Renewable Feedstock Conversion via Integrated Electrolysis and HDO
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Solution Overview
Problem
Current methods for converting pyrolysis gas from solid renewable feedstocks into valuable products like methane or methanol are inefficient, with low carbon recovery and limited integration of producing transportation fuels such as diesel, jet fuel, and gasoline.
Innovation Solution
A process that includes thermal decomposition of solid renewable feedstocks to produce off-gas and solid carbon, followed by hydro/deoxygenation, olefin removal, and either methanation or steam reforming, with electrolysis providing hydrogen, allowing for near 100% carbon recovery into methane or methanol and hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If pyrolysis gas is flared to the atmosphere or burned for heat generation, then the process is simple and energy needs are met, but carbon recovery is low and valuable products are lost
Solution Approach 1:
The patent converts the previously wasted pyrolysis gas (harms) into valuable products like methane, methanol, and hydrocarbon fuels (benefits). The off-gas stream containing CO, CO2, and light hydrocarbons is transformed through hydroprocessing, methanation, or steam reforming into useful energy carriers, achieving near 100% carbon recovery while eliminating the need for flaring
Solution Approach 2:
The patent creates a multi-functional process where a single integrated system produces multiple valuable products from one feedstock. The same pyrolysis off-gas can be converted into methane, methanol, or hydrocarbon fuels depending on the selected pathway, and the system simultaneously produces liquid oils and handles oxygen removal, making the process highly versatile and adaptable
2Loss of substance
If pyrolysis gas is sent to HDO reactor for catalytic deoxygenation, then oxygen content is reduced, but carbon recovery in liquid phase drops below 50%
Solution Approach 1:
The patent segments the oxygen removal process into distinct stages: first removing oxygen from the liquid oil phase through hydroprocessing, and then handling oxygen-containing gases separately through methanation or steam reforming. This segmentation allows carbon from both liquid and gas phases to be recovered in different product streams, achieving near 100% overall carbon recovery while effectively reducing oxygen content
3Adaptability or versatility
If multiple separate processes are used to produce different fuels, then product variety is achieved, but integration and efficiency are limited
Solution Approach 1:
The patent merges multiple fuel production pathways into a single integrated system. Pyrolysis off-gas can be directed to methanation for methane production, steam reforming for methanol synthesis, or hydroprocessing for hydrocarbon fuels. The system combines these different chemical transformation routes with unified feedstock preparation and product separation, achieving high versatility while maintaining efficient resource utilization and near-complete carbon recovery
4Loss of substance
If external hydrogen sources are used for hydroprocessing, then hydrogen needs are met, but process self-sufficiency and sustainability are reduced
Solution Approach 1:
The patent makes the process self-sufficient by producing the required hydrogen internally through electrolysis of water generated during the pyrolysis and hydroprocessing steps. This internal hydrogen production eliminates the need for external hydrogen sources, creates a closed-loop sustainable system, and ensures continuous operation without external dependencies
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 process achieves high carbon recovery and integration, producing a full range of transportation fuels from a single solid renewable feedstock, enhancing the value of pyrolysis gas and solid carbon streams.
Implementation Method 1
a pyrolysis unit (110), for conducting a solid renewable feedstock (101) to a thermal decomposition step for producing: a first off-gas stream (103)
Implementation Method 2
an electrolysis unit (122), for converting steam (121) into a hydrogen stream (123) and an oxygen stream (125)
Implementation Method 3
an HDO unit (112), for removing oxygen from the first off-gas stream (103)
Implementation Method 4
a methanation reactor (120), for converting the upgraded first off-gas stream (111) into a methane product (119)
Data Source
AI summary
Process for producing methane or methanol, said process comprising the steps of: i) conducting a solid renewable feedstock to a thermal decomposition step, this being a pyrolysis step or a hydrothermal liquefaction step, for producing: a first off-gas stream comprising hydrocarbons, a solid carbon stream, and optionally a first liquid oil stream; upgrading the first off-gas stream by conducting it to a hydro/deoxygenation (HDO/DO) step i.e. hydrodeoxygenation or deoxygenation step in which said HDO/DO step is conducted in the absence of steam, and a subsequent separation step, for generating water, a second liquid oil stream and an upgraded first off-gas stream; ii) conducting the first off-gas stream or the upgraded first off-gas stream to an olefin removal step, for generating a further upgraded first off-gas stream which is free of olefins; iii-1) conducting the first off-gas stream, or the upgraded first off-gas stream, or the further upgraded first off-gas stream, to a methanation step under the generation of steam for producing said methane; or iii-2) conducting the first off-gas stream, or the upgraded first off-gas stream, or the further upgraded first off-gas stream, to a steam reforming step for producing a methanol synthesis gas and subsequently conducting the methanol synthesis gas to a methanol synthesis step under the generation of steam for producing said methanol; iv) conducting steam, such as at least a portion of the steam generated in step iii-1) or iii-2), to an electrolysis step for producing an oxygen stream and a hydrogen stream; v) conducting at least a portion of the hydrogen stream from the electrolysis step to any of the: thermal decomposition step including HDO-step, olefin hydrogenation step, methanation step, methanol synthesis step, or combinations thereof.