Structured Catalyst Resistance Heating for On-Demand Synthesis Gas
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Solution Overview
Problem
Small-scale synthesis gas production is challenging due to energy-intensive reactions and the toxicity of carbon monoxide, making storage and handling difficult.
Innovation Solution
A structured catalyst comprising electrically conductive macroscopic structures with connectors, supporting catalytically active material, is used in a reactor system with a pressure shell and heat insulation, enabling on-demand gas production and efficient heat delivery through resistance heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large chemical plants are used for synthesis gas production, then production capacity is sufficient, but plant size and complexity increase
Solution Approach 1:
The catalyst is divided into multiple modular macroscopic structures (e.g., honeycomb monoliths) that can be individually manufactured and then assembled together. Each macroscopic structure contains catalytically active material in its cells, allowing the system to achieve large production capacity through parallel arrangement of standardized modules rather than requiring a single large complex plant
Solution Approach 2:
The patent embeds multiple functional elements within nested structures: catalytically active material is deposited on the walls of honeycomb cells, which are arranged in macroscopic structures that are then assembled into arrays. This nested organization allows high surface area catalyst support in compact volumes, achieving large production capacity without proportional increase in plant size
2Productivity
If synthesis gas is produced in large quantities, then production capacity is met, but storage becomes difficult and risky due to carbon monoxide toxicity
Solution Approach 1:
The invention extracts the catalytic function from traditional large-scale continuous production systems and concentrates it into compact modular reactors. By using structured catalysts with high surface area-to-volume ratio, the system achieves large production capacity in small footprints, eliminating the need for large storage facilities and reducing CO toxicity risks associated with storage
Solution Approach 2:
The structured catalyst design enables continuous on-demand synthesis gas production directly at the point of use. The modular reactors can be operated continuously to meet production requirements without interrupting for storage management, eliminating the harmful storage phase and associated CO toxicity risks
3Productivity
If endothermic reactions are used for synthesis gas production, then chemical conversion is achieved, but energy consumption increases
Solution Approach 1:
The patent applies local quality by creating regions of high catalytic activity within the honeycomb cells where the catalytically active material is deposited. This localized catalysis occurs at specific sites (cell walls) rather than requiring bulk heating of entire large volumes, reducing overall energy consumption while maintaining high production capacity
Solution Approach 2:
The honeycomb structure provides high surface area porous walls within each cell for catalyst deposition. This porous architecture increases the effective catalytic surface area without increasing reactor volume, enabling efficient endothermic reactions with lower energy input requirements per unit of synthesis gas produced
4Adaptability or versatility
If modular macroscopic structures are used, then plant design flexibility increases, but manufacturing complexity increases
Solution Approach 1:
The catalyst is segmented into standardized modular macroscopic structures (honeycomb monoliths) with uniform cell geometries. These standardized modules can be manufactured using consistent processes and then assembled in various configurations to meet different production requirements, providing design flexibility without proportionally increasing manufacturing complexity
Solution Approach 2:
The modular macroscopic honeycomb structures serve multiple functions: they provide structural support, define flow channels, support catalytic material deposition, and enable scalable assembly. This multi-functionality reduces the number of separate manufacturing steps needed compared to traditional catalyst forms, balancing manufacturing complexity with design flexibility
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 setup allows compact, safe, and efficient synthesis gas production in decentralized plants, reducing the need for gas storage and handling risks, with high production capacity and flexible plant design.
Implementation Method 1
heat for the endothermic reaction is provided by resistance heating
Implementation Method 2
the macroscopic structure supports a catalytically active material
Data Source
AI summary
A structured catalyst for catalyzing an endothermic reaction of a feed gas to convert it to a product gas Including at least one macroscopic structure of an electrically conductive material and at least one connector attached to the at least one macroscopic structure, wherein the macroscopic structure supports a catalytically active material.