Steam Reformer CO2-Rich Gas Split for Low-CO Syngas Production
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Solution Overview
Problem
Existing steam reforming processes for producing synthesis gas release carbon monoxide into the atmosphere in excess of permissible emission limits due to its co-absorption in carbon dioxide scrubbing agents, necessitating additional investment for CO separation methods like flash stages.
Innovation Solution
The method involves dividing the carbon dioxide-rich gas stream into two parts, with one part being reintroduced into the reformer furnace or flue gas system for oxidation or afterburning, and the other part being recycled to the synthesis gas product stream, utilizing existing catalysts for CO conversion, thereby reducing CO emissions without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If carbon dioxide scrubbing is performed using physical or chemical absorption, then carbon dioxide separation is achieved, but carbon monoxide is co-absorbed and released in the carbon dioxide rich gas stream, exceeding emission limits
Solution Approach 1:
The carbon dioxide rich gas stream is divided into two parts: one part is reintroduced into the reformer furnace or flue gas system for oxidation, while the other part is recycled to the synthesis gas product stream. This segmentation allows selective treatment of CO-containing streams to meet emission requirements.
Solution Approach 2:
The harmful carbon monoxide in the carbon dioxide rich gas stream is converted into a valuable resource by recycling it to the synthesis gas product stream, where it can be utilized in downstream processes. Simultaneously, part of the CO is oxidized in the reformer furnace to reduce emissions, transforming the harmful substance into both a resource and an emission control solution.
2Object-generated harmful factors
If a flash stage is added between absorption and regeneration to separate carbon monoxide, then CO emission limits are met, but significant additional investment costs are incurred
Solution Approach 1:
The system uses its own existing infrastructure (reformer furnace, flue gas system, and synthesis gas product stream) to treat the carbon monoxide problem. By reintroducing part of the CO-rich stream into the reformer furnace for oxidation and recycling the other part to the synthesis gas stream, the process serves itself without requiring external separation equipment like flash stages.
Solution Approach 2:
The existing reformer furnace and synthesis gas product stream are given additional functions: the reformer furnace now also serves as a CO oxidation reactor, and the synthesis gas product stream becomes a destination for CO recycling. This multi-functionality eliminates the need for dedicated CO separation equipment.
3Ease of operation
If carbon monoxide is released with the carbon dioxide rich gas stream, then process simplicity is maintained, but emission limits are exceeded
Solution Approach 1:
The carbon dioxide rich gas stream is divided into two parts with different destinations: one part is sent to the reformer furnace/flue gas system for oxidation to reduce emissions, while the other part is recycled to the synthesis gas product stream. This segmentation maintains operational simplicity by using existing process streams while effectively controlling CO emissions.
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 effectively reduces carbon monoxide emissions below regulatory limits, eliminates the need for costly flash stages, and recycles CO as a valuable resource, enhancing process efficiency and reliability.
Implementation Method 1
one part being reintroduced into the reformer furnace or flue gas system for oxidation or afterburning
Implementation Method 2
one part being reintroduced into the reformer furnace or flue gas system for oxidation or afterburning
Implementation Method 3
utilizing existing catalysts for CO conversion
Data Source
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AI summary
A process and plant for producing a synthesis gas product stream by steam reforming of hydrocarbons is proposed, wherein the emission of carbon monoxide, which is released into the environment together with a carbon dioxide-rich gas stream, is reduced. According to the invention, a first portion of the carbon monoxide-containing carbon dioxide-rich gas stream is introduced into the reformer furnace via at least one burner and/or into the reformer furnace outside the burners and at a point in the reformer furnace where the local gas temperature is at least 1000 °C and/or into the flue gas duct and/or into the flue gas stack. A second portion of the carbon monoxide-containing carbon dioxide-rich gas stream is introduced into the reformer tubes.