Syngas Feed Preparation Using Distilled PFO and PGO Streams
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Solution Overview
Problem
Conventional refinery residues used in gasification processes for producing synthesis gas have high kinematic viscosity, leading to increased differential pressure, poor atomization, and environmental pollution due to sulfur and nitrogen content, necessitating a need for pretreatment and higher operating costs.
Innovation Solution
Utilizing pyrolysis fuel oil (PFO) and pyrolysis gas oil (PGO) from a naphtha cracking center process as raw materials, which are pretreated in a distillation column to adjust kinematic viscosity and flash point, then supplied to a combustion chamber for gasification, reducing greenhouse gas emissions and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If refinery residue is used as raw material for gasification process, then synthesis gas can be produced, but kinematic viscosity is high causing increased differential pressure and poor atomization
Solution Approach 1:
The patent changes the physical parameters of the raw material by selecting pyrolysis fuel oil and pyrolysis gas oil instead of refinery residue. These alternative materials have lower kinematic viscosity and flash point, which fundamentally alters the flow and combustion characteristics in the gasification process, enabling better atomization without requiring extensive pretreatment
Solution Approach 2:
The patent utilizes by-products (pyrolysis fuel oil and pyrolysis gas oil) from the naphtha cracking process that would otherwise be discarded or used as simple fuels. By converting these low-value waste streams into valuable gasification feedstocks, the process achieves both economic and operational benefits while solving the viscosity problem associated with conventional refinery residues
2Productivity
If refinery residue is used as raw material, then gasification can proceed, but sulfur and nitrogen content increases leading to acidic gas production and environmental pollution
Solution Approach 1:
The patent converts what would be harmful emissions into beneficial outcomes by selecting raw materials (pyrolysis fuel oil and pyrolysis gas oil) that inherently have lower sulfur and nitrogen content. This choice transforms the potential harm of acidic gas production into a benefit of reduced environmental pollution and lower operating costs, while maintaining high gasification throughput
Solution Approach 2:
The patent fundamentally changes the chemical composition parameters of the raw material by replacing refinery residue with pyrolysis-derived oils. This substitution alters the elemental composition, specifically reducing sulfur and nitrogen content, which directly decreases the production of hydrogen sulfide and ammonia during gasification, thereby resolving the environmental pollution issue
3Reliability
If refinery residue requires pretreatment before gasification, then combustion performance can be improved, but operating costs increase
Solution Approach 1:
The patent enables the system to be self-sufficient by selecting raw materials that inherently possess the necessary properties for effective gasification. Pyrolysis fuel oil and pyrolysis gas oil naturally have lower viscosity and flash point, eliminating the need for external pretreatment processes such as heating, dilution, or water addition that would be required for refinery residue, thus reducing both device complexity and operating costs while maintaining reliable combustion performance
4Ease of operation
If pyrolysis fuel oil is used as fuel without pretreatment, then it can be combusted, but high sulfur content violates environmental regulations
Solution Approach 1:
The patent transforms the situation by not treating pyrolysis fuel oil as a simple fuel to be combusted, but rather as a feedstock for gasification. This fundamental shift in usage converts the potential harm of high sulfur content into a benefit: the oil is converted into synthesis gas where the sulfur content is significantly reduced, enabling environmentally compliant operation while maintaining ease of use
Solution Approach 2:
The patent changes the operational parameters by transitioning from direct combustion to gasification process. This process transformation fundamentally alters how the sulfur content is handled - instead of being directly emitted during combustion, the sulfur is processed through the gasification reaction, resulting in reduced emissions that comply with environmental regulations while preserving the ease of operation
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
The method reduces greenhouse gas emissions, lowers operating costs, and improves process efficiency by using PFO and PGO as raw materials, addressing the limitations of conventional refinery residues.
Implementation Method 1
supplying a PFO stream including a pyrolysis fuel oil (PFO) and a PGO stream including a pyrolysis gas oil (PGO) discharged from a naphtha cracking center (NCC) process to a distillation column as a feed stream
Implementation Method 2
A gasifying agent and a raw material are supplied to a combustion chamber positioned at the foremost end of the gasification process to produce synthesis gas by a combustion process at a temperature of 700° C. or higher
Implementation Method 3
The gasification process is a process of converting a hydrocarbon such as coal, petroleum, and biomass as a raw material into synthesis gas mainly composed of hydrogen and carbon monoxide by pyrolysis or a chemical reaction with a gasifying agent
Data Source
AI summary
Provided is a method for preparing synthesis gas, and more particularly, a method for preparing synthesis gas including: supplying a pyrolysis fuel oil (PFO) stream including a PFO and a pyrolysis gas oil (PGO) stream including a PGO discharged from a naphtha cracking center (NCC) process to a distillation column as a feed stream (S10); and supplying a lower discharge stream from the distillation column to a combustion chamber for a gasification process to obtain synthesis gas (S20).