Steam Electrolysis Heat Integration for Carbon Dioxide Conversion
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Solution Overview
Problem
Existing power-to-fuel processes face high energy requirements and inefficiencies in converting carbon dioxide to chemicals and fuels, particularly in large-scale applications, necessitating improved energy efficiency through optimized heat integration to reduce external energy input.
Innovation Solution
Implementing a heat integration design that recovers and utilizes heat from various sources within the process to heat material streams for the steam electrolyzer, minimizing external electrical energy consumption and enhancing overall process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external energy is supplied to heat material streams for steam electrolysis, then the electrolyzer can operate at required temperatures, but external energy consumption increases
Solution Approach 1:
The patent combines multiple heat sources (exothermic reactor, combustion unit, cathode effluent, anode effluent) into a unified heat integration system that collectively heats the steam feed stream to the electrolyzer, replacing the need for separate external heating systems and reducing overall external energy consumption
Solution Approach 2:
The system uses its own internal heat sources (exothermic reactions within the process, combustion of tail gas, and hot effluents from the electrolyzer itself) to provide the heating energy required for steam electrolysis, making the system self-sufficient for thermal energy needs
2Use of energy by moving object
If heat integration design is implemented to recover and utilize heat from process sources, then external electrical energy consumption is reduced, but system complexity increases
Solution Approach 1:
The heat integration system performs multiple functions simultaneously: the exothermic reactor generates product chemicals while producing heat; the combustion unit processes tail gas while generating thermal energy; the heat exchangers transfer heat between streams while also serving as temperature control devices. This multi-functionality reduces the need for separate dedicated equipment
Solution Approach 2:
The system optimizes temperature parameters of various process streams by adjusting heat exchange conditions, flow rates, and reaction conditions to maximize heat recovery efficiency while maintaining product quality and process stability, thereby reducing external energy requirements without proportionally increasing 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
The proposed method and system achieve high energy efficiency by maximizing the utilization of available heat sources, reducing electrolyzer electricity consumption, and lowering energy costs while producing valuable chemicals and fuels like methanol and dimethyl ether.
Implementation Method 1
heating a steam feed stream having a temperature of from about 250° C. to about 350° C. received from a reactor unit in a first heat exchanger using an anode effluent from an anode of an electrolyzer as a heat transfer medium
Implementation Method 2
heating the first heated steam effluent in a second heat exchanger using a cathode effluent from the cathode of the electrolyzer as a heat transfer medium
Implementation Method 3
combusting, in a combustion unit, a first tail gas stream to transfer heat to the second heated steam effluent to generate a third heated steam effluent having a temperature of about 700° C. to about 950° C.
Implementation Method 4
converting carbon dioxide to chemicals and/or fuels utilizing steam electrolysis
Data Source
AI summary
A method includes heating a steam feed stream received from a reactor unit in a first heat exchanger using an anode effluent from an anode of an electrolyzer as a heat transfer medium to generate a first heated steam effluent, heating the first heated steam effluent in a second heat exchanger using a cathode effluent from a cathode of the electrolyzer as a heat transfer medium to generate a second heated steam effluent, combusting, in a combustion unit, a first tail gas stream to transfer heat to the second heated steam effluent to generate a third heated steam effluent, and passing the third heated steam effluent to the cathode of the electrolyzer.