Reactor for Syngas Production via CO2 Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reactors for synthesis gas production face issues such as soot formation, energy inefficiency, and economic inefficiency due to multi-stage processes, which lead to carburization and destruction of steel surfaces, and require expensive purification and complex reactor construction.
Innovation Solution
A pressure- and temperature-resistant reactor with at least two fluid-tight supply lines for CO2 and H2 reactant fluids, recuperative countercurrent heat exchange zones, and a reaction zone with a catalyst bed, designed to minimize soot formation and optimize energy use, allowing for single-stage processing and recycling of waste gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperature and pressure are used to drive the endothermic CO2 and H2 conversion reaction, then synthesis gas production efficiency is improved, but soot formation increases leading to carburization and destruction of steel surfaces
Solution Approach 1:
A water vapor injection system is introduced as an intermediary substance into the reaction zone. The water vapor acts as a mediator that suppresses soot formation and carburization of the steel surface while allowing the endothermic reaction to proceed at high temperature and pressure conditions, thus resolving the contradiction between productivity and harmful factor generation
Solution Approach 2:
The patent changes the chemical composition parameters of the reaction mixture by introducing water vapor. This parameter change modifies the reaction environment to suppress soot formation and protect the steel surface, enabling the system to operate at optimal temperature and pressure for synthesis gas production without the harmful side effects
2Productivity
If multi-stage processes with repeated catalyst passage are used to achieve highest yield, then synthesis gas production yield is improved, but process complexity and energy consumption increase
Solution Approach 1:
The patent merges multiple functional zones (heating zone, reaction zone, heat exchange zones) into a single integrated reactor system. This combining of functions allows the process to achieve high yield in a single pass through optimized reaction conditions and heat recovery, eliminating the need for complex multi-stage processes with repeated catalyst passage
Solution Approach 2:
The patent implements continuous heat exchange and reaction in a single-stage process. The countercurrent heat exchange zones maintain continuous heat transfer to the reactants, ensuring optimal reaction conditions are maintained throughout the single pass through the catalyst, thereby achieving high yield without repeated processing stages
3Reliability
If steel reactors are used to withstand high temperature and pressure, then reactor durability is improved, but soot formation on surfaces leads to carburization and destruction of the steel
Solution Approach 1:
Water vapor is introduced as an intermediary protective substance into the reaction zone. It acts as a mediator that suppresses soot formation and prevents carburization of the steel surface, thereby protecting the reactor material from degradation while maintaining the high temperature and pressure conditions necessary for reaction durability
Solution Approach 2:
The patent creates a protective atmosphere in the reaction zone by introducing water vapor. This inert-like environment suppresses the formation of soot and prevents direct contact between carbon-containing species and the steel surface, thereby preventing carburization and extending the lifespan of the reactor material
4Productivity
If recycling of waste gases is implemented to increase utilization, then economic efficiency is improved, but soot formation in the reactor increases
Solution Approach 1:
Water vapor is introduced as an intermediary substance into the reaction zone where waste gases are recycled. It acts as a mediator that suppresses soot formation while allowing the recycling process to proceed, thus enabling high utilization of carbon-containing species without the harmful side effect of increased soot formation
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
The reactor achieves efficient synthesis gas production with reduced soot formation, optimized energy use, and improved economic efficiency by minimizing reactor complexity and enabling the use of different starting materials and reactions, while maintaining stability up to 50 bar pressure and 1100°C temperature.
Implementation Method 1
at least one reaction zone with at least one catalyst in a catalyst bed
Implementation Method 2
at least two recuperative countercurrent heat exchange zones, partial areas of the at least two feed lines being arranged in both countercurrent heat exchange zones
Implementation Method 3
at least one heating zone, wherein at least a partial area of the at least second supply line for the second educt fluid is arranged in the heating zone
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The invention relates to a pressure- and temperature-resistant reactor for preparing syngas in a reverse CO conversion, in which gases containing CO2 are converted under high pressure with the aid of hydrogen into a syngas mixture (CO and H2), and relates to a method for preparing a syngas mixture using said reactor.