Noncatalytic Partial Oxidation Reactor for Synthesis Gas
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Solution Overview
Problem
Current synthesis gas production methods generate CO2 emissions and require thermal utilization of carbon-containing by-products, which can be reduced by physically utilizing these by-products through gasification, but struggle to achieve optimal H2/CO ratios suitable for industrial processes like the oxo process without increasing CO2 emissions.
Innovation Solution
A noncatalytic partial oxidation process that reacts hydrocarbons with oxygen and recycled CO2 at high temperatures (1200-1550°C) to produce synthesis gas with a controlled H2/CO ratio, allowing for the import of additional CO2 to optimize the ratio and achieve virtually complete methane conversion, thereby reducing CO2 emissions and utilizing carbon-containing streams effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CO2 is recycled into the gasification to adjust H2/CO ratio, then the H2/CO ratio can be optimized for specific processes, but additional CO2 emissions are generated
Solution Approach 1:
The patent converts the harmful CO2 emissions into a useful resource by recycling them back into the gasification process. The CO2 that would otherwise be emitted is instead fed back to adjust the H2/CO ratio, transforming a waste product into a process control parameter that optimizes synthesis gas composition for downstream applications.
2Productivity
If fossil energy carriers are converted to synthesis gas through gasification, then synthesis gas is produced, but CO2 is formed during conversion
Solution Approach 1:
The patent addresses CO2 formation during gasification by capturing and recycling the CO2 back into the gasification process. This converts the harmful emission into a useful component that helps control the H2/CO ratio, thereby maintaining high synthesis gas productivity while mitigating CO2 emissions.
Solution Approach 2:
Instead of discarding CO2 as a waste product, the patent recovers it by separating and recycling CO2 back into the gasification process. This closed-loop approach maintains synthesis gas production while preventing CO2 release to the environment.
3Manufacturing precision
If H2 is separated off to increase H2/CO ratio, then the desired ratio is achieved, but process complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where CO2 is recycled from the product gas back to the gasification process. This feedback loop automatically adjusts the H2/CO ratio without requiring complex separation units, as the recycled CO2 directly influences the composition of the synthesis gas at the source.
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 process generates synthesis gas with a H2/CO ratio suitable for the oxo process, achieves complete methane conversion, and physically utilizes CO2, reducing overall CO2 emissions by utilizing carbon-containing by-products as feedstock, enabling the production of synthesis gas with minimal methane content.
Implementation Method 1
noncatalytic partial oxidation of hydrocarbons in the presence of oxygen and carbon dioxide
Implementation Method 2
reacted at a temperature in the range from 1200 to 1550° C. to give a product gas mixture
Implementation Method 3
by separating a portion of the carbon dioxide from the product gas mixture and recycling it into the partial oxidation reactor
Implementation Method 4
achieves complete methane conversion, thereby reducing CO2 emissions
Data Source
AI summary
A process for producing a synthesis gas mixture comprising hydrogen and carbon monoxide by noncatalytic partial oxidation of hydrocarbons in the presence of oxygen and carbon dioxide, in which at least one reactant gas comprising hydrocarbons, an oxygen-comprising reactant gas and a carbon dioxide-comprising reactant gas are fed into a partial oxidation reactor and reacted at a temperature in the range from 1200 to 1550° C. to give a product gas mixture comprising water, carbon monoxide and carbon dioxide, at least by separating a portion of the carbon dioxide from the product gas mixture and recycling it into the partial oxidation reactor, wherein the carbon dioxide fed into the partial oxidation reactor comprises additional imported carbon dioxide, giving a product gas mixture in the partial oxidation reactor that has a molar ratio of hydrogen to carbon monoxide in the range from 0.8:1 to 1.6:1.