Integrated Oxy-Combustion and Partial Oxidation Process
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Solution Overview
Problem
Current technologies face challenges in reducing emissions while maintaining project economics and ensuring safe, reliable operation, particularly in integrating air separation units, oxycombustion power generation, and high-pressure partial oxidation based synthesis gas generation plants.
Innovation Solution
A method of co-producing a carbon dioxide containing stream and a syngas stream by introducing high-pressure hydrocarbon and oxygen streams into a syngas generator, followed by low-pressure streams into an oxy-combustion device, and utilizing the resulting carbon dioxide stream in a waste heat boiler to generate steam for work expansion, thereby reducing emissions and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stand-alone process units are used for air separation, oxycombustion power generation, and partial oxidation syngas generation, then each unit can operate independently with established technology, but overall operating and capital expenditures increase and CO2 emissions are not significantly reduced
Solution Approach 1:
The patent combines air separation unit, oxycombustion power generation unit, and partial oxidation syngas generation unit into a single integrated process system. The air separation unit provides oxygen to both the oxycombustion unit and partial oxidation unit, while the waste heat boiler integrates steam generation from oxycombustion exhaust to drive turbines connected to both power generation and syngas compression, creating a unified system that reduces overall complexity and cost while maintaining operational reliability
2Productivity
If conventional combustion processes are used, then power generation and heating are achieved, but CO2 and criteria pollutants such as SOX, NOX, CO, VOC, and particles are significantly emitted
Solution Approach 1:
The patent uses an oxygen-enriched environment from the air separation unit in both the oxycombustion unit and partial oxidation unit, replacing conventional air combustion. This oxygen-enriched combustion process improves combustion efficiency and power generation output while significantly reducing CO2 and criteria pollutant emissions. The integrated system further captures and utilizes CO2 in the waste heat boiler, converting it to useful steam without releasing it to the atmosphere
Solution Approach 2:
The patent converts the harmful CO2 exhaust from the oxycombustion unit into a useful resource by feeding it to the waste heat boiler where it serves as a combustion gas to generate steam. This transforms the harmful emission into a valuable product, eliminating CO2 release while maintaining power generation productivity
3Productivity
If high-pressure partial oxidation is used for syngas generation, then syngas production efficiency increases, but energy consumption and operational risks increase
Solution Approach 1:
The patent merges the waste heat recovery system with the syngas compression system by using the waste heat boiler to generate steam that drives turbines. These turbines are mechanically coupled to provide both power generation and mechanical drive for the syngas compression process. This integration reduces the external energy consumption for compression by utilizing the thermal energy from oxycombustion exhaust, thereby reducing overall energy consumption while maintaining high syngas production efficiency
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 integrated process significantly reduces direct and indirect CO2 and criteria pollutants, lowers capital expenditures, and enhances operational safety and reliability by optimizing the integration of air separation, partial oxidation, and oxy-combustion units.
Implementation Method 1
introducing the low-pressure carbon dioxide containing stream into a waste heat boiler, thereby producing steam
Implementation Method 2
introducing the steam into a work expander, thereby generating work and a carbon dioxide containing stream
Implementation Method 3
introducing a high-pressure hydrocarbon containing stream and a high-pressure oxygen containing stream into a syngas generator, thereby producing a high-pressure syngas stream
Implementation Method 4
introducing a low-pressure hydrocarbon containing stream and a low-pressure oxygen containing stream into an oxy-combustion device, thereby producing a low-pressure carbon dioxide containing stream
Data Source
AI summary
A method of co-producing a carbon dioxide containing stream and a syngas stream, including introducing a high-pressure hydrocarbon containing stream and a high-pressure oxygen containing stream into a syngas generator, thereby producing a high-pressure syngas stream, introducing a low-pressure hydrocarbon containing stream and a low-pressure oxygen containing stream into an oxy-combustion device, thereby producing a low-pressure carbon dioxide containing stream, and introducing the low-pressure carbon dioxide containing stream into a waste heat boiler, thereby producing steam, and introducing the steam into a work expander, thereby generating work and a carbon dioxide containing stream.