Redox System for Synthetic Fuel with In-Situ CO2 Capture

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Solution Overview

Problem

Current synthetic fuel production processes from carbonaceous sources are inefficient, capital-intensive, and associated with significant CO2 emissions and energy losses, particularly due to the irreversibility of gasification/reforming steps and exothermic nature of Fischer-Tropsch synthesis reactions, as well as high capital costs and low energy conversion efficiencies.

Innovation Solution

Integration of a redox system using chemical intermediates with indirect Fischer-Tropsch synthesis and pyrolysis processes to generate hydrogen and CO2 streams for synthetic fuel production, where CO2 is captured in-situ and utilized to reduce exothermicity and endothermicity of reactions, improving energy conversion efficiency and reducing carbon footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional gasification/reforming processes are used for synthetic fuel production, then fuel can be produced from carbonaceous sources, but the processes are capital-intensive and have low energy conversion efficiency

Engineering Contradiction:

Improvesynthetic fuel productionVSAvoidenergy conversion efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent combines the gasification/reforming process with Fischer-Tropsch synthesis into an integrated system where the syngas produced is directly fed into the synthesis reactor. This merging eliminates intermediate processing steps, reduces capital costs, and improves energy conversion efficiency by minimizing heat loss and process irreversibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent optimizes operating parameters including temperature, pressure, and catalyst composition to enhance reaction efficiency. By carefully controlling these parameters, the process achieves higher energy conversion efficiency while maintaining fuel production output.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If Fischer-Tropsch synthesis is used for liquid fuel production, then synthetic fuel can be generated, but the exothermic nature of the reaction causes energy losses and process inefficiency

Engineering Contradiction:

Improveliquid fuel synthesisVSAvoidexothermic energy loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent performs preliminary gasification and syngas purification before Fischer-Tropsch synthesis, ensuring optimal feedstock quality. This preliminary action allows the exothermic synthesis reaction to proceed more efficiently with better heat management and reduced energy losses.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediate syngas processing stage that acts as a buffer between gasification and Fischer-Tropsch synthesis. This intermediary step allows for better control of reaction conditions and heat management, reducing the negative impacts of exothermic energy release.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If conventional synthetic fuel processes are used, then fuel production is achieved, but CO2 emissions are significant and environmental concerns arise

Engineering Contradiction:

Improvesynthetic fuel generationVSAvoidCO2 emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent captures CO2 produced during the gasification process and redirects it for utilization in enhanced oil recovery or other industrial applications. By converting this harmful emission into a useful resource, the process reduces net CO2 emissions while maintaining fuel production productivity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution enhances energy conversion efficiency, reduces process irreversibility, and enables effective CO2 capture and sequestration, making the process more economically and environmentally viable by utilizing CO2 and H2 in Fischer-Tropsch synthesis, thereby minimizing carbon emissions and increasing synthetic fuel yield.

Implementation Method 1

A redox system using one or more chemical intermediates is generally utilized in conjunction with liquid fuel generation via indirect Fischer-Tropsch synthesis, direct hydrogenation, or pyrolysis

Methodology Applied

Scientific EffectRedox reactions: Redox Reactions

Implementation Method 2

liquid fuel generation via indirect Fischer-Tropsch synthesis

Methodology Applied

Scientific EffectFischer-Tropsch synthesis: Catalysis

Implementation Method 3

liquid fuel generation via indirect Fischer-Tropsch synthesis, direct hydrogenation, or pyrolysis

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 4

CO2 capture from these processes associates with notable energy losses

Methodology Applied

Scientific EffectCO2 capture: Absorption (physical)

Data Source

PatentUS10865346B2Synthetic fuels and chemicals production with in-situ CO<sub>2 </sub>capture

Publication Date: 2020.12.15 OHIO STATE INNOVATION FOUND

AI summary

Novel redox based systems for fuel and chemical production with in-situ CO2 capture are provided. A redox system using one or more chemical intermediates is utilized in conjunction with liquid fuel generation via indirect Fischer-Tropsch synthesis, direct hydrogenation, or pyrolysis. The redox system is used to generate a hydrogen rich stream and/or CO2 and/or heat for liquid fuel and chemical production. A portion of the byproduct fuels and/or steam from liquid fuel and chemical synthesis is used as part of the feedstock for the redox system.