Syngas Production via Solid-Solids Reactor Segmentation
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Solution Overview
Problem
Existing non-catalytic methods for producing syngas streams have a fixed H2/CO volume ratio, which limits flexibility for subsequent processing, such as in Fischer-Tropsch reactions, and require catalysts that are poisoned by contaminants like mercaptans, necessitating expensive treatment and catalyst replacement.
Innovation Solution
A method involving a reactor with a heated mass of solids at temperatures above 1000°C, where hydrocarbons are cracked to produce C and H2, and the C is converted using a high H2O/CO2 feed ratio to achieve a flexible H2/CO volume ratio in the syngas stream, allowing for the processing of hydrocarbon streams containing mercaptans without catalysts or expensive treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed non-catalytic method is used for producing syngas, then the process is simple, but the H2/CO ratio is fixed at 3:1 which limits flexibility for subsequent processing
Solution Approach 1:
The syngas production process is divided into two separate reaction zones: a first zone for producing H2-rich syngas and a second zone for producing CO-rich syngas. This segmentation allows independent control of H2 and CO production, enabling flexible adjustment of the final H2/CO ratio by combining streams from both zones in different proportions.
Solution Approach 2:
The invention introduces dynamic control capability by allowing continuous adjustment of the H2/CO ratio through variable mixing proportions of the two syngas streams. The system can adapt to different downstream processing requirements (e.g., Fischer-Tropsch synthesis needing specific ratios) without changing the fundamental process configuration.
2Productivity
If catalysts are used for syngas production, then the conversion efficiency is improved, but the catalysts are poisoned by contaminants like mercaptans requiring expensive treatment
Solution Approach 1:
The harmful contaminants (mercaptans and other sulfur compounds) are extracted and removed from the hydrocarbon feedstock before it enters the reaction zones. This is achieved through a dedicated removal step that prevents catalyst poisoning while maintaining high conversion efficiency in the subsequent cracking and reforming zones.
Solution Approach 2:
Instead of merely removing contaminants, the process converts the challenge of contaminant removal into a beneficial separation step that also pre-treats the feedstock for optimal cracking performance. The same unit that removes mercaptans also prepares the hydrocarbon stream for efficient conversion in the high-temperature zones.
3Reliability
If mercaptans are removed before processing, then catalyst poisoning is prevented, but expensive amine treating units are required
Solution Approach 1:
The contaminant removal function is merged with the existing syngas production process rather than being a separate pre-treatment step. The removal of mercaptans is integrated into the overall process flow, combining multiple functions (contaminant removal, feedstock preparation, and reaction optimization) into a unified system that reduces overall complexity and cost.
Solution Approach 2:
The process uses its own high-temperature reaction zones to simultaneously achieve contaminant decomposition and syngas production. The harsh conditions in the first reaction zone naturally decompose and remove mercaptans while producing H2, making the process self-sufficient for both contaminant removal and syngas generation without requiring external expensive treatment units.
4Temperature
If solid fuel bed is ignited to provide heat for pyrogenous decomposition, then the decomposition is enabled, but the fuel bed is consumed and needs replacement
Solution Approach 1:
The process replaces the mechanical/consumable fuel bed system with a electrically or externally heated system. Instead of relying on a consumable solid fuel bed that must be periodically replaced, the invention uses sustainable heating methods (electric heaters or heat exchange with product streams) to maintain the high temperatures required for pyrogenous decomposition, eliminating the need for fuel bed replacement.
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 method produces a syngas stream with a flexible H2/CO ratio, enabling more versatile processing options and eliminating the need for catalysts and costly treatments, while using CO2 to produce CO and handling hydrocarbon streams with contaminants like mercaptans.
Implementation Method 1
cracking the hydrocarbon-containing stream provided in step (a) in the reactor containing the heated mass of solids provided in step (b), thereby at least obtaining C and H2
Implementation Method 2
converting the C obtained in step (c) in the reactor at an H2O/CO2 vol.% feed ratio of greater than 0.0001, thereby obtaining a CO/H2-containing stream
Data Source
AI summary
The present invention provides a method for producing a syngas stream, the method at least comprising the steps of: (a) providing a hydrocarbon-containing stream; (b) providing a reactor containing a heated mass of solids at a temperature of at least 1000°C; (c) cracking the hydrocarbon-containing stream provided in step (a) in the reactor containing the heated mass of solids provided in step (b), thereby at least obtaining C and H2; (d) removing an H2-containing stream from the reactor; (e) converting the C obtained in step (c) in the reactor at an H2O/CO2 vol.% feed ratio of greater than zero, thereby obtaining a CO/H2-containing stream; (f) removing the CO/H2-containing stream from the reactor; (g) combining the H2-containing stream removed in step (d) with the CO/H2-containing stream removed in step (f) thereby obtaining a syngas stream.