Stand-Alone Autothermal Reformer for Carbon-Efficient Gasoline Synthesis
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Solution Overview
Problem
Conventional processes for converting sustainable feeds to gasoline suffer from significant carbon and hydrogen loss in by-products and off-gases, leading to inefficient use and increased carbon dioxide emissions, with limited commercial value and high energy consumption.
Innovation Solution
A gasoline synthesis plant incorporating a stand-alone autothermal reformer (ATR) to convert by-product streams rich in paraffins and off-gases into synthesis gas, which is then recycled to enhance methanol synthesis, reducing the need for upstream reforming units and optimizing hydrogen and carbon efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional steam methane reforming is used to convert by-product streams, then synthesis gas can be produced, but the process requires complex upstream reforming units and has high energy consumption
Solution Approach 1:
The invention extracts and eliminates the complex upstream reforming units from the process by using a stand-alone autothermal reformer that directly processes the by-product streams (LPG and off-gases) into synthesis gas, which is then recycled to the methanol loop. This simplification reduces device complexity while maintaining productivity.
Solution Approach 2:
The invention changes the reforming approach from conventional steam methane reforming to autothermal reforming, which alters the chemical and thermal parameters of the process. This enables direct conversion of by-product streams into synthesis gas without requiring complex upstream reforming infrastructure.
2Loss of substance
If by-product streams and off-gases are vented or used in fired equipment, then carbon efficiency is low, but recycling them requires additional reforming process
Solution Approach 1:
The invention converts the previously harmful waste streams (LPG and off-gases containing CO2, H2, CH4) into valuable synthesis gas through autothermal reforming. This transforms substances that caused carbon loss and required venting into useful resources that enhance methanol synthesis, thereby reducing carbon loss while the simplified stand-alone ATR minimizes added complexity.
Solution Approach 2:
Instead of discarding by-product streams and off-gases through venting or combustion, the invention recovers and reprocesses them through the stand-alone autothermal reformer into synthesis gas that is recycled to the methanol loop, thereby recovering valuable carbon and hydrogen resources.
3Productivity
If methanol synthesis unit size is increased to maintain catalyst volume, then gasoline production increases, but capital and operating costs increase
Solution Approach 1:
The invention introduces feedback by recycling the synthesis gas produced from autothermal reforming of by-product streams back to the methanol synthesis unit. This feedback loop enhances methanol production efficiency and gasoline yield without requiring proportional increases in catalyst volume or unit size, thereby maintaining productivity while controlling manufacturing costs.
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 increases product-to-hydrogen efficiency by 15-25%, minimizes carbon dioxide emissions, and reduces the size and cost of the methanol synthesis unit, while maintaining catalyst volume and hydrogen consumption.
Implementation Method 1
a reforming system for reforming a by-product stream rich in paraffins from the gasoline synthesis section and/or from the upgrading section, to provide an ATR-based syngas stream
Implementation Method 2
a methanol synthesis unit arranged to receive the first CO2 rich feed and the first H2 rich feed, or arranged to receive the first syngas feed, or arranged to receive the second syngas feed, and provide an effluent stream comprising methanol
Data Source
AI summary
A reforming system is provided for autothermal reforming of a by-product stream rich in paraffins of a gasoline synthesis plant incorporating the reforming system. The invention provides an overall more efficient feed-to-gasoline system and process.