Parallel Compressor Stages for Flexible Syngas By-Product Recycling
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Solution Overview
Problem
Existing processes for producing pure carbon monoxide and hydrogen by steam reforming of hydrocarbons face challenges in achieving flexible production capacities and optimal material utilization of by-product streams, leading to inefficient operation and complex control of distillation and separation steps.
Innovation Solution
The process involves recycling selected streams, such as carbon dioxide, methane, and hydrogen-containing streams, through a configuration of parallel compressor stages to the steam reforming unit and low-temperature fractionation unit, allowing for flexible operation and material utilization of components like hydrogen and carbon oxides, thereby optimizing production capacity and simplifying control of distillation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If by-product streams are not recycled to the steam reforming unit, then the production capacity can be increased, but the material utilization of components like hydrogen and carbon oxides deteriorates
Solution Approach 1:
The patent recovers and recycles by-product streams containing hydrogen and carbon oxides back to the steam reforming unit instead of discarding them. This is achieved through a recycling loop that directs these streams back into the reforming process, thereby improving material utilization while maintaining production capacity.
Solution Approach 2:
The patent converts the previously harmful or wasted by-product streams into beneficial resources by recycling them to the steam reforming unit. The carbon oxides and hydrogen that would otherwise be lost are now utilized as feedstock, improving both material efficiency and production economics.
2Productivity
If the production capacity is increased, then the output of carbon monoxide and hydrogen is improved, but the control complexity of distillation and separation steps worsens
Solution Approach 1:
The patent segments the compression process into multiple parallel compressor stages, each handling a portion of the total gas flow. This segmentation allows for more manageable control of each stage while achieving the overall production capacity target, thereby reducing the control complexity of the separation and distillation steps.
Solution Approach 2:
The patent employs dynamic control strategies where the recycling ratio and compressor stage operations can be adjusted in real-time based on production requirements. This dynamic adaptability allows the system to maintain optimal control complexity across varying production capacities.
3Loss of substance
If parallel compressor stages are used to recycle by-product streams, then the material utilization is enhanced, but the device complexity worsens
Solution Approach 1:
The patent designs the parallel compressor stages to be universal units that can handle different by-product streams (containing hydrogen, carbon monoxide, and carbon dioxide) with the same basic compression mechanism. This multi-functionality reduces the overall device complexity compared to having specialized equipment for each stream.
Solution Approach 2:
The patent merges the recycling functions of multiple by-product streams into a unified parallel compression system. Instead of separate recycling loops for each stream, the parallel compressor stages combine these functions into a single integrated system, thereby managing device complexity more effectively.
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 configuration enables flexible operation across a wide range of production capacities, enhances material utilization of by-products, and stabilizes the operation of distillation and separation steps, reducing the need for input hydrocarbons and improving the ratio of produced carbon monoxide and hydrogen.
Implementation Method 1
steam reforming of hydrocarbons, preferably methane or naphtha, to afford a raw synthesis gas
Implementation Method 2
Hydrocarbons may be catalytically reacted with steam to afford synthesis gas, i.e. mixtures of hydrogen (H2) and carbon monoxide (CO)
Implementation Method 3
multistage cryogenic gas fractionation
Implementation Method 4
The hot synthesis gas product gas is partially cooled in indirect heat exchange against process media to be heated
Implementation Method 5
The hot synthesis gas product gas is partially cooled in indirect heat exchange against process media to be heated
Implementation Method 6
process for removing further unwanted concomitants, for example by physical or chemical absorption or gas scrubbing
Data Source
AI summary
Proposed is a process and a plant for production of pure carbon monoxide and hydrogen by steam reforming of hydrocarbons, preferably methane or naphtha, to afford a raw synthesis gas and subsequent, multistage workup, purification and fractionation of the raw synthesis gas to afford the target products, wherein the material streams obtained as by-products of the process chain are also to be advantageously utilized. This is achieved according to the invention by providing the recirculating compressor provided for recycling of the by-product material streams with a plurality of parallel, independently operable compressor stages.