Micro-channel WGS Device with Through-type Metal Catalyst
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Solution Overview
Problem
In the water-gas shift (WGS) reaction for before-combustion carbon capture and storage (CCS) and hydrogen production from coal gasification, existing technologies face challenges in efficiently removing the high reaction heat generated during high-temperature processing of high-concentration CO, leading to catalyst deactivation and reduced CO conversion rates due to thermodynamic equilibrium.
Innovation Solution
A micro-channel WGS reaction device employing a through-type metal catalyst and a feed-through metal catalyst configuration, which includes a unique laminated structure with heat transfer units and reaction units to facilitate rapid heat removal through enhanced heat transfer rates and areas, allowing for efficient processing of high-concentration CO in a single-stage high-temperature section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a double-stage WGS reactor is used to process high-concentration CO, then CO conversion rate is improved, but device complexity and installation space increase
Solution Approach 1:
The reactor is divided into multiple functional zones along the axial direction: a high-temperature reaction section with endothermic material for initial CO conversion, and a low-temperature reaction section for final CO conversion. This segmentation allows each zone to operate at optimal temperature conditions, achieving high overall conversion in a single integrated reactor rather than requiring separate double-stage reactors.
Solution Approach 2:
The patent combines multiple functions into a single reactor: high-temperature reaction, low-temperature reaction, and heat storage/release functions are all integrated in one device. The endothermic material serves dual purposes of heat absorption during high-temperature reaction and heat release during low-temperature reaction, merging thermal management and chemical conversion functions.
2Temperature
If heat exchange is performed to lower synthetic gas temperature, then reaction heat is removed, but vaporization of water is suppressed and CO conversion rate decreases
Solution Approach 1:
The endothermic material is pre-loaded into the high-temperature reaction section before synthesis gas enters. This preliminary preparation allows the material to immediately absorb reaction heat as CO conversion begins, preventing temperature rise before it becomes a problem, rather than requiring post-reaction cooling that would suppress water vaporization.
Solution Approach 2:
The endothermic material acts as an intermediary between the exothermic WGS reaction and the surrounding environment. It absorbs excess reaction heat through endothermic decomposition reactions, converting thermal energy into chemical potential energy, thereby maintaining reaction temperature within the optimal range for both water vaporization and CO conversion.
3Productivity
If a huge amount of reaction heat is generated during high-concentration CO processing, then CO conversion is promoted, but hot spots generate on catalyst layer causing catalyst deactivation
Solution Approach 1:
Different sections of the reactor are assigned different thermal characteristics: the high-temperature reaction section contains endothermic material with heat absorption capability to prevent hot spots, while the low-temperature reaction section maintains conditions favorable for catalyst activity. This local differentiation of thermal properties allows high CO conversion while protecting catalyst integrity in each zone.
Solution Approach 2:
The patent converts the harmful effect of reaction heat (which causes hot spots and catalyst deactivation) into a beneficial effect by using endothermic material that absorbs this heat through decomposition reactions. The heat that would otherwise damage the catalyst is transformed into chemical energy stored in the endothermic material, preventing temperature runaway while maintaining high conversion rates.
4Temperature
If high-temperature WGS reaction is performed to maintain vaporization, then CO conversion is improved, but thermodynamic equilibrium limits conversion rate
Solution Approach 1:
The reactor operates in a periodic thermal cycle: during the forward reaction, endothermic material absorbs heat maintaining high temperature for vaporization; after heat saturation, the system transitions to a cooling phase where the endothermic material decomposes, releasing stored heat and lowering temperature to shift thermodynamic equilibrium toward higher CO conversion. This periodic thermal management overcomes the limitation of continuous high-temperature operation.
Solution Approach 2:
The system dynamically changes temperature parameters along the reaction path and over time. High temperature is maintained in the high-temperature reaction section to promote water vaporization and initial conversion, while the low-temperature reaction section operates at lower temperatures to favor thermodynamic equilibrium toward complete CO conversion. The endothermic material enables this parameter differentiation by absorbing and releasing heat as needed.
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 configuration enables rapid heat removal, reducing installation space and costs while maintaining high efficiency in CO conversion, achieving equilibrium CO conversion rates and preventing catalyst deactivation.
Implementation Method 1
a high-temperature reaction section, and a low-temperature reaction section, wherein the high-temperature reaction section has an endothermic material loaded therein before the synthesis gas is introduced
Implementation Method 2
a WGS catalyst and a metal catalyst that are alternately laminated with each other in the low-temperature reaction section
Implementation Method 3
an upper heat transfer unit which is disposed under the upper plate and includes an upper heat transfer gas flow path which is connected with the heat transfer gas supply pipe to flow the heat transfer gas, and an upper product gas flow path which is formed in contact with the upper heat transfer gas flow path so as to allow heat transfer therebetween
Data Source
AI summary
The present invention relates to a micro-channel water-gas shift (WGS) reaction device for WGS for generating hydrogen and pre-combustion carbon capture and storage (CCS) from coal gasification, the device using a micro-channel heat exchanger and through-type metal catalyst capable of rapidly dissipating heat generated during single-stage WGS reaction of high concentration CO in a high temperature space.