Solid Carbon Production via CO2 Reduction and Thermal Recovery
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Solution Overview
Problem
Current methods for producing solid carbon materials are energy and cost inefficient, and they do not effectively utilize carbon oxides as a carbon source, which are abundant and inexpensive, particularly in point source emissions and atmospheric CO2.
Innovation Solution
A method and system for producing solid carbon by reacting carbon oxides with gaseous reducing materials in the presence of a catalyst at elevated temperatures and pressures, followed by thermal energy recovery from the gaseous effluent stream, using a reactor and heat exchanger configuration to enhance energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pyrolysis methods using hydrocarbons are used to produce solid carbon, then solid carbon can be produced, but energy efficiency is low and production costs are high
Solution Approach 1:
The patent changes the chemical parameters of the carbon source from hydrocarbons to carbon oxides (CO2, CO), and modifies reaction conditions to use catalysts at lower temperatures. This transforms the energy-intensive pyrolysis process into a more efficient catalytic reduction process, directly addressing the energy consumption problem while maintaining solid carbon production.
Solution Approach 2:
The patent converts carbon oxides, which are typically harmful emissions requiring costly capture and disposal, into valuable carbon sources for solid carbon production. This transforms waste carbon dioxide and carbon monoxide into useful products, simultaneously reducing greenhouse gas emissions and lowering production costs by using inexpensive carbon feedstocks.
2Ease of manufacture
If carbon oxides are utilized as carbon source, then production costs decrease, but current methods do not effectively utilize abundant carbon oxides
Solution Approach 1:
The patent enables carbon oxides to serve dual purposes: they are both the carbon source for solid carbon production and the feedstock for energy generation through combustion. The system design allows the process to be self-sufficient by using part of the produced solid carbon or associated hydrocarbons to generate energy, eliminating the need for external energy inputs and reducing operational costs.
Solution Approach 2:
The patent creates a multi-functional system where carbon oxides serve multiple roles: as carbon source material, as combustion fuel, and as a means to generate process heat. The solid carbon product also serves multiple functions as a valuable material while potentially serving as fuel. This multi-functionality maximizes the value extracted from inexpensive carbon oxide feedstocks.
3Device complexity
If thermal energy is not recovered from effluent stream, then process is simpler, but operational costs increase due to energy loss
Solution Approach 1:
The patent implements a feedback loop where thermal energy from the effluent stream is recovered and fed back into the system to preheat incoming carbon oxide streams or sustain reaction temperatures. This creates a self-regulating energy system where waste heat automatically returns to the process, reducing external energy requirements without complex external energy supply infrastructure.
Solution Approach 2:
The patent merges the thermal energy recovery function with the existing process equipment by integrating heat exchangers into the flow path. The effluent stream cooling and the reactant stream heating occur in an integrated manner, combining what would otherwise be separate energy management systems into a unified thermal management approach that reduces overall process complexity.
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 approach enables the energy-efficient production of solid carbon materials while recovering excess thermal energy, reducing operational costs and improving the overall efficiency of the process.
Implementation Method 1
reacting at least one carbon oxide material and at least one gaseous reducing material at a temperature of greater than or equal to about 400° C., at a pressure of greater than or equal to about 1×105 pascal, and in the presence of at least one catalyst material to produce at least one solid carbon material
Implementation Method 2
Thermal energy is extracted from the gaseous effluent stream
Implementation Method 3
reacting at least one carbon oxide material and at least one gaseous reducing material... to produce at least one solid carbon material and a gaseous effluent stream comprising water vapor
Data Source
AI summary
A method of thermal energy recovery from production of at least one solid carbon material comprises reacting at least one carbon oxide material and at least one gaseous reducing material at a temperature of greater than or equal to about 400° C., at a pressure greater than or equal to about 1×105 pascal, and in the presence of at least one catalyst material to produce at least one solid carbon material and a gaseous effluent stream comprising water vapor. Thermal energy is extracted from the gaseous effluent stream comprising water vapor. Other methods of generating recoverable thermal energy are disclosed, as is a solid carbon production system having thermal energy recovery.