Process and plant for producing synthesis gas with variable composition
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Solution Overview
Problem
Existing processes for producing synthesis gas with a hydrocarbonaceous feed gas are limited in adjusting the hydrogen to carbon monoxide (H2/CO) molar ratio, making it difficult to meet the diverse needs of downstream processes within integrated production networks.
Innovation Solution
A process and plant design that involves providing a feed gas mixture with hydrocarbonaceous gas and steam, and a heating gas mixture with fuel and oxygen, which includes catalytic steam reformation, separation of carbon dioxide, fractionation of raw synthesis gas, and recirculation of gases to adjust the H2/CO ratio by admixing methane, hydrogen, or carbon monoxide to the feed or heating gas mixtures, allowing for wider control of the H2/CO ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional catalytic steam reformation is used to produce synthesis gas, then the base H2/CO ratio is determined by chemical equilibrium, but the ability to adjust the H2/CO ratio is limited to narrow ranges
Solution Approach 1:
The synthesis gas production process is segmented into multiple independent stages: (1) catalytic steam reformation stage producing raw synthesis gas with base H2/CO ratio, (2) separation stage dividing the gas into H2-rich stream, CO-rich stream, and CH4-rich stream, and (3) mixing stage where the separated streams are recombined in adjustable proportions. This segmentation allows independent control of each stage, enabling wide H2/CO ratio adjustment without complicating the overall system design.
Solution Approach 2:
The invention extracts and separates the hydrogen, carbon monoxide, and methane components from the raw synthesis gas into distinct streams. By taking out each component separately through fractionation, the process enables selective recombination of these streams in varying proportions to achieve target H2/CO ratios that would be impossible to obtain directly from the reforming reaction alone.
2Adaptability or versatility
If the H2/CO ratio is adjusted by changing feed gas composition or operating conditions, then some flexibility is achieved, but the adjustment range remains narrow and cannot satisfy diverse downstream process needs
Solution Approach 1:
Instead of changing feed gas composition or operating conditions to adjust the H2/CO ratio, the invention changes the parameter of product stream mixing ratios. After separating the raw synthesis gas into H2-rich, CO-rich, and CH4-rich streams, the process adjusts the H2/CO ratio by varying the proportions in which these streams are recombined. This parameter change approach allows wide ratio adjustment without modifying the feed gas or reforming conditions.
Solution Approach 2:
The fractionation and mixing system serves multiple functions: it separates components for purification, enables wide H2/CO ratio adjustment, and provides flexible composition control for different downstream applications. This multi-functionality allows a single production plant to satisfy diverse downstream process needs without requiring multiple specialized units.
3Adaptability or versatility
If a single production plant is used to produce synthesis gas for multiple downstream processes, then resource utilization is improved, but the ability to meet varying H2/CO ratio demands is insufficient
Solution Approach 1:
The invention introduces dynamic adjustability to the synthesis gas production process through variable mixing ratios of the separated gas streams. The system can dynamically change the H2/CO ratio in real-time based on downstream process demands, transforming a static reforming process into a dynamic, flexible production system capable of serving multiple applications with different requirements.
Solution Approach 2:
The process implements feedback control by monitoring the H2/CO ratio of the produced synthesis gas and adjusting the mixing proportions of the H2-rich, CO-rich, and CH4-rich streams accordingly. This feedback mechanism ensures precise control of the final gas composition, maintaining manufacturing precision while providing adaptability to different downstream process needs.
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
Enables the H2/CO ratio to be set within wider limits, providing greater flexibility in synthesis gas production to meet varying demands of downstream processes while maintaining stable and trouble-free operation of the reformer plant.
Implementation Method 1
splitting the feed gas mixture under reforming conditions by catalytic steam reformation in a tubular reformer fired by burners into a raw synthesis gas containing hydrogen, carbon monoxide, carbon dioxide and methane
Implementation Method 2
the heat necessary for splitting, which is indirectly transmitted to the feed gas mixture, is produced by combustion of the heating gas mixture
Implementation Method 3
fractionating the raw synthesis gas into a gas rich in hydrogen, a gas rich in carbon monoxide and a gas rich in methane
Data Source
AI summary
A process and a plant for the continuous conversion of a hydrocarbonaceous feed gas into a synthesis gas comprising carbon monoxide and hydrogen, wherein the H2/CO molar ratio of the product gases can be varied within a wide range. This is achieved in that at least a part of a methane-rich gas obtained during the fractionation of the raw synthesis gas is admixed to the feed gas mixture, and that in the alternativeat least a part of the H2 product gas and/or a fraction of a hydrogen-rich gas increased with respect to the normal operation of the process is admixed to the heating gas mixture, in order to lower the H2/CO ratio, orat least a part of the CO product gas and/or a fraction of a carbon monoxide-rich gas increased with respect to the normal operation of the process is admixed to the heating gas mixture, in order to increase the H2/CO ratio.