OTM Reforming Methanol Synthesis Gas Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methanol production methods face challenges in optimizing the integration of synthesis gas production with the methanol synthesis process, particularly in addressing hydrogen deficiency and inefficiencies in conventional reforming processes, leading to increased catalyst usage and by-product formation.
Innovation Solution
A method integrating an oxygen transport membrane based reforming system with conventional steam methane reforming or autothermal reforming to produce synthesis gas, where a combined feed stream is processed to achieve optimal hydrogen to carbon monoxide ratios, and unconverted hydrogen and methane are recycled to enhance the synthesis gas quality and reduce methane slip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional steam methane reforming is used to produce synthesis gas, then the process is well-established and reliable, but hydrogen deficiency occurs and catalyst deactivation increases
Solution Approach 1:
The patent combines conventional steam methane reforming with oxygen transport membrane (OTM) based reforming in an integrated system. The OTM reactor produces hydrogen-rich synthesis gas that is merged with the output from conventional reforming, thereby increasing the overall hydrogen content while maintaining process reliability through the use of established conventional reforming technology.
Solution Approach 2:
The oxygen transport membrane acts as an intermediary device that selectively transports oxygen from the air stream to the hydrocarbon feed, enabling partial oxidation and steam reforming reactions that produce hydrogen-rich synthesis gas. This intermediary component bridges the gap between conventional reforming and the desired hydrogen-rich output.
2Ease of operation
If conventional reforming processes are used, then the system is simpler to operate, but productivity and cost-effectiveness are reduced
Solution Approach 1:
The patent merges conventional reforming and OTM-based reforming into a single integrated system that produces synthesis gas with optimal composition for methanol synthesis. This combination improves productivity by generating hydrogen-rich synthesis gas that reduces the need for catalyst and minimizes by-product formation, while the modular design maintains ease of operation.
3Device complexity
If synthesis gas composition is not optimized, then the process is simpler, but catalyst deactivation rate increases
Solution Approach 1:
The patent changes the composition parameters of synthesis gas by integrating OTM-based reforming, which produces a hydrogen-rich gas stream. This parameter change (increased hydrogen content and optimized H2/CO ratio) directly reduces catalyst deactivation rate by minimizing water formation and improving reaction conditions, while the integrated design manages complexity through systematic process integration.
4Stability of the object's composition
If purge flow is increased to remove inerts, then inert buildup is prevented, but hydrogen loss increases
Solution Approach 1:
The patent implements a feedback mechanism where the purge stream from the methanol synthesis loop is recycled back to the OTM-based reforming system. This feedback loop allows inerts to be removed while the hydrogen-containing purge gas is reused as feedstock in the reforming process, thereby preventing inert buildup while minimizing hydrogen loss.
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 integration improves the productivity and cost-effectiveness of methanol production by optimizing synthesis gas composition, reducing catalyst deactivation, and minimizing by-product formation, while lowering utility costs and methane slip.
Implementation Method 1
an oxygen permeate produced by the oxygen transport membrane from an oxygen containing feed stream
Implementation Method 2
by reforming a combined feed stream in the presence of a reforming catalyst and heat generated from reaction
Implementation Method 3
heat generated from reaction of a hydrogen containing stream contacting a permeate side of an oxygen transport membrane and an oxygen permeate
Data Source
AI summary
A method and system for producing methanol that employs both an oxygen transport membrane (OTM) based reforming system together with a more traditional steam methane reforming (SMR) and/or autothermal (ATR) synthesis gas production system is disclosed. The dual mode system and method for producing the synthesis gas in a methanol production process optimizes the efficiency and productivity of the methanol plant by using the OTM based reforming system as an independent source of synthesis gas. The disclosed methods and systems are configurable either as a retrofit to existing methanol production facilities or as an integrated package into newly constructed methanol production facilities.