PFO-PGO Mixed Oil Feed for Safe Synthesis Gas Gasification

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Solution Overview

Problem

Conventional refinery residues used in gasification processes for producing synthesis gas have high kinematic viscosity, leading to increased differential pressure, poor atomization, and a risk of explosion, while pyrolysis fuel oil (PFO) from naphtha cracking centers is not used due to high sulfur content, necessitating a method to utilize PFO as a raw material to reduce greenhouse gas emissions and operating costs.

Innovation Solution

A method involving mixing PFO and PGO streams from a naphtha cracking center process at a specific flow rate ratio to produce a mixed oil stream, which is then supplied to a combustion chamber for gasification, controlling kinematic viscosity and flash point within optimal ranges to improve process efficiency and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If refinery residue is used as raw material for gasification process, then synthesis gas can be produced, but kinematic viscosity increases leading to poor atomization and increased explosion risk

Engineering Contradiction:

Improveraw material utilizationVSAvoidcombustion safety

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent changes the physical and chemical parameters of the raw material by selecting pyrolysis fuel oil with specific properties (kinematic viscosity 2-10 cSt at 40°C, sulfur content 0.03-0.5 wt%, nitrogen content 0.01-0.2 wt%) instead of conventional refinery residue. This parameter optimization resolves the contradiction by achieving both adequate raw material utilization and combustion safety through controlled viscosity and low sulfur/nitrogen content.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite approach by combining pyrolysis fuel oil (PFO) and pyrolysis gas oil (PGO) in a specific ratio (PFO:PGO = 90:10 to 70:30 by weight) to create a mixed raw material stream. This composite formulation optimizes the balance between viscosity, atomization performance, and combustion safety, resolving the technical contradiction between raw material utilization and reliability.

Inventive Principle:

Principle #40Composite materials

2Productivity

If refinery residue is used as raw material, then gasification can proceed, but sulfur and nitrogen content increases production of acidic gases

Engineering Contradiction:

Improvegasification outputVSAvoidacidic gas production

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by selecting pyrolysis fuel oil with significantly lower sulfur (0.03-0.5 wt%) and nitrogen (0.01-0.2 wt%) content compared to conventional refinery residue. This parameter optimization maintains gasification productivity while reducing acidic gas production to meet environmental regulations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the previously harmful high-sulfur pyrolysis fuel oil into a beneficial low-sulfur raw material by changing the operational context from fuel combustion to gasification feedstock. This transforms a waste product that caused environmental harm into a clean raw material that reduces acidic gas production while maintaining productivity.

Inventive Principle:

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

3Use of energy by moving object

If pyrolysis fuel oil is used as fuel, then energy can be generated, but high sulfur content limits market due to environmental regulations

Engineering Contradiction:

Improveenergy utilizationVSAvoidenvironmental compliance

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies multi-functionality by enabling pyrolysis fuel oil to serve dual purposes: it can be used as fuel for energy generation when sulfur content is acceptable, and as a clean gasification raw material when environmental compliance is prioritized. This universal application resolves the contradiction between energy utilization and environmental compliance by adapting the use based on regulatory requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes the application parameters by shifting from direct combustion (fuel use) to gasification process (raw material use). This parameter change allows the same pyrolysis fuel oil to meet environmental regulations while still providing energy value through synthesis gas production, resolving the contradiction between energy utilization and environmental compliance.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If refinery residue requires pretreatment, then combustion performance can be improved, but process complexity increases

Engineering Contradiction:

Improvecombustion performanceVSAvoidpretreatment process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies self-service by selecting a raw material (pyrolysis fuel oil) that inherently possesses the required properties for direct gasification without pretreatment. The material's natural viscosity (2-10 cSt at 40°C) and chemical composition enable direct feeding into the gasification process, eliminating the need for external pretreatment facilities and reducing device complexity while maintaining combustion performance.

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

The method reduces greenhouse gas emissions, lowers operating costs, and enhances process efficiency by using PFO and PGO as raw materials, ensuring proper atomization and safety in the gasification process.

Implementation Method 1

mixing a PFO stream including a pyrolysis fuel oil (PFO) and a PGO stream including a pyrolysis gas oil (PGO) discharged from a naphtha cracking center (NCC) process to produce a mixed oil stream

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

converting a hydrocarbon such as coal, petroleum, and biomass as a raw material into synthesis gas mainly composed of hydrogen and carbon monoxide by pyrolysis or a chemical reaction with a gasifying agent such as oxygen, air, and water vapor

Methodology Applied

Scientific EffectGasification:

Implementation Method 3

A gasifying agent and a raw material are supplied to a combustion chamber positioned at the foremost end of the gasification process to produce synthesis gas by a combustion process at a temperature of 700°C or higher

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 4

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentEP4074652B1Method for preparing synthesis gas

Publication Date: 2026.04.22 LG CHEM LTD

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AI summary

Provided is a method for preparing synthesis gas, and more particularly, a method for preparing synthesis gas including: mixing a PFO stream including a pyrolysis fuel oil (PFO) and a PGO stream including a pyrolysis gas oil (PGO) discharged from a naphtha cracking center (NCC) process to produce a mixed oil stream (S10); and supplying the mixed oil stream to a combustion chamber for a gasification process (S20), wherein a ratio of a flow rate of the PGO stream in the mixed oil stream relative to a flow rate of the mixed oil stream is 0.01 to 0.3.