Plasma Reactor and Refractory for Hydrogen Production

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Solution Overview

Problem

Current methods for hydrogen production, such as Steam Methane Reforming (SMR), result in high CO2 emissions and energy consumption, and flaring of hydrocarbon gases is wasteful and contributes to greenhouse gas emissions, necessitating a cleaner and more efficient alternative.

Innovation Solution

A method involving the use of plasma reactors to convert hydrocarbon feed streams into acetylene-containing streams, which are then decomposed in a refractory at high temperatures to produce hydrogen and solid carbon, reducing CO2 emissions and energy requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If Steam Methane Reforming (SMR) is used for hydrogen production, then hydrogen production capacity is improved, but CO2 emissions increase significantly

Engineering Contradiction:

Improvehydrogen production capacityVSAvoidCO2 emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention extracts and removes carbon from the hydrogen production process by decomposing hydrocarbon feedstocks to produce hydrogen and solid carbon products. The carbon is separated as a usable product (carbon black, graphite, carbon fibers) rather than being emitted as CO2, effectively taking the harmful carbon emission out of the traditional SMR process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the chemical reaction parameters from oxidative reforming (SMR) to pyrolytic decomposition. By operating at high temperatures without oxygen or with limited oxygen, the process transforms hydrocarbons into hydrogen and solid carbon instead of hydrogen and CO2, fundamentally altering the reaction pathway to eliminate CO2 emissions.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If flaring is used to dispose of hydrocarbon gases, then safety is improved, but energy waste and CO2 emissions increase

Engineering Contradiction:

ImprovesafetyVSAvoidenergy waste

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention converts the harmful act of flaring (which wastes energy and emits CO2) into a beneficial process. By using controlled pyrolysis instead of combustion, the hydrocarbon gases are transformed into valuable hydrogen fuel and solid carbon products, turning what was previously waste into useful resources.

Inventive Principle:

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

Solution Approach 2:

The invention replaces the thermal combustion mechanism of flaring with a pyrolytic decomposition mechanism. Instead of burning hydrocarbons to produce heat and light (flaring), the process uses controlled thermal decomposition to produce chemical products (hydrogen and carbon), substituting a destructive mechanical process with a constructive chemical process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Quantity of substance

If conventional hydrogen production methods are used, then hydrogen supply is improved, but energy consumption increases

Engineering Contradiction:

Improvehydrogen supplyVSAvoidenergy consumption

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The invention performs preliminary thermal decomposition of hydrocarbon feedstocks to break down complex molecules into simpler components (hydrogen and carbon). This preliminary action prepares the feedstock for easier hydrogen extraction and reduces the overall energy required for subsequent hydrogen production steps compared to conventional SMR processes.

Inventive Principle:

Principle #10Preliminary action

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 process achieves a 37.61% reduction in CO2 emissions compared to flaring and enables the production of high-purity hydrogen with reduced energy consumption, suitable for integration with existing SMR plants and capable of retrofitting or augmenting existing installations.

Implementation Method 1

activating microwave pyrolysis in the plasma reactor to convert the first feed stream to an acetylene-containing feed stream

Methodology Applied

Scientific EffectMicrowave pyrolysis: Pyrolysis

Implementation Method 2

activating decomposition of the acetylene-containing feed stream into hydrogen in the refractory

Methodology Applied

Scientific EffectThermal decomposition: Decomposition (biological)

Implementation Method 3

decomposing the acetylene-containing feed stream into hydrogen and solid carbon, reducing CO2 emissions

Methodology Applied

Scientific EffectHigh temperature decomposition: Pyrolysis

Data Source

PatentUS20240092637A1Processing of feed stream using refractory for hydrogen production and reduced carbon emissions

Publication Date: 2024.03.21 H QUEST VANGUARD INC

AI summary

Systems and methods for producing hydrogen and solid carbon from gaseous feedstock. The system includes a plasma reactor configured to receive and convert feedstock comprising hydrocarbons into acetylene-containing feed stream, and a refractory coupled to the plasma reactor that is configured to receive and decompose acetylene to hydrogen and solid carbon. The system is further configured to deliver one or more auxiliary feedstock comprising hydrocarbons directly to the refractory for decomposition into hydrogen and carbon. The energy required to decompose the auxiliary feedstock is provided by the energy released from decomposition of acetylene in the refractory.