduces fuel consumption, increases methanol production efficiency, and converts previously vented carbon dioxide into valuable products, thereby lowering production costs and environmental impact.
Implementation Method 1
combusting feed hydrocarbons with an oxidant that comprises 70 to 99.5 wt. % oxygen to generate heat and produce a heated gas stream
Implementation Method 2
heating natural gas, with heat from the heated gas stream, to a temperature sufficient to reform the natural gas
Implementation Method 3
reacting the natural gas with water to form synthesis gas
Implementation Method 4
reacting the synthesis gas and at least some of the carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce the methanol
Data Source
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AI summary
A method for producing methanol is disclosed. The method includes supplying a high oxygen content oxidant to combust hydrocarbons, in particular methane, and then using the resulting hot gases to heat natural gas so as to convert the natural gas to synthesis gas. The synthesis gas is used to produce methanol in a methanol synthesis reactor. At least some of the carbon dioxide from the hot gases is fed to the methanol synthesis reactor to make methanol.