Reformer-Based Hydrogen Delivery for C/C CO2 Methanization
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Solution Overview
Problem
Carbon dioxide emissions in carbon/carbon preform production processes, such as aircraft brake manufacturing, are significant and challenging to manage due to the high costs and logistical issues associated with sequestration, especially for smaller emission sources.
Innovation Solution
A system that converts carbon dioxide into methane through a methanization reaction using hydrogen generated during the production process, supplemented with green hydrogen, and recycles water back into a steam generator, utilizing a reformer and methanization reactor to produce methane for reuse in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If CO2 emissions are captured and stored via pipeline sequestration, then CO2 management is achieved, but the cost and complexity increase significantly
Solution Approach 1:
The patent converts harmful CO2 emissions into beneficial methane fuel through a methanation reactor. The CO2 captured from the C/C preform production process is reacted with hydrogen to produce methane, which is then reused as fuel in the production process, transforming a waste product into a valuable resource and eliminating the need for complex sequestration infrastructure
Solution Approach 2:
The system uses its own CO2 emissions as input for methane production, creating a self-sufficient fuel generation system. The methane produced is fed back into the C/C preform production process, making the system self-serviceable and reducing dependence on external fuel sources and complex storage infrastructure
2Object-affected harmful factors
If CO2 emissions are captured and stored, then sustainability goals are met, but operational costs increase
Solution Approach 1:
Instead of incurring costs for CO2 storage, the system generates valuable methane fuel from CO2 emissions. This conversion process turns a cost center (emission management) into a profit center (fuel generation), reducing operational costs while meeting sustainability goals
Solution Approach 2:
The system recovers energy in the form of methane from what would otherwise be discarded CO2 emissions. By capturing and converting the emissions rather than discarding them, the system recovers valuable energy that can be reused, thereby reducing operational costs
3Object-affected harmful factors
If CO2 emissions are managed through sequestration, then environmental goals are achieved, but logistical challenges arise for small emission sources
Solution Approach 1:
The system processes CO2 emissions on-site and converts them into usable fuel, eliminating the need for external logistics infrastructure. This self-service approach allows small emission sources to manage their CO2 independently without requiring connection to regional sequestration networks
Solution Approach 2:
The system transforms the logistical burden of CO2 management into a beneficial fuel production process. By converting CO2 into methane on-site, the system eliminates the need for complex transportation and storage logistics that would be required for traditional sequestration approaches
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 effectively manages CO2 emissions by converting them into usable methane, reducing waste and lowering operational costs, aligning with sustainability goals by utilizing existing process inputs and outputs.
Implementation Method 1
a reformer configured to convert an input into hydrogen and carbon monoxide
Implementation Method 2
convert the hydrogen, the carbon monoxide, and the carbon dioxide via methanization to produce methane
Implementation Method 3
The condenser is configured to receive the hydrogen, the carbon monoxide, and water from the reformer, condense the water into a liquid form
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A system for carbon dioxide emission recovery is disclosed herein. The system includes a reformer (412, 512) configured to convert an input into hydrogen and carbon monoxide and a methanization reactor (410, 510) coupled to the reformer (412, 512). The methanization reactor (410, 510) is configured to receive carbon dioxide from one or more off gases of a carbon/carbon (C/C) preform production process, receive the hydrogen and the carbon monoxide from the reformer (412, 512), convert the hydrogen, the carbon monoxide, and the carbon dioxide via methanization to produce methane, and supply the produced methane to at least one of the C/C preform production process or another system for heat generation.