Pneumatic Carbon Removal From Molten Pyrolysis Reactors
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Solution Overview
Problem
The separation and removal of solid carbon products from high-temperature, high-pressure reaction environments in chemical reactors is challenging, particularly when using molten salts and metals, as existing methods lead to catalyst deactivation and inefficient carbon recovery.
Innovation Solution
A method involving the use of molten salts and metals at high temperatures to decompose hydrocarbons into solid carbon and hydrogen, followed by in-situ or ex-situ separation using floatation, filtration, and pneumatic conveying techniques to separate solid carbon from the liquid reaction medium, utilizing cyclone separators and controlled gas flows to manage turbulence and facilitate removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional separation methods (PSA units) are used to separate hydrogen and carbon oxides, then separation efficiency is improved, but energy consumption and operational cost increase significantly
Solution Approach 1:
The patent extracts and removes carbon oxides directly from the reactor effluent stream before they enter the PSA unit. By using a separate carbon oxide removal unit that selectively captures CO and CO2, the system reduces the load on the PSA unit and eliminates the need for energy-intensive pressure swing operations, thereby maintaining separation efficiency while dramatically reducing energy consumption
Solution Approach 2:
The patent introduces an intermediary carbon oxide removal unit between the reactor and the PSA unit. This intermediary component selectively captures carbon oxides using a absorption medium or membrane technology, allowing hydrogen to pass through to the PSA unit without the need for high-energy separation processes, thus resolving the contradiction between separation efficiency and energy consumption
2Device complexity
If carbon oxides are released to the environment directly, then operational complexity is reduced, but environmental harm and carbon footprint increase
Solution Approach 1:
The patent converts the harmful carbon oxide emissions into a beneficial resource by capturing them in a carbon oxide removal unit. The captured carbon oxides can be utilized in other industrial processes or stored, transforming what was previously a harmful waste product into a valuable commodity, thereby reducing environmental harm while adding value to the process
Solution Approach 2:
The patent creates an inert environment for carbon oxide capture by using absorption media or membrane barriers that selectively trap CO and CO2 molecules. This inert barrier prevents carbon oxides from being released into the environment while allowing the main hydrogen product to pass through, thus eliminating harmful emissions without significantly increasing process complexity
3Productivity
If solid carbon accumulates in the liquid reaction medium, then reaction efficiency is maintained, but catalyst deactivation occurs and carbon recovery becomes inefficient
Solution Approach 1:
The patent applies preliminary action by implementing a flotation preparation step before the main separation process. Gas bubbles are introduced to attach to solid carbon particles, causing them to float to the surface and form a removable layer. This preliminary action prevents carbon accumulation on catalysts while maintaining reaction efficiency, as the floating carbon can be easily removed without affecting the liquid reaction medium
Solution Approach 2:
The patent segments the separation process into distinct stages: flotation for initial carbon removal, followed by filtration for fine particle separation, and finally centrifugation for complete liquid-solid separation. This segmentation allows each stage to target specific aspects of carbon removal, maintaining catalyst stability while preserving reaction efficiency through systematic multi-stage processing
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
Effectively separates and recovers solid carbon from the reaction environment, preventing catalyst deactivation and enhancing the efficiency of carbon recovery processes.
Implementation Method 1
A method involving the use of molten salts and metals at high temperatures to decompose hydrocarbons into solid carbon and hydrogen
Implementation Method 2
followed by in-situ or ex-situ separation using floatation, filtration, and pneumatic conveying techniques to separate solid carbon from the liquid reaction medium
Implementation Method 3
utilizing cyclone separators and controlled gas flows to manage turbulence and facilitate removal
Implementation Method 4
pneumatic conveying techniques to separate solid carbon from the liquid reaction medium
Data Source
AI summary
A pyrolysis process comprises introducing one or more chemical reactants into a reactor containing a liquid maintained at a high temperature, producing chemical products in the liquid based on the high temperature, allowing the solid product to grow in particle size, accumulating the solid product in the liquid, and removing the solid product from the reactor while retaining a substantial portion of the liquid within the reactor. The chemical products comprise a solid chemical product that is mixed with the liquid.