Parallel Compressor Staging for Flexible Synthesis Gas Recirculation
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Solution Overview
Problem
Existing methods for producing pure carbon monoxide and hydrogen by steam reforming hydrocarbons face challenges in adjusting to varying production capacities and fail to optimally utilize by-product streams, leading to inefficient material use and complex control of distillation and separation steps.
Innovation Solution
The method involves recycling streams containing carbon dioxide, methane, and hydrogen to a compressor unit, allowing for flexible operation by adjusting compressor stage configurations, and using by-product streams to create an artificial load on the low-temperature fractionation unit, thereby improving material utilization and stabilizing process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If by-product streams are not recycled to the steam reforming unit, then the process is simpler to operate, but material utilization is inefficient and feedstock consumption increases
Solution Approach 1:
The patent recovers valuable materials (hydrogen, carbon monoxide, methane) from by-product streams that would otherwise be discarded or used only for heating. These streams are compressed and recycled to the steam reforming unit, converting waste into useful feedstock and reducing overall hydrocarbon consumption.
Solution Approach 2:
The by-product streams serve multiple functions: they are recycled as feedstock to the steam reforming unit and also used to create artificial load on the low-temperature fractionation unit. This multi-functionality addresses both material utilization and process stability simultaneously.
2Adaptability or versatility
If compressor stages are not configured flexibly, then the device is simpler, but the plant cannot adapt to varying production capacities
Solution Approach 1:
The compression system is divided into multiple compressor stages that can be independently configured. This segmentation allows flexible arrangement of stages in series or parallel to match varying production demands, enabling the plant to adapt to different capacity requirements.
Solution Approach 2:
The compressor configuration is made dynamic and adjustable rather than fixed. The system can be reconfigured by changing the arrangement and operation of individual compressor stages, allowing the plant to optimize performance across a wide range of production capacities.
3Reliability
If by-product streams are not used to create artificial load, then the fractionation unit operates at base load, but process control becomes complex during part-load conditions
Solution Approach 1:
The by-product streams are redirected to serve the low-temperature fractionation unit by creating artificial load. This self-service approach uses available process materials to maintain fractionation unit operation during part-load conditions, ensuring stable process control without external interventions.
4Productivity
If material streams are not effectively utilized, then the process is easier to manage, but productivity and material efficiency decrease
Solution Approach 1:
Valuable materials in by-product streams are recovered and recycled to the steam reforming unit, transforming what would be waste or low-value heating fuel into useful feedstock. This significantly improves material utilization efficiency and reduces the need for fresh hydrocarbon feedstock.
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 enables a wide range of production capacities and enhances the use of by-product streams, reducing the need for feedstock hydrocarbons and stabilizing the operation of the synthesis gas production plant, particularly during part-load conditions.
Implementation Method 1
steam reforming of hydrocarbons, preferably methane or naphtha, to a crude synthesis gas
Implementation Method 2
introduced into a compressor unit, which in this case comprises two compressor stages connected in parallel
Implementation Method 3
multi-stage cryogenic fractionation unit, which in this case is configured as a cold box
Implementation Method 4
A well-known and frequently used process is the Rectisol process, which involves scrubbing the raw synthesis gas with cryogenic methanol as an absorbent
Data Source
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AI summary
A process and plant for producing pure carbon monoxide and hydrogen by steam reforming hydrocarbons, preferably methane or naphtha, to a raw synthesis gas, followed by multi-stage processing, purification, and fractionation of the raw synthesis gas to the target products, is proposed, with the material streams obtained as byproducts of the process chain also being used effectively. According to the invention, this is achieved by equipping the recirculating compressor provided for the recirculation of the byproduct material streams with several parallel-connected, independently operable compressor stages. In this way, recirculation streams of varying sizes can be realized for the steam reforming unit.In an alternative configuration, an additional return current can be generated to artificially increase the load on the low-temperature fractionation unit, so that the distillation and separation steps contained therein can be controlled more easily and operated in a more stable manner.