Syngas Mixing and Compression Layout for Lower Hydrogen Compression Energy
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Solution Overview
Problem
The production of synthetic fuels like methane or methanol requires a synthesis gas mixture of hydrogen and carbon dioxide at high pressures, but compressing hydrogen alone is energy-intensive and complex due to its low molar mass, necessitating numerous compressor stages and high energy consumption.
Innovation Solution
A device that splits the carbon dioxide flow into two partial flows, one expanded via a turbine and mixed with hydrogen, and the other bypassing the turbine to a second mixing device, allowing for efficient compression of the mixture with reduced equipment complexity and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If hydrogen gas is compressed from low pressure to high pressure using conventional compressors, then the required pressure level for synthetic fuel production is achieved, but the equipment complexity and energy consumption increase significantly due to the low molar mass of hydrogen
Solution Approach 1:
Carbon dioxide is introduced as an intermediary substance to mix with hydrogen, forming a synthesis gas mixture with higher average molar mass. This intermediary approach allows the use of fewer compressor stages since the mixture is easier to compress than pure hydrogen, thereby reducing equipment complexity while achieving the required pressure level
Solution Approach 2:
The invention changes the physical parameter of the gas being compressed by mixing hydrogen with carbon dioxide. The resulting synthesis gas mixture has different compositional parameters (higher average molar mass) compared to pure hydrogen, which fundamentally alters the compression characteristics and reduces the number of compressor stages needed
2Stress or pressure
If hydrogen gas is compressed from low pressure to high pressure using conventional compressors, then the required pressure level for synthetic fuel production is achieved, but the energy consumption increases significantly
Solution Approach 1:
Carbon dioxide serves as an intermediary that modifies the compression characteristics of hydrogen. By mixing CO2 with H2, the resulting mixture has higher average molar mass and requires less energy for compression to the same pressure level, thereby reducing energy consumption while achieving the required pressure
Solution Approach 2:
The compositional parameters of the gas mixture are changed by adding carbon dioxide to hydrogen. This parameter change (increased average molar mass) directly reduces the energy required for compression, as evidenced by the lower energy consumption when compressing the synthesis gas mixture compared to pure hydrogen
3Use of energy by moving object
If carbon dioxide is expanded through a partial mass flow turbine, then the energy consumption for compression is reduced, but the equipment complexity increases
Solution Approach 1:
The carbon dioxide mass flow is segmented into two partial mass flows: one portion is expanded through the partial mass flow turbine to recover energy and reduce compression energy requirements, while the other portion bypasses the turbine. This segmentation allows energy recovery without requiring a full-scale turbine handling the entire mass flow, thereby reducing equipment complexity
Solution Approach 2:
Instead of expanding the entire carbon dioxide mass flow through a turbine, only a partial mass flow is routed through the turbine for expansion. This partial action is sufficient to achieve the energy recovery goal while avoiding the complexity of designing and operating a turbine capable of handling the full mass flow
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 device provides a synthesis gas mixture at lower energy costs and minimal equipment complexity by increasing the molar mass through mixing and polytropic expansion, reducing the need for compressor stages and energy use.
Implementation Method 1
a partial mass flow turbine (14) for expanding the first partial mass flow of at least carbon dioxide
Implementation Method 2
a compression device (17) for compressing the mixture of at least carbon dioxide and hydrogen supplied by the first mixing device (16) to a third pressure level
Data Source
Figure 1
Figure 2
AI summary
Device (10) for providing a synthesis gas mixture of at least carbon dioxide and hydrogen, wherein the device (10) is supplied with a mass flow of at least carbon dioxide at a first pressure level and a mass flow of at least hydrogen at a second pressure level, comprising a dividing device (13) for dividing the mass flow of at least carbon dioxide into a first and second partial mass flow, comprising a partial mass flow turbine (14) for expanding the first partial mass flow, comprising a first mixing device (16) for mixing the first partial mass flow expanded by the partial mass flow turbine (14) with the mass flow of at least hydrogen, comprising a compression device (17) for compressing the mixture of at least carbon dioxide and hydrogen supplied by the first mixing device (16) to a third pressure level, comprising a bypass line (20),via which the second partial mass flow can be fed past the partial mass flow turbine (14), past the first mixing device (16) and past the compression device (17) to a second mixing device (21) in order to mix the second partial mass flow guided via the bypass line (20) with the mixture compressed by the compression device (17) in the area of the second mixing device (17).