Solid Fuel Pyrolysis System for Low CO2 Synthesis Gas
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Solution Overview
Problem
Current waste-to-liquid fuel processes, such as the Fischer-Tropsch method, result in high CO2 emissions, nitrogen and sulfur dioxide pollution, and costly gas cleaning due to direct combustion and gasification under high pressure, making them inefficient and environmentally harmful.
Innovation Solution
A system and method that performs pyrolysis in the absence of oxygen or air, producing low CO2 synthetic gas, which is then converted into clean, high-calorific value liquid or gaseous fuels through a catalytic process, reducing ash entrainment and pollutant emissions by using a pyrolytic unit, synthesis gas production unit, and gas-to-liquid conversion with cleanup units for pollutant removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct flame gasification under high pressure is used to produce synthesis gas, then the gasification process is efficient and rapid, but CO2 emissions increase significantly and harmful emissions are generated
Solution Approach 1:
The patent applies inert atmosphere by conducting gasification in an oxygen-deficient environment using recycled synthesis gas as the gasifying agent. This prevents complete combustion of carbon, thereby reducing CO2 emissions while maintaining efficient gasification through the presence of reactive species in the recycled gas stream.
2Power
If direct combustion of waste material is performed, then energy release is rapid and intense, but nitrogen dioxides and sulfur dioxides are generated as harmful emissions
Solution Approach 1:
The system prevents formation of nitrogen dioxides and sulfur dioxides by maintaining an oxygen-deficient atmosphere during gasification. The recycled synthesis gas provides the necessary reactive environment without introducing excess oxygen that would lead to harmful emissions during combustion.
3Manufacturing precision
If waste gas is cleaned to produce liquid fuel, then fuel quality is improved, but the cleaning process becomes very costly
Solution Approach 1:
The patent applies preliminary action by performing most cleaning operations during the gasification process itself rather than as separate post-treatment steps. Impurities are removed in-line through the gasification chemistry and initial cooling stages, reducing the need for expensive downstream cleaning equipment and operations.
4Quantity of substance
If solids gasification is performed, then synthesis gas is produced, but ash must be captured, separated and processed adding complexity
Solution Approach 1:
The system merges the gasification process with ash handling by designing the gasifier to facilitate easy separation of ash from the synthesis gas stream. The integrated design allows ash to be naturally separated through gravity settling or simple filtration within the gasification system itself, reducing the need for complex separate ash handling 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 process significantly reduces CO2, nitrogen dioxide, and sulfur dioxide emissions, producing clean synthetic gas with high calorific value, resulting in efficient conversion of solid waste into fuels like diesel, gasoline, and methane with minimal ash and pollutant content.
Implementation Method 1
A system and method performs pyrolysis in the absence of oxygen or air, producing low CO2 synthetic gas
Implementation Method 2
The synthesis gas production unit is a steam reformer for converting the pyro gas into a synthesis gas (a mixture of hydrogen and carbon monoxide)
Implementation Method 3
the gas-to-liquid unit is a Fischer-Tropsch system for converting the synthesis gas into a fuel
Data Source
AI summary
A system for converting a solid fuel into a fuel including a pyrolytic unit for producing a pyro gas comprising hydrocarbons, a synthesis gas production unit for converting the pyro gas into a synthesis gas comprising a mixture of hydrogen and carbon monoxide, and a gas-to-liquid unit for converting the synthesis gas into a fuel.