PFO and PGO Blending for Stable Synthesis Gas Gasification

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Solution Overview

Problem

Conventional refinery residues used in gasification processes for producing synthesis gas have high kinematic viscosity, leading to increased differential pressure, poor atomization, and a risk of explosion, while pyrolysis fuel oil (PFO) from a naphtha cracking center (NCC) process is not effectively utilized due to high sulfur content, necessitating a method to reduce greenhouse gas emissions and operating costs.

Innovation Solution

A method involving mixing PFO and pyrolysis gas oil (PGO) streams from the NCC process at a specific ratio to form a mixed oil stream, which is then supplied to a combustion chamber for gasification, controlling kinematic viscosity and flash point within optimal ranges to improve combustion performance and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If refinery residue is used as raw material for gasification, then synthesis gas can be produced, but high kinematic viscosity causes increased differential pressure and poor atomization

Engineering Contradiction:

Improvesynthesis gas productionVSAvoidcombustion performance

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The patent changes the physical parameters of the raw material by mixing PFO with PGO to adjust kinematic viscosity to an optimal range (10-100 cSt at 40°C), transforming the material from a high-viscosity state that causes operational problems to a low-viscosity state that enables efficient combustion and atomization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite liquid fuel by combining PFO and PGO in specific ratios (PGO:PFO = 1:4 to 1:1 by mass), where the composite material exhibits improved flow characteristics and combustion performance compared to PFO alone, resolving the atomization and differential pressure issues

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If refinery residue is used as raw material, then synthesis gas can be produced, but high sulfur and nitrogen content increases acidic gas production

Engineering Contradiction:

Improvesynthesis gas productionVSAvoidacidic gas production

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the previously harmful high-sulfur PFO into a beneficial raw material by mixing it with PGO, which dilutes the sulfur and nitrogen content to levels that reduce acidic gas production while maintaining synthesis gas production capability, thus transforming a harmful material into a useful resource

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical composition parameters of the raw material mixture, specifically reducing sulfur and nitrogen content through blending with PGO, thereby decreasing the formation of hydrogen sulfide and ammonia during gasification while maintaining CO and H2 production

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If PFO is used directly as fuel, then operating costs can be reduced, but high sulfur content violates environmental regulations

Engineering Contradiction:

Improveoperating cost reductionVSAvoidsulfur content

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent introduces PGO as an intermediary substance that mixes with PFO to dilute the sulfur content, acting as a mediator that allows PFO to be used as fuel while complying with environmental regulations, thus enabling both cost reduction and regulatory compliance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the sulfur content parameter of the fuel by controlling the mixing ratio of PGO and PFO, reducing sulfur concentration to levels that satisfy environmental standards while maintaining the economic benefits of using PFO as a raw material

Inventive Principle:

Principle #35Parameter changes

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

Reduces greenhouse gas emissions, lowers operating costs, and enhances process efficiency by using PFO and PGO as raw materials, addressing the limitations of conventional refinery residues.

Implementation Method 1

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

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

The gasification process is a process of 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

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS12534366B2Method for preparing synthesis gas

Publication Date: 2026.01.27 LG CHEM LTD

AI summary

Provided is a method for preparing synthesis gas, and more particularly, a method for preparing synthesis gas including: mixing 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 produce a mixed oil stream (S10); and supplying the mixed oil stream to a combustion chamber for a gasification process to obtain synthesis gas (S20), wherein a ratio of a flow rate of the PGO stream in the mixed oil stream to a flow rate of the mixed oil stream is 0.01 to 0.3.