Syngas Cooling and Filtration for Microbial Organic Synthesis
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Solution Overview
Problem
Conventional methods for purifying synthesis gas for use in organic synthesis with microbial catalysts face challenges in achieving high conversion efficiency due to temperature control issues and the presence of impurities, particularly nitrogen or air, which can degrade the catalyst.
Innovation Solution
A method involving a gas cooling tower for water-cooled synthesis gas purification followed by a filtration-type dust collector and a water scrubber, with subsequent contact with a microbial catalyst to generate organic substances, ensuring precise temperature control and impurity removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If synthesis gas is cooled using conventional methods (indirect heat exchanger, spray tower, wet-type electric dust collecting device), then the gas temperature is reduced to protect equipment, but the conversion efficiency of organic substance synthesis decreases due to mixed nitrogen or air
Solution Approach 1:
A water scrubber is introduced as an intermediary cooling device between the synthesis gas generation unit and the organic substance synthesis unit. The water scrubber cools the synthesis gas through direct contact with water, reducing temperature without introducing nitrogen or air that would harm the microbial catalyst's conversion efficiency.
Solution Approach 2:
The harmful components (nitrogen and air) are extracted from the cooling process by replacing conventional cooling methods that introduce atmospheric gases with a water-based cooling system that does not contaminate the synthesis gas with inert gases.
2Reliability
If synthesis gas is cooled to 40°C or lower to protect microbial catalyst, then catalyst survival is ensured, but the cooling process introduces nitrogen or air that decreases conversion efficiency
Solution Approach 1:
The water scrubber serves as a mediator that provides the necessary cooling to protect the microbial catalyst while avoiding the introduction of harmful nitrogen or air, thus maintaining both catalyst reliability and conversion efficiency.
3Object-generated harmful factors
If synthesis gas is passed through bag filter for tar removal, then tar mist is effectively removed, but high-temperature gas cannot pass through the filter directly requiring additional cooling equipment
Solution Approach 1:
The water scrubber combines multiple functions: it cools the synthesis gas to protect downstream equipment and introduces water vapor that helps condense and remove tar components, thereby merging cooling and tar removal functions into a single device.
Solution Approach 2:
The water scrubber performs multiple functions simultaneously: cooling the synthesis gas, removing tar components through condensation, and preparing the gas for subsequent filtration without requiring separate dedicated cooling equipment.
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 enables high-conversion efficiency in producing organic substances like ethanol by effectively cooling and purifying synthesis gas, preventing catalyst degradation and enhancing the synthesis process.
Implementation Method 1
a step of passing a synthesis gas discharged from a gasifier through a gas cooling tower to cool the synthesis gas with water sprayed in the gas cooling tower
Implementation Method 2
cool the synthesis gas with water sprayed in the gas cooling tower
Implementation Method 3
a step of passing the synthesis gas cooled in the gas cooling tower through a filtration-type dust collector
Implementation Method 4
a step of bringing the synthesis gas that has passed through at least the gas cooling tower and the filtration-type dust collector into contact with a microbial catalyst to generate an organic substance
Data Source
AI summary
A method for producing an organic substance includes a step of passing a synthesis gas G1 discharged from a gasifier 11 through a gas cooling tower 21 to cool the synthesis gas G1 with water sprayed in the gas cooling tower 21, a step of passing the synthesis gas G1 cooled in the gas cooling tower 21 through a filtration-type dust collector 22 and a step of bringing a synthesis gas G2 that has passed through at least the gas cooling tower 21 and the filtration-type dust collector 22 into contact with a microbial catalyst to generate an organic substance.