Modular Electrolysis-Methanation Reactor for Thermal Coupling
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Solution Overview
Problem
Current energy storage solutions like hydraulic and compressed air storage face geographical limitations and inefficiencies, while hydrogen storage requires significant infrastructure. Additionally, methanation processes are costly due to the need for distinct reactors with different geometries, leading to high investment costs and poor thermal coupling between electrolysis/co-electrolysis and methanation reactions.
Innovation Solution
A modular design for reactors that integrates common components for high-temperature electrolysis/co-electrolysis and methanation, featuring a stack of flat sheets with specific perforations for fluid communication and thermal management, allowing for reduced investment costs and improved thermal coupling between reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distinct reactors with different geometries are used for electrolysis and methanation, then each reaction can be optimized independently, but investment costs increase and thermal coupling between reactions deteriorates
Solution Approach 1:
The patent combines the electrolysis reactor and methanation reactor into a single integrated reactor system. The electrolysis cell and methanation catalyst are positioned in the same reactor vessel, allowing both reactions to occur in one device. This merging eliminates the need for separate reactors with different geometries, reducing investment costs while enabling thermal coupling between the endothermic electrolysis and exothermic methanation reactions.
Solution Approach 2:
The integrated reactor serves multiple functions: it performs both high-temperature electrolysis to produce hydrogen and simultaneous methanation to convert CO2 and H2 into methane. The reactor design accommodates different reaction zones within the same vessel, with the electrolysis cell in one region and the methanation catalyst in another, allowing one device to fulfill multiple process requirements.
2Device complexity
If integrated reactor design is used, then investment costs decrease and thermal coupling improves, but manufacturing complexity increases
Solution Approach 1:
The integrated reactor is constructed using a modular stack of flat sheets, each sheet being a simple, flat component that is easy to manufacture. The sheets are stacked and assembled to form the complete reactor structure, with each sheet containing standardized perforations for fluid communication. This segmentation into simple, repeatable modules makes the manufacturing process more straightforward despite the complex overall functionality.
Solution Approach 2:
The patent uses standardized sheet thicknesses (0.1 to 1mm) and standardized perforation patterns that can be manufactured using consistent manufacturing parameters. By maintaining consistent geometric parameters across all sheets and using standard assembly procedures, the manufacturing complexity is reduced despite the integrated design's functional sophistication.
3Manufacturing precision
If flat sheets with standardized perforations are used, then manufacturing precision is improved, but fluid distribution complexity increases
Solution Approach 1:
The flat sheets with standardized perforations serve multiple fluid distribution functions simultaneously. The same sheet structure distributes reactants to both the electrolysis cell and the methanation catalyst, collects products from both reactions, and enables thermal coupling. The standardized perforation patterns are designed to handle the complex fluid distribution requirements through their geometric arrangement rather than through complex mechanical components.
Solution Approach 2:
Different regions of the flat sheets have different perforation patterns optimized for their local function. Sheets in contact with the electrolysis cell have perforations optimized for electrolyte and gas distribution, while sheets in contact with the methanation catalyst have perforations optimized for reactant distribution and product collection. This local optimization of perforation patterns allows complex fluid distribution through simple geometric variations.
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 design reduces the overall size of the reactors, facilitates integration, and enhances thermal management, leading to lower production costs and more efficient energy storage through the production of synthetic natural gas, which can be used in existing infrastructure and has a potentially zero or negative carbon footprint.
Implementation Method 1
a electrolyte membrane, placed between the anodic and cathodic compartments, which is pierced with at least one light for allowing a fluidic communication between said compartments
Implementation Method 2
converting by heterogeneous catalysis into the desired combustible gas, the synthesis gas previously obtained
Implementation Method 3
electrolysis of water at high temperature (EHT, or EVHT for electrolysis of water vapor at high temperature)
Implementation Method 4
co-electrolysis of water and carbon dioxide CO2 at high temperature
Data Source
Figure 1~2
Figure 3~5
Figure 6A~6B
AI summary
The invention relates to the production, by means of common components, of both HTE reactors or SOFC fuel cells, and of catalytic reactors-heat exchangers such as methanation reactors that are intended to be kept cool and are supplied with H2 or with an H2+CO mixture from an SOEC electrolyser, or reforming reactors that are intended to be kept hot and that are used to supply an SOFC fuel cell, and more generally all types of catalytic reactors that require thermal management of the reaction (cooling or heating).