Steam Reforming Loop for SAF By-Product Syngas Recycling
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Solution Overview
Problem
Existing processes for converting sustainable feeds to jet fuel generate by-product streams rich in paraffins and/or olefins and off-gas streams with little commercial value, leading to inefficient carbon and hydrogen use and increased CO2 emissions.
Innovation Solution
A jet fuel synthesis plant that integrates a reforming system to convert these by-product and off-gas streams into syngas, which is then fed back into the methanol synthesis process, optimizing the CO/CO2 molar ratio and reducing catalyst volume, thereby improving overall carbon and hydrogen efficiency while minimizing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If by-product streams rich in paraffins and/or olefins and off-gas streams are discarded or used in fired equipment, then the process is simple to operate, but carbon and hydrogen efficiency is poor and CO2 emissions increase
Solution Approach 1:
The patent implements feedback by recycling by-product streams rich in paraffins and/or olefins and off-gas streams back into the steam reformer. These streams are converted to syngas and fed to the methanol synthesis loop, creating a closed-loop system that improves carbon and hydrogen efficiency while reducing CO2 emissions.
Solution Approach 2:
The system uses its own by-product streams and off-gas as feedstock for the steam reformer, making the process self-sufficient. The by-product streams that would otherwise be waste are converted into valuable syngas, reducing the need for external feedstock and minimizing emissions.
2Productivity
If syngas is produced from sustainable feeds via gasification and methanol synthesis, then jet fuel is produced, but by-product streams with little commercial value are generated
Solution Approach 1:
Instead of discarding the by-product streams rich in paraffins and/or olefins and off-gas streams, the patent recovers them by feeding them back to the steam reformer. This converts the waste streams into useful syngas, which is then used in the methanol synthesis loop to produce additional jet fuel.
Solution Approach 2:
The patent converts what would be harmful waste streams (by-products with little commercial value and CO2 emissions) into beneficial resources. The by-product streams are transformed into valuable syngas feedstock, turning a liability into an asset that improves overall process efficiency.
3Loss of energy
If steam reforming is implemented in a dedicated reformer to recycle by-product streams, then carbon and hydrogen efficiency improves, but plant complexity increases
Solution Approach 1:
The steam reformer serves multiple functions: it processes the main hydrocarbon feedstock to produce syngas for methanol synthesis, and simultaneously processes by-product streams rich in paraffins and/or olefins and off-gas streams. This multi-functionality improves carbon and hydrogen efficiency without requiring separate dedicated units for each feedstock.
4Object-generated harmful factors
If by-product streams are recycled via steam reforming, then CO2 emissions are minimized, but the process requires additional reforming equipment
Solution Approach 1:
The steam reformer is designed to handle multiple feedstocks including the by-product streams rich in paraffins and/or olefins and off-gas streams. This multi-functional approach allows the system to minimize CO2 emissions by recycling these streams without requiring entirely separate reforming equipment.
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 higher carbon and hydrogen efficiency, reduces catalyst volume, and minimizes CO2 emissions by recycling by-product and off-gas streams, enabling a more compact and cost-effective jet fuel production process.
Implementation Method 1
reforming system for reforming a by-product stream rich in paraffins and/or olefins, optionally also an off-gas stream, from the MTJ synthesis section and/or from the upgrading section, to provide a reformer-based syngas stream
Implementation Method 2
a methanol synthesis unit arranged to receive a first CO2 rich feed comprising CO2, a first H2 rich feed comprising H2, or a first syngas feed combining these streams; or a second syngas feed comprising a carbon oxide and hydrogen
Data Source
AI summary
A reforming system is provided for dedicated steam reforming of a stream rich in paraffins and/or olefins of a jet fuel synthesis plant incorporating the reforming system. The invention provides an overall more efficient feed-to-jet fuel system and process.