Synthesis Gas Production via Adiabatic Post Converter
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Solution Overview
Problem
Current methods for producing synthesis gas with a low H2/CO ratio face challenges such as carbon formation on catalysts and high oxygen consumption, particularly in autothermal reforming processes, which also result in larger reactor sizes and inefficiencies.
Innovation Solution
A process involving an autothermal reforming reactor followed by an adiabatic post converter with a second catalyst for steam methane reforming, methanation, and reverse water gas shift reactions, where a heated CO2 rich gas stream is introduced to adjust the H2/CO ratio and increase CO production, reducing the risk of carbon formation and oxygen usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam reforming is used to produce synthesis gas with low H2/CO ratio, then CO production is improved, but carbon formation on catalyst increases
Solution Approach 1:
The reforming process is divided into two separate reactors: an autothermal reforming reactor for initial reforming, and a second reactor for completing the reforming reaction. This segmentation allows each reactor to operate under optimized conditions, with the second reactor specifically designed to achieve low H2/CO ratio without excessive carbon formation by using a different heating mechanism.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component to transfer heat from the effluent of the autothermal reforming reactor to the feed stream entering the second reactor. This indirect heat transfer mechanism allows the second reactor to achieve the necessary temperature for reforming without direct combustion, thereby reducing carbon formation on the catalyst while still achieving low H2/CO ratio in the product gas.
2Quantity of substance
If autothermal reforming is used to achieve low H2/CO ratio, then CO production is improved, but oxygen consumption and reactor size increase
Solution Approach 1:
The reforming process is divided into two separate reactors: an autothermal reforming reactor for initial reforming, and a second reactor for completing the reforming reaction. This segmentation allows each reactor to operate under optimized conditions, with the second reactor specifically designed to achieve low H2/CO ratio without excessive carbon formation by using a different heating mechanism.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component to transfer heat from the effluent of the autothermal reforming reactor to the feed stream entering the second reactor. This indirect heat transfer mechanism allows the second reactor to achieve the necessary temperature for reforming without direct combustion, thereby reducing carbon formation on the catalyst while still achieving low H2/CO ratio in the product gas.
3Quantity of substance
If high CO2 concentration and low steam concentration are used in feed stream, then low H2/CO ratio is promoted, but carbon formation risk increases
Solution Approach 1:
The reforming process is divided into two separate reactors: an autothermal reforming reactor for initial reforming, and a second reactor for completing the reforming reaction. This segmentation allows each reactor to operate under optimized conditions, with the second reactor specifically designed to achieve low H2/CO ratio without excessive carbon formation by using a different heating mechanism.
Solution Approach 2:
The invention changes the operating parameters of the second reactor by using indirect heating through a heat exchanger instead of direct combustion. This parameter change allows the reactor to operate at temperatures sufficient for reforming while avoiding the localized high temperatures that cause carbon formation, enabling the use of high CO2 and low steam concentrations to achieve low H2/CO ratio.
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 effectively tailors the H2/CO ratio of the synthesis gas to below 1.0, increases CO production, and reduces the size of the ATR reactor while minimizing carbon formation and oxygen consumption, making it suitable for revamping existing systems to enhance carbon monoxide production capacity.
Implementation Method 1
letting at least a part of the first synthesis gas stream and the heated CO2 rich gas stream undergo steam methane reforming, methanation and reverse water gas shift reactions
Implementation Method 2
letting at least a part of the first synthesis gas stream and the heated CO2 rich gas stream undergo steam methane reforming, methanation and reverse water gas shift reactions
Implementation Method 3
letting at least a part of the first synthesis gas stream and the heated CO2 rich gas stream undergo steam methane reforming, methanation and reverse water gas shift reactions
Implementation Method 4
providing a heated CO2 rich gas stream to an adiabatic post converter
Data Source
AI summary
A process for producing synthesis gas, the process including the steps of: a) in a reforming reactor, reacting a hydrocarbon feed stream together with an oxidant gas stream, thereby producing a first synthesis gas stream; b) providing a heated CO2 rich gas stream to an adiabatic post converter including a second catalyst active for catalyzing steam methane reforming, methanation and reverse water gas shift reactions; and c) in the adiabatic reforming post converter, letting at least a part of the first synthesis gas stream and the heated CO2 rich gas stream undergo steam methane reforming, methanation and reverse water gas shift reactions to thereby provide a product gas stream, the product gas stream being a synthesis gas stream. Also, a system for producing synthesis gas.