SOEC-eSMR Hybrid Syngas Production System
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Solution Overview
Problem
Current synthesis gas generation methods using co-electrolysis and reverse water gas shift reactions face limitations such as carbon formation, methane production, and diffusion issues in Solid Oxide Electrolysis Cells, which restrict operating temperatures and efficiency.
Innovation Solution
Combining Solid Oxide Electrolysis Cells (SOEC) with electrically heated reformers (eSMR) and a downstream boiler to achieve high-temperature reverse water gas shift and methane steam reforming, allowing for efficient CO-rich synthesis gas production while minimizing carbon formation and methane conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher process temperatures are used in SOEC to improve CO-rich synthesis gas production, then conversion efficiency increases, but material technology limitations prevent operation above 850-865°C
Solution Approach 1:
The patent combines SOEC with eSMR technology to create a hybrid system. The eSMR reactor operates at higher temperatures (950-1050°C) than the SOEC, enabling endothermic reforming reactions that produce CO-rich synthesis gas. The two technologies are merged through heat integration where the eSMR reactor serves as both a reforming reactor and a heat source for the SOEC, allowing the system to operate at temperatures that would be too high for SOEC alone while maintaining material integrity.
Solution Approach 2:
The eSMR reactor performs multiple functions: it acts as a reforming reactor for CO2 and H2O conversion, serves as a high-temperature heat source, and provides thermal energy to the SOEC. This multi-functionality allows the system to overcome the temperature limitation of SOEC while maintaining its electrochemical conversion capabilities.
2Productivity
If CO2 conversion is increased in SOEC, then synthesis gas production improves, but carbon formation risk increases due to Boudouard reaction
Solution Approach 1:
The patent converts the harmful Boudouard reaction (which produces carbon) into a beneficial process by operating the eSMR at high temperatures where the reaction equilibrium favors CO production. The high-temperature environment transforms carbon-forming conditions into CO-generating conditions, turning a harmful side reaction into a useful source of synthesis gas.
Solution Approach 2:
The patent changes the temperature parameter from SOEC operating range (850-865°C) to eSMR operating range (950-1050°C). This parameter change shifts the chemical equilibrium of the Boudouard reaction to favor CO over carbon formation, eliminating the carbon deposition problem while maintaining high conversion rates.
3Quantity of substance
If methane is produced in SOEC, then carbon balance is maintained, but downstream synthesis efficiency decreases due to inert gas accumulation
Solution Approach 1:
The patent changes the operating temperature to 950-1050°C in the eSMR, which is sufficient to drive complete methane steam reforming. At these temperatures, the equilibrium constant for methane reforming becomes very large, ensuring near-complete conversion of methane to CO and H2, thereby eliminating inert gas accumulation in downstream processes.
Solution Approach 2:
The patent implements continuous methane reforming through the eSMR process, ensuring that methane is continuously converted to useful CO and H2 rather than accumulating as an inert gas. This continuous conversion maintains high synthesis gas quality for downstream applications.
4Loss of energy
If feed/effluent recuperator is used to preheat feed gas, then energy efficiency improves, but metal dusting and carbon formation occur in the heat exchanger
Solution Approach 1:
The patent introduces a radiant heat exchanger as an intermediary that transfers heat through radiation rather than direct contact between hot gas and heat exchanger tubes. This radiant heat transfer mechanism allows efficient energy transfer without exposing the heat exchanger materials to the corrosive, carbon-forming atmosphere, thereby preventing metal dusting and carbon deposition.
Solution Approach 2:
The patent replaces conventional convective heat transfer (which requires direct contact between gas and heat exchanger surfaces) with radiant heat transfer. This substitution eliminates the mechanical contact that leads to metal dusting and carbon formation, while maintaining high energy efficiency through direct radiant heating.
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 combination enables higher CO-rich synthesis gas production with reduced methane formation and metal dusting issues, extending the operating regime and improving energy efficiency by utilizing the boiler for instantaneous cooling and steam generation.
Implementation Method 1
co-electrolysis of CO2 and steam in a Solid Oxide Electrolyser Cell stack
Implementation Method 2
electrically heated reformers (eSMR)
Implementation Method 3
methane steam reforming
Implementation Method 4
utilizing the boiler for instantaneous cooling and steam generation
Implementation Method 5
reverse water gas shift (RWGS) reaction according to: CO2+H2=CO+H2O
Data Source
AI summary
The present invention describes a method of combining electrolysis, preferably SOEC with reforming, preferably eSMR, to produce a carbon monoxide (CO) rich synthesis gas, providing several synergies and overcoming some limitations of the SOEC technology.