Modular SOEC for CO2 and NGL Conversion
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Solution Overview
Problem
The current cryogenic gas separation technologies are not cost-effective for individual well-head gas throughputs, and there is a need for modular methods that can directly convert natural gas liquids (NGLs) into more value-added intermediates or materials without prior separation, to address the oversupply and separation bottlenecks in the natural gas industry, particularly in regions like the Utica and Bakken shale plays.
Innovation Solution
The development of an intermediate temperature solid oxide electrolyzer cell (SOEC) technology that simultaneously converts CO2 into CO and separates C2H6 from wet natural gas using electrical power, along with a modular electrogenerative oxidative dehydrogenation (e-ODH) process to convert NGLs into fungible fuels and pipeline-quality natural gas, reducing the need for prior separation and alleviating mid-stream gas separation bottlenecks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cryogenic gas separation technologies are used, then CO and H2 can be separated with high purity, but the process becomes capital intensive and not cost-effective for individual well-head gas throughputs
Solution Approach 1:
The patent divides the gas separation process into multiple stages: first removing CO2 and water to prevent freezing, then performing partial condensation at cryogenic temperatures to separate CO from H2. This segmentation allows each stage to operate under optimized conditions, achieving high purity while managing complexity through modular processing steps.
Solution Approach 2:
The patent applies preliminary action by removing CO2 and water from the feed gas before entering the cryogenic separation section. This pre-treatment prevents freezing and operational issues during the low-temperature separation process, ensuring smooth operation and maintaining purity without requiring overly complex equipment design.
2Quantity of substance
If cryogenic separation process is implemented, then bulk CO can be produced, but capital costs increase due to compression/expansion and heat integration requirements
Solution Approach 1:
The patent utilizes phase transitions by cooling the gas mixture to cryogenic temperatures where CO condenses while H2 remains gaseous, enabling separation. The process leverages the distinct condensation points of different gases to achieve separation without requiring excessive energy input for mechanical separation methods.
Solution Approach 2:
The patent employs thermal expansion and contraction principles through compression and expansion cycles. Gas is compressed to increase density, then expanded through turbines or valves to achieve cooling and condensation. This thermal cycling enables cryogenic separation while recovering some energy through expansion work, reducing net energy consumption.
3Productivity
If conventional CO production facilities are built with capacity greater than 5 MMscf/day, then production costs decrease, but the facilities cannot address individual well-head gas throughputs
Solution Approach 1:
The patent proposes modular cryogenic separation units that can be deployed at individual well-head locations. Each module is sized appropriately for local throughput requirements, enabling scalable deployment from small to large capacities. This segmentation allows the technology to adapt to various well-head gas throughputs while maintaining production efficiency through standardized modular designs.
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 reduces lifecycle CO2 emissions, provides a cost-effective means to convert CO2 and NGLs into valuable products, and addresses the oversupply and separation bottlenecks in the natural gas industry, offering a sustainable carbon lifecycle and increased economic potential for regions with limited petrochemical processing capacity.
Implementation Method 1
an intermediate temperature solid oxide electrolyzer cell (SOEC) technology that simultaneously converts CO2 into CO
Implementation Method 2
separates C2H6 from wet natural gas using electrical power
Implementation Method 3
a modular electrogenerative oxidative dehydrogenation (e-ODH) process to convert NGLs into fungible fuels and pipeline-quality natural gas
Data Source
AI summary
An apparatus for converting carbon dioxide and natural gas liquids into other chemicals and/or fuels, comprising at least one electrochemical cell, wherein the electrochemical cell reduces the endothermic load associated with electrochemical CO2 reduction, and a method for converting carbon dioxide and natural gas liquids into carbon monoxide and other chemicals and/or fuels, comprising converting CO2 into CO and converting C2H6 into C2H4 at a temperature in the range of 650° C.-750° C.