Steam Reforming Fluidized Bed with Pulse Combustion Heating
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Solution Overview
Problem
Current methods for converting carbonaceous materials into fuel sources, such as steam reforming, face limitations in efficiency and throughput, particularly when dealing with materials like spent black liquor, which contain sulfur compounds, and require improvements in carbon conversion and sulfur separation.
Innovation Solution
The process involves pre-drying carbonaceous materials to at least 80% solids content before steam reforming in a fluidized bed, using a pulse combustion device for indirect heating, and incorporating a carbon trim cell for partial oxidation to enhance throughput and efficiency, while also removing sulfur compounds using sodium carbonate solutions or amine absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carbonaceous materials are directly steam reformed without pre-drying, then the process is simpler, but the throughput and efficiency are limited due to moisture content
Solution Approach 1:
The patent applies preliminary action by pre-drying carbonaceous materials to at least 80% solids content before steam reforming. This preliminary drying step removes moisture that would otherwise limit throughput and efficiency during the reforming process, allowing the fluidized bed to operate at optimal temperatures and achieve higher carbon conversion rates.
2Manufacturing precision
If a fluidized bed is used for steam reforming, then carbon conversion is improved, but sulfur compounds remain in the product gas requiring additional separation
Solution Approach 1:
The patent applies the extraction principle by removing sulfur compounds from the product gas through contact with sodium carbonate solution or amine absorption. This separates the harmful sulfur elements from the useful hydrogen-rich product gas, allowing the fluidized bed to maintain high carbon conversion while producing a cleaned fuel gas suitable for downstream applications.
3Speed
If higher temperatures are used in steam reforming, then reaction rate increases, but sulfur separation becomes more difficult and calcination load increases
Solution Approach 1:
The patent applies parameter changes by optimizing the fluidized bed temperature to balance reaction rate and sulfur separation. By controlling temperature parameters and using chemical absorption methods with sodium carbonate or amines, the system achieves effective sulfur removal without requiring excessively high temperatures that would increase calcination loads and make sulfur separation more difficult.
4Loss of substance
If spent black liquor is used as feedstock, then waste utilization is improved, but sulfur compounds and other impurities require additional treatment
Solution Approach 1:
The patent applies the 'blessing in disguise' principle by converting the harmful sulfur compounds in spent black liquor into useful products. The sulfur is captured and converted to sodium sulfide or other valuable sulfur-containing compounds through reaction with sodium carbonate, transforming a pollutant into a recoverable resource while the carbonaceous material is converted to hydrogen-rich fuel gas.
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 significantly increases the throughput and efficiency of steam reforming, achieves high carbon conversion, and effectively separates sulfur from the product gas, enabling the reuse of sulfur and reducing calcination loads, thus improving the overall energy conversion process.
Implementation Method 1
The fluidized bed may be indirectly heated by at least one pulse combustion device
Implementation Method 2
The pulse combustion device creates a pulsating combustion stream and an acoustic pressure wave that are transmitted through at least one resonance tube inserted into the fluidized bed
Implementation Method 3
In the bed, the carbonaceous material is endothermically converted into a product gas
Implementation Method 4
the carbonaceous fluid is dried so as to have a solids content of at least 80%
Implementation Method 5
removing sulfur compounds using sodium carbonate solutions or amine absorption
Implementation Method 6
incorporating a carbon trim cell for partial oxidation to enhance throughput and efficiency
Data Source
AI summary
Various processes and systems are disclosed for converting carbonaceous materials into a product gas stream. For instance, the product gas stream may be endothermically converted to a gas through a steam reforming process. The present invention is directed to various methods and systems for increasing throughput and efficiency of the system. Further, the present invention is also directed to sulfur removal methods and systems from a gas stream.