Renewable Fuel Synthesis Reactor with Hydrogen Buffer
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Solution Overview
Problem
Existing renewable fuel synthesis systems face challenges in efficiently producing renewable fuels from intermittent hydrogen and non-combustible gas sources due to kinetic or equilibrium limitations, leading to incomplete reactions and high energy consumption during start-up and shut-down processes, which limits their ability to adapt to fluctuating renewable energy sources.
Innovation Solution
A dynamic reactor system with a hydrogen gas buffer and controllable non-combustible gas feed, coupled with a heat exchanger and phase separator, allows for variable operation modes based on hydrogen supply conditions, minimizing hydrogen feed during low supply periods and maintaining reactor temperatures through hydrogen combustion, thus optimizing fuel production and reducing energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the reactor operates continuously with fixed feed rates, then the reaction kinetics are maintained, but the system cannot adapt to intermittent hydrogen supply from renewable sources
Solution Approach 1:
The patent implements dynamic operation modes (normal, start-up, shut-down, idle) that allow the reactor system to adapt its feed rates and operating parameters in real-time according to hydrogen supply conditions. The non-combustible gas feed rate and hydrogen feed rate are adjusted dynamically based on the operational state, enabling the system to respond to intermittent renewable energy input while maintaining optimal reaction conditions and productivity.
2Loss of energy
If the reactor is shut down during low hydrogen supply, then energy consumption is reduced, but catalyst contamination and start-up time increase
Solution Approach 1:
The patent introduces a pre-shut-down phase where the non-combustible gas feed is reduced before complete shut-down, and an idle mode where minimal feeds are maintained to prevent catalyst contamination. These preliminary actions protect the catalyst from exposure to air or contaminants during transition periods, maintaining catalyst performance while still allowing for energy reduction during low supply periods.
Solution Approach 2:
The system maintains continuous operation in an idle mode rather than complete shut-down, with minimal feeds of non-combustible gas and hydrogen continuing to flow through the reactor. This continuous action prevents catalyst contamination and eliminates start-up delays while consuming minimal energy during periods of low hydrogen supply from renewable sources.
3Stress or pressure
If the non-combustible gas feed rate is increased to maintain pressure, then the reaction equilibrium shifts, but energy consumption increases
Solution Approach 1:
The patent dynamically adjusts the non-combustible gas feed rate based on the operational mode and hydrogen availability. During normal operation, the feed rate is optimized for both pressure maintenance and reaction equilibrium. During start-up and shut-down phases, the feed rate is temporarily increased to maintain pressure stability. The system balances these competing requirements by adjusting parameters according to the specific operational context.
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 system enhances the efficiency and cost-effectiveness of renewable fuel production by maintaining reactor temperatures and preventing catalyst contamination, allowing for flexible operation with intermittent energy sources and increasing the overall output of renewable fuels.
Implementation Method 1
a heat exchanger coupled to an outlet of the reactor
Implementation Method 2
a phase separator coupled to an outlet of the heat exchanger, the phase separator being configured to separate a gas stream including un-reacted hydrogen and un-reacted non-combustible gas from a liquid stream including the renewable fuel product
Implementation Method 3
a burner configured to combust the un-reacted hydrogen contained in the gas stream
Implementation Method 4
The reactor can include an internal heat exchanger configured to provide cooling to the reactor in a normal operating mode and to provide heating to the reactor in an idle mode
Data Source
AI summary
Systems and methods for producing fuel products from renewable energy sources are disclosed herein. A reactor system includes a variable feed of non-combustible gas, a hydrogen gas buffer providing a variable feed of hydrogen gas, a reactor coupled to the variable feeds and configured to convert the non-combustible gas and the hydrogen gas into a renewable fuel product, a heat exchanger coupled to an outlet of the reactor, a phase separator coupled to an outlet of the heat exchanger and configured to separate a gas stream including un-reacted hydrogen and un-reacted non-combustible gas from a liquid stream including the renewable fuel product, and a burner configured to combust the un-reacted hydrogen contained in the gas stream. The reactor includes an internal heat exchanger configured to provide cooling to the reactor in a normal operating mode and to provide heating to the reactor in an idle mode.