Recycle Compressor for Methanol Synthesis Hydrogen Pressure

Solution Overview

Problem

The existing methods for methanol synthesis require the compression of recovered hydrogen, leading to increased energy consumption and the need for a larger synthesis gas compressor.

Innovation Solution

The pressure of the recovered hydrogen is increased using the recycle compressor, which circulates unreacted residual gas through the methanol reactor, thereby reducing the burden on the synthesis gas compressor and lowering energy costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If the synthesis gas compressor is used to compress the recovered hydrogen, then the hydrogen pressure is increased, but the compressor size and energy consumption increase

Engineering Contradiction:

Improvehydrogen pressureVSAvoidenergy consumption

Core Design Contradiction:

Stress or pressureVSUse of energy by moving object

Solution Approach 1:

The recycle compressor is designed to perform multiple functions: it not only recycles the residual gas from the PSA unit back to the synthesis gas stream, but also compresses the recovered hydrogen to the required pressure. This eliminates the need for a separate hydrogen compression system and reduces overall energy consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The recycle compressor utilizes the pressure differential and flow characteristics of the residual gas recycling process to simultaneously provide the compression service needed for the recovered hydrogen. The system serves itself by using an existing compressor to fulfill an additional compression need without requiring external energy input beyond what is already allocated for residual gas recycling.

Inventive Principle:

Principle #25Self-service

2Stress or pressure

If the synthesis gas compressor is used to compress the recovered hydrogen, then the hydrogen pressure is increased, but the compressor size increases

Engineering Contradiction:

Improvehydrogen pressureVSAvoidcompressor size

Core Design Contradiction:

Stress or pressureVSWeight of stationary object

Solution Approach 1:

The recycle compressor is designed to perform multiple functions: it not only recycles the residual gas from the PSA unit back to the synthesis gas stream, but also compresses the recovered hydrogen to the required pressure. This eliminates the need for a separate hydrogen compression system and reduces overall energy consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the function of residual gas recycling and hydrogen compression into a single recycle compressor unit. By merging these two compression functions, the system avoids the need for two separate compressors, thereby reducing the overall size and weight of compression equipment while maintaining the required pressure for hydrogen.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If a separate hydrogen compression system is used, then the hydrogen can be compressed efficiently, but the device complexity increases

Engineering Contradiction:

Improvehydrogen compression efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The recycle compressor is designed to perform multiple functions: it not only recycles the residual gas from the PSA unit back to the synthesis gas stream, but also compresses the recovered hydrogen to the required pressure. This eliminates the need for a separate hydrogen compression system and reduces overall energy consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The recycle compressor is designed to perform multiple functions: it not only recycles the residual gas from the PSA unit back to the synthesis gas stream, but also compresses the recovered hydrogen to the required pressure. This eliminates the need for a separate hydrogen compression system and reduces overall energy consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 energy consumption and compressor size by displacing the pressurization of recovered hydrogen from the synthesis gas compressor to the recycle compressor, resulting in more economical methanol synthesis.

Implementation Method 1

The pressure of the recovered hydrogen is increased using the recycle compressor

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

a synthesis gas compressor for increasing pressure

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12215072B2Method and system for the synthesis of methanol

Publication Date: 2025.02.04 GASCONTEC

AI summary

A method for the synthesis of methanol, wherein a carbonaceous energy source flow is supplied to a synthesis gas reactor arrangement for obtaining a synthesis gas flow having hydrogen and carbon oxides, wherein the synthesis gas flow is supplied to a thermal recovery apparatus for recovering heat from the synthesis gas flow and then to a synthesis gas compressor for pressure increase. The synthesis gas flow is supplied at least in part to a first reactor stage of a methanol reactor arrangement for partial conversion to methanol, a residual gas flow having unreacted carbon oxides being obtained from the methanol reactor arrangement, which residual gas flow is supplied to a recycling compressor for increasing its pressure, the pressure-increased gas flow being supplied to the methanol reactor arrangement for partial conversion to methanol, a recovery flow from an unreacted residual gas being supplied to the first reactor stage of a hydrogen recovery arrangement to obtain a H-recycling flow. The