Monolithic Synthetic Fuel Reactor With Integrated Reaction Zones
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional synthetic fuel production processes are complex and costly due to the use of discrete processing and storage tanks, pipelines, and heating/cooling systems, which increase the complexity and cost of the production plants.
Innovation Solution
A monolithic block comprising stacked and bonded plates forms a plurality of reaction regions, integrating input ports for hydrogen and carbon dioxide/syngas, and output ports for hydrocarbon fuel, facilitating efficient conversion into synthetic fuel through a series of catalytic reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete processing and storage tanks with pipelines and heating/cooling systems are used, then the chemical reactions can be sustained, but the device complexity and cost increase
Solution Approach 1:
The patent merges multiple discrete processing tanks, pipelines, and heating/cooling systems into a single integrated monolithic reactor. The reactor contains multiple reaction zones (Fischer-Tropsch, methanol synthesis, water-gas shift) combined with heating and cooling channels within one unified structure, eliminating the need for separate discrete components while maintaining all necessary functions for sustainable chemical reactions.
Solution Approach 2:
The monolithic reactor serves multiple functions simultaneously: it performs Fischer-Tropsch synthesis, methanol synthesis, water-gas shift reactions, heating, cooling, and pressure regulation all within a single device. The reactor walls contain both reaction channels and thermal management channels, allowing one component to replace what would traditionally require multiple separate systems.
2Reliability
If multiple discrete tanks and piping are used, then the process can be maintained, but the cost of production increases
Solution Approach 1:
The patent combines multiple discrete tanks and piping systems into a single monolithic reactor unit, reducing the total number of components that need to be manufactured, installed, and maintained. This integration lowers material costs, reduces installation complexity, and decreases the overall cost of producing synthetic fuel while maintaining process reliability.
3Reliability
If discrete processing tanks and piping are used, then the chemical reactions can be sustained, but the time required for processing increases
Solution Approach 1:
The monolithic reactor integrates multiple reaction zones and thermal management systems into a single unified structure, eliminating the time delays associated with transferring materials between separate tanks and piping systems. The direct integration of reaction channels with heating and cooling channels allows for more efficient heat transfer and faster reaction cycles, reducing overall processing time while maintaining sustainable chemical reactions.
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 monolithic block design reduces complexity and costs by integrating multiple reaction regions into a single unit, enhancing efficiency and reducing the need for separate tanks and piping, thereby simplifying the fuel generation process.
Implementation Method 1
The Fischer-Tropsch synthetic fuel production process uses catalyzed chemical reactions undertaken at high temperatures to convert syngas into liquid hydrocarbons
Implementation Method 2
heating and cooling systems connected to such tanks and pipelines to maintain the temperature of the contents thereof to sustain the chemical reactions
Implementation Method 3
heating and cooling systems connected to such tanks and pipelines to maintain the temperature of the contents thereof
Data Source
AI summary
A fuel generator and a method for generating fuel are disclosed in which a monolithic block includes a plurality of plates stacked and bonded together to form a plurality of reaction regions. A first input port and a second input port are disposed on the monolithic block. The first input port is coupled to a source of hydrogen gas and the second input port is coupled to a source of carbon dioxide or syngas. An output port is disposed on the monolithic block and is coupled to a fuel reservoir. A first subset of the plurality of plates is bonded together to form a first reaction region, a second subset of the plurality of plates is bonded together to form a second reaction region, and a third subset of the plurality of plates is bonded together to from a channel that fluidically connects the first and the second reaction regions.