Polygeneration Hydrogen Production via Partial Oxidation and PSA
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Solution Overview
Problem
Industrial processes for producing hydrogen, such as those used in ammonia and urea production, face challenges with high feedstock costs, excessive energy requirements, and high emissions, necessitating the development of more efficient methods for hydrogen production that reduce costs and emissions.
Innovation Solution
A polygeneration process involving an oxygen-supplied partial oxidation process to produce hydrogen, which includes steps like supplying a hydrocarbon feedstock and oxygen to generate synthesis gas, converting it through multiple reactors to produce a carbon dioxide-rich gas stream, and then using pressure swing adsorption to obtain pure hydrogen, while also capturing exothermic heat for power generation and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional hydrogen production methods are used, then hydrogen can be produced for industrial processes, but feedstock costs are high and emissions are excessive
Solution Approach 1:
The patent segments the hydrogen production process into multiple distinct stages: partial oxidation to generate synthesis gas, water-gas shift reactions in sequential reactors to convert CO to H2, condensation to remove water, and pressure swing adsorption to purify hydrogen. This segmentation allows optimization of each stage independently, improving overall efficiency and reducing emissions while controlling costs through targeted interventions at critical points in the process
Solution Approach 2:
The patent employs parameter changes by operating water-gas shift reactors at different temperatures (high-temperature and low-temperature stages) and pressures to maximize hydrogen yield. The partial oxidation process uses controlled oxygen-to-fuel ratios to optimize synthesis gas composition. These parameter optimizations improve production efficiency and reduce waste emissions while maintaining cost-effectiveness
2Use of energy by moving object
If conventional hydrogen production methods are used, then hydrogen can be produced for industrial processes, but energy requirements are excessive
Solution Approach 1:
The patent implements continuous hydrogen production through a series of interconnected reactors and separation units operating in sequence. The partial oxidation continuously generates synthesis gas, which flows through water-gas shift reactors that continuously convert CO to H2. The pressure swing adsorption system continuously purifies the hydrogen stream. This continuous operation eliminates idle time and maximizes productivity while optimizing energy utilization across all process stages
Solution Approach 2:
The patent utilizes phase transitions in the condensation step where water vapor in the synthesis gas is condensed to liquid water for removal. This phase change efficiently separates water from the hydrogen-rich gas stream without requiring additional energy-intensive separation methods. The pressure swing adsorption process also exploits phase-like transitions in gas adsorption and desorption to achieve continuous purification while minimizing energy consumption
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 method reduces production costs and emissions by efficiently generating high-purity hydrogen while utilizing waste heat for power production and minimizing environmental impact.
Implementation Method 1
supplying a hydrocarbon or carbonaceous feedstock and oxygen to an oxygen supplied partial oxidation process to produce a synthesis gas
Implementation Method 2
supplying the synthesis gas to a first reactor, the first reactor comprising a catalyst and is to convert at least a portion of the carbon monoxide to carbon dioxide
Implementation Method 3
supplying the modified synthesis gas to a second reactor, the second reactor comprising a catalyst configured to convert remaining carbon monoxide to carbon dioxide
Implementation Method 4
supplying the carbon dioxide-rich synthesis gas from the second reactor to a first condenser to remove water
Implementation Method 5
supplying the hydrogen and carbon dioxide stream to a pressure swing adsorption process to produce a pure hydrogen stream
Implementation Method 6
extracting exothermic heat for the production of power, heating and cooling of the process
Data Source
AI summary
Provided are processes for production of hydrogen to be used in various industrial processes, including in processes for production of ammonia and urea. Included are polygeneration processes that result in ultra-low emissions.