Syngas Conversion Sequence for High-Rate CO2 Separation
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Solution Overview
Problem
Current methods for carbon dioxide removal in industrial processes, such as steam reforming, are inefficient and costly due to low partial pressure in flue gases, limiting their practical application, while separating carbon dioxide from synthesis gas results in lower removal rates.
Innovation Solution
A process involving an electrically heated conversion step and a combustion-heated conversion step, arranged upstream and/or downstream, to enhance carbon dioxide separation rates from synthesis gas, with optional feed preparation and water-gas conversion steps, and subsequent purification using pressure swing adsorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If amine scrubbing is used to remove carbon dioxide from flue gas, then carbon dioxide removal efficiency is improved (approximately 95%), but the process becomes technically complex and costly to operate due to energy requirements for amine regeneration
Solution Approach 1:
The process segments carbon dioxide removal into two parts: (1) preliminary concentration of carbon dioxide through selective combustion of a portion of the synthesis gas, and (2) final separation using amine scrubbing. This segmentation allows the amine scrubbing unit to operate on a smaller, pre-concentrated stream rather than the entire flue gas volume, reducing complexity and energy requirements.
Solution Approach 2:
The selective combustion step performs a preliminary action by converting carbon monoxide to carbon dioxide and concentrating the carbon dioxide content before the main separation process. This preliminary concentration makes the subsequent amine scrubbing more efficient and less complex.
2Ease of operation
If carbon dioxide is separated from synthesis gas without additional conversion steps, then the process is simpler to operate, but carbon dioxide removal rate is limited to approximately 60%
Solution Approach 1:
The process implements continuous carbon dioxide removal through a multi-stage conversion and separation sequence. The electrically heated converter continuously converts remaining carbon monoxide to carbon dioxide, and the amine scrubbing unit continuously separates carbon dioxide from the synthesis gas, achieving over 90% removal efficiency.
Solution Approach 2:
The process replaces conventional thermal heating with electrical heating in the converter unit. This substitution allows for more precise temperature control and efficient conversion of carbon monoxide to carbon dioxide, improving overall removal efficiency while maintaining operational simplicity.
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
Achieves carbon dioxide separation rates of up to 90% from synthesis gas, reducing emissions and increasing plant capacity without significant modifications to existing plants, and enabling the use of low-carbon fuels.
Implementation Method 1
an electrically heated conversion step and a combustion-heated conversion step arranged upstream and/or downstream of this step
Implementation Method 2
an electrically heated conversion step and a combustion-heated conversion step arranged upstream and/or downstream of this step
Implementation Method 3
subsequent purification using pressure swing adsorption
Data Source
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AI summary
A process (100, 200) for providing a process product (21) is proposed, wherein the process (100, 200) comprises processing a carbon-containing feedstock (1) in a processing sequence (110, 120, 130, 140, 150) to obtain a first component mixture (17) containing carbon dioxide, and separating (160) at least a portion of the carbon dioxide from the first component mixture (17) or a portion thereof to obtain a second component mixture (20) containing the process product, wherein the processing sequence (110, 120, 130, 140, 150) comprises an electrically heated conversion step (120) and a combustion-heated conversion step (130) arranged upstream and/or downstream thereof. A corresponding plant is also proposed.