Electrically Heated RWGS Reactor for CO2 Conversion
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Solution Overview
Problem
Existing carbon capture and utilization technologies face challenges such as high energy requirements, unwanted methanation reactions, carbon formation, and inefficient use of hydrocarbons in reverse Water Gas Shift (RWGS) processes, leading to suboptimal CO2 conversion and increased costs.
Innovation Solution
An electrically heated RWGS reactor system that allows for simultaneous reverse water gas shift and methanation reactions using a catalyst capable of both processes, reducing carbon formation and utilizing hydrocarbons without external feeds, thereby optimizing CO2 conversion and energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used to achieve sufficient CO2 conversion in RWGS reaction, then CO2 conversion is improved, but methanation side-reactions increase reducing process yield
Solution Approach 1:
The patent converts the harmful methanation side-reaction into a beneficial process by introducing a dual-function catalyst that performs both RWGS and methanation reactions. The methanation reaction, previously considered unwanted, is now utilized to consume excess H2 and regulate the H2/CO ratio in the synthesis gas, while the produced methane can be further converted to synthesis gas components through steam reforming.
Solution Approach 2:
The patent employs a catalyst with universal activity that can catalyze both the reverse water-gas shift reaction and the methanation reaction. This multi-functional catalyst eliminates the need for separate catalysts or reaction stages, allowing simultaneous CO2 conversion and H2 consumption to produce synthesis gas with controlled composition.
2Productivity
If high H2/CO2 ratio is used to achieve high CO2 conversion, then CO2 conversion is improved, but synthesis gas H2/CO ratio becomes too high for downstream synthesis
Solution Approach 1:
The patent converts the excess H2, which creates an unfavorable high H2/CO ratio in synthesis gas, into a beneficial component by utilizing it for the methanation reaction. This consumes the excess H2 and produces methane that can be reformed back into synthesis gas components, effectively regulating the final H2/CO ratio to be suitable for downstream synthesis processes.
3Object-generated harmful factors
If traditional catalysts are used to avoid methanation, then methanation is reduced, but CO2 conversion requires higher temperatures increasing energy input
Solution Approach 1:
The patent employs a catalyst with universal activity that can catalyze both the reverse water-gas shift reaction and the methanation reaction. This multi-functional catalyst eliminates the need for separate catalysts or reaction stages, allowing simultaneous CO2 conversion and H2 consumption to produce synthesis gas with controlled composition.
Solution Approach 2:
The patent converts the harmful methanation side-reaction into a beneficial process by introducing a dual-function catalyst that performs both RWGS and methanation reactions. The methanation reaction, previously considered unwanted, is now utilized to consume excess H2 and regulate the H2/CO ratio in the synthesis gas, while the produced methane can be further converted to synthesis gas components through steam reforming.
4Device complexity
If hydrocarbon streams from downstream synthesis are not used for additional synthesis gas production, then process simplicity is maintained, but overall process feasibility is reduced
Solution Approach 1:
The patent merges the syngas production stage with the hydrocarbon utilization stage by integrating the e-RWGS reactor with steam reforming capability. This allows hydrocarbon streams from downstream synthesis to be directly reformed and converted into additional synthesis gas within the same reactor system, eliminating the need for separate processing units and maximizing resource utilization.
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 achieves high CO2 conversion with a desired H2:CO ratio, reduces carbon formation, and effectively utilizes hydrocarbons, enhancing overall CO2 utilization and energy efficiency while minimizing unwanted by-products.
Implementation Method 1
a structured catalyst comprising a macroscopic structure of electrically conductive material... by passing an electrical current through said macroscopic structure of electrically conductive material
Implementation Method 2
a structured catalyst comprising a macroscopic structure of electrically conductive material capable of catalysing both a reverse water gas shift reaction and a methanation reaction
Implementation Method 3
a structured catalyst comprising a macroscopic structure of electrically conductive material capable of catalysing both a reverse water gas shift reaction and a methanation reaction
Data Source
AI summary
A plant, such as a hydrocarbon plant, is provided, which has a syngas stage (A) for syngas generation and a synthesis stage (B) where said syngas is synthesized to produce syngas derived product, such as hydrocarbon product. The syngas stage (A) primarily includes electrically heated reverse water gas shift (e-RWGS) section. Additionally, an electrically-heated steam methane reforming (e-SMR) section (II) can be arranged in parallel to the e-RWGS section (I). The plant makes effective use of various streams; in particular CO2 and H2. A method for producing a product stream, such as a hydrocarbon product stream is also provided.