Synthesis Gas Preparation with PFO–PGO Distillation Feed Conditioning
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Solution Overview
Problem
Conventional refinery residues used as raw materials for synthesis gas production have high kinematic viscosity, leading to increased differential pressure, poor atomization, and a risk of explosion in the combustion chamber, while also producing excessive greenhouse gases and acidic gases, necessitating a need for pretreatment and compliance with environmental regulations.
Innovation Solution
Utilizing pyrolysis fuel oil (PFO) and pyrolysis gas oil (PGO) from a naphtha cracking center process as raw materials, which are pretreated by supplying PGO to the upper end and PFO to the lower end of a distillation tower to optimize kinematic viscosity and flash point, thereby reducing greenhouse gas emissions and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If refinery residue is used as raw material for gasification process, then synthesis gas production is achieved, but kinematic viscosity increases causing poor atomization and increased explosion risk
Solution Approach 1:
The patent applies preliminary action by conducting distillation separation of PFO and PGO before gasification. The raw material is pre-processed to remove high-viscosity components and adjust composition, ensuring optimal atomization performance before entering the combustion chamber. This preliminary separation prevents the atomization problems that would occur with direct use of high-viscosity refinery residue.
2Quantity of substance
If refinery residue is used as raw material, then synthesis gas is produced, but differential pressure in combustion chamber increases
Solution Approach 1:
The distillation process performs preliminary separation to remove high-viscosity components from the raw material before gasification. By pre-adjusting the physical properties of the feedstock through selective separation of PFO and PGO, the system prevents excessive differential pressure buildup in the combustion chamber during operation.
3Productivity
If refinery residue is used as raw material, then gasification process operates, but greenhouse gas and acidic gas emissions increase
Solution Approach 1:
The patent applies the extraction principle by using distillation to separate and remove harmful components from the raw material stream. The distillation process extracts high-viscosity fractions and concentrates desirable components (PFO and PGO) with lower sulfur and nitrogen content, thereby reducing the formation of harmful emissions during gasification while maintaining productivity.
Solution Approach 2:
The patent changes the compositional parameters of the raw material by selectively separating PFO and PGO through distillation. This parameter change results in a feedstock with optimized carbon-hydrogen ratio and reduced sulfur-nitrogen content, leading to decreased greenhouse gas and acidic gas emissions during the gasification process.
4Quantity of substance
If refinery residue is used as raw material, then synthesis gas production continues, but pretreatment processes are required increasing complexity
Solution Approach 1:
The patent integrates the distillation separation as a preliminary action that consolidates multiple pretreatment functions into a single process step. By performing composition optimization and viscosity reduction in one integrated distillation unit, the system eliminates the need for separate heat treatment, diluent addition, and water injection processes, thereby reducing overall device complexity while maintaining synthesis gas production.
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 method reduces greenhouse gas emissions, lowers operating costs, and improves process efficiency by using PFO and PGO as raw materials, ensuring proper atomization and safety in the gasification process.
Implementation Method 1
supplying a pyrolysis fuel oil (PFO) stream including a PFO and a pyrolysis gas oil (PGO) stream including a PGO discharged from a naphtha cracking center (NCC) process to a distillation tower as a feed stream
Implementation Method 2
converting a hydrocarbon such as coal, petroleum, and biomass as a raw material into synthesis gas mainly composed of hydrogen and carbon monoxide by pyrolysis or a chemical reaction with a gasifying agent such as oxygen, air, and water vapor
Implementation Method 3
A gasifying agent and a raw material are supplied to a combustion chamber positioned at the foremost end of the gasification process to produce synthesis gas by a combustion process at a temperature of 700° C. or higher
Data Source
AI summary
Provided is a method for preparing synthesis gas, and more particularly, a method for preparing synthesis gas including: supplying a pyrolysis fuel oil (PFO) stream including a PFO and a pyrolysis gas oil (PGO) stream including a PGO discharged from a naphtha cracking center (NCC) process to a distillation tower as a feed stream (S10); and supplying a lower discharge stream from the distillation tower to a combustion chamber for a gasification process to obtain synthesis gas (S20), wherein the PGO stream is supplied to an upper end of the distillation tower and the PFO stream is supplied to a lower end of the distillation tower.