Synthesis Gas Splitting and Scrubbing for Flexible CO, H2, and Methanol Feed
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Solution Overview
Problem
Existing methods face challenges in economically producing methanol, H2, and CO from fluctuating amounts of H2- and CO-containing synthesis gas, particularly when the gas is highly contaminated and of variable composition.
Innovation Solution
The method involves dividing the synthesis gas into two substreams, where CO in the first substream is converted to CO2 and H2 through a watergas-shift reaction, and both substreams are scrubbed using an amine-containing medium to achieve the required (H2-CO2)/(CO+CO2) ratio for methanol synthesis, with the scrubbed streams being apportioned to produce H2 and CO products efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the synthesis gas stream is compressed at the outset, then the desired product pressures are achieved without further compression and plant component dimensions are reduced, but the energy consumption for compression increases
Solution Approach 1:
The synthesis gas stream is compressed at the very beginning of the process (outset) to the desired product pressure. This preliminary compression action eliminates the need for subsequent compression stages, reducing the number of compressors and plant component dimensions while achieving the required pressure for both H2 and methanol synthesis products.
2Adaptability or versatility
If the synthesis gas is divided into two substreams with different treatments, then flexible production of H2, CO, and methanol synthesis gas with controlled ratios is achieved, but the device complexity increases
Solution Approach 1:
The synthesis gas stream is divided into two separate substreams. The first substream undergoes water-gas shift reaction to convert CO to CO2 and H2, while the second substream remains unconverted. This segmentation allows independent control of each substream's treatment, enabling flexible adjustment of the final product composition and ratios for H2, CO, and methanol synthesis gas production.
Solution Approach 2:
The process configuration allows dynamic adjustment of the ratio between converted and unconverted substreams. By controlling the proportion of each substream that is scrubbed and mixed, the system can adaptively produce different product compositions and ratios according to market demands, making the production process highly versatile.
3Ease of manufacture
If acetylene off-gas is used as feedstock, then a cost-effective feedstock is utilized, but the high contamination and variable composition make economical production challenging
Solution Approach 1:
The process handles the variable composition and high contamination of acetylene off-gas by applying parameter changes through the water-gas shift reaction and selective scrubbing. The dual substream approach with selective CO conversion and CO2 removal allows the system to adapt to composition fluctuations, maintaining reliable and stable production despite the challenging feedstock characteristics.
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 allows for flexible production of H2, CO, and methanol synthesis gas with a controlled (H2-CO2)/(CO+CO2) ratio, optimizing product yields and reducing plant component dimensions and energy consumption, while utilizing underutilized acetylene off-gas as a cost-effective feedstock.
Implementation Method 1
only CO contained in the first synthesis gas substream is converted to CO2 and H2 (watergas-shift reaction) using steam admixed to the first synthesis gas substream
Implementation Method 2
the first converted synthesis gas substream and a part of the second unconverted synthesis gas substream are respectively fed to two separate scrubbing columns for scrubbing out CO2 with an amine-containing scrubbing medium
Data Source
AI summary
The invention relates to a method for production of a methanol-synthesis gas product stream (2), an H2 product stream (3) and a CO product stream (4) from an H2- and CO-containing synthesis gas stream (5).