Process for producing a synthesis gas
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Solution Overview
Problem
Current ammonia synthesis gas production from natural gas is inefficient due to high natural gas consumption and the high costs associated with coal-to-ammonia plants, which require extensive purification and are not suitable for revamping existing plants.
Innovation Solution
A process that converts natural gas into hydrogen-containing synthesis gas, using a carbonaceous feedstock like coal for partial oxidation to provide heat and fuel, reducing natural gas consumption and eliminating the need for extensive purification, while allowing for the use of coal as a more affordable energy source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural gas is used as fuel for reforming process, then sufficient heat for reforming is provided, but natural gas consumption increases significantly
Solution Approach 1:
The fuel supply is segmented into two sources: natural gas and coal-derived gasification products. The coal gasification unit produces syngas (CO and H2) that can be combusted to provide reforming heat, thereby segmenting the dependency on natural gas and reducing overall natural gas consumption while maintaining sufficient thermal input for the reforming process
Solution Approach 2:
The coal gasification unit serves multiple functions: it produces fuel gas for combustion to provide reforming heat, generates additional syngas for the synthesis gas stream, and reduces natural gas consumption. This multi-functionality allows the system to maintain reforming temperature requirements while diversifying the fuel base and reducing reliance on natural gas
2Quantity of substance
If coal is used as feedstock for synthesis gas production, then feedstock availability increases, but extensive purification equipment is required
Solution Approach 1:
The patent extracts only the necessary function from coal gasification - producing syngas for the synthesis gas stream - rather than implementing a complete coal-to-ammonia purification train. By taking out only the gasification step and integrating it with existing natural gas reforming and purification equipment, the system benefits from coal's wide availability without requiring the extensive purification equipment needed for direct coal gasification
Solution Approach 2:
The coal gasification unit is merged with the existing natural gas reforming and synthesis gas production train. The syngas from coal gasification is combined with the reformed natural gas stream, and the existing purification equipment (desulfurization, shift conversion, CO2 removal) handles both streams together. This merging allows the system to utilize coal's availability advantage while leveraging existing purification infrastructure
3Quantity of substance
If coal-to-ammonia process is implemented, then feedstock cost decreases, but plant complexity and investment cost increase
Solution Approach 1:
Instead of implementing the complete coal-to-ammonia process with all associated purification and conversion equipment, the patent applies partial action by only introducing a coal gasification unit that produces syngas. This syngas is then fed into the existing natural gas-based reforming and synthesis gas production train, which handles the remaining purification and conversion steps. This partial implementation reduces feedstock costs by incorporating cheaper coal while avoiding the excessive plant complexity of a full coal-to-ammonia facility
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 approach reduces natural gas consumption by up to 25%, lowers energy costs, and allows for the environmentally friendly use of coal, making it more economically viable and suitable for revamping existing plants.
Implementation Method 1
using a carbonaceous feedstock like coal for partial oxidation to provide heat and fuel
Implementation Method 2
at least part of a heat input to said process is provided by combustion of a fuel
Data Source
AI summary
Process for manufacturing a hydrogen-containing synthesis gas from a natural gas feedstock, comprising the conversion of said natural gas into a raw product gas and purification of said product gas, the process having a heat input provided by combustion of a fuel; said process comprises a step of conversion of a carbonaceous feedstock, and at least a portion of said fuel is a gaseous fuel obtained by said step of conversion of said carbonaceous feedstock.