Tri-Reforming Catalyst for Integrated DME Synthesis
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Solution Overview
Problem
Conventional DME production from hydrocarbons requires multiple reaction steps and reactors, leading to high operating costs and carbon dioxide emission.
Innovation Solution
A process that combines tri-reforming and gas-phase DME direct synthesis over specific catalysts in one step, utilizing a tri-reforming catalyst (Ni/Ce/ZrO2/MgO/Cr/γ-Al2O3) and a hybrid catalyst (Cu/Zn/Zr/Al/Mn/Ga) to synthesize DME from hydrocarbons, with carbon dioxide recovery and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-step reforming and synthesis processes are used to prepare DME from hydrocarbons, then product purity and yield can be maintained, but the number of reactors and reaction steps increases, leading to higher operating costs and complexity
Solution Approach 1:
The patent combines three separate reforming reactions (steam reforming, dry reforming, and partial oxidation) into a single tri-reforming process that occurs simultaneously in one reactor. This merging of multiple reaction pathways eliminates the need for separate reforming units and reduces the overall number of reaction steps from multiple sequential processes to a single integrated process, directly reducing device complexity while maintaining productivity
Solution Approach 2:
The tri-reforming catalyst system is designed to perform multiple functions simultaneously: it catalyzes steam reforming, dry reforming, and partial oxidation reactions all within a single reactor. This multi-functional catalyst enables one reactor to accomplish what previously required multiple specialized reactors, thereby reducing device complexity without sacrificing DME production efficiency
2Reliability
If multiple reaction procedures are implemented for syngas synthesis and DME production, then reaction completeness can be achieved, but operating costs and apparatus requirements increase
Solution Approach 1:
The patent merges the syngas production function and DME synthesis function into a single continuous process within one reactor system. The tri-reforming generates syngas in-situ, which is then directly converted to DME over the same catalyst bed, eliminating the need for separate syngas synthesis and DME production apparatus. This integration reduces apparatus requirements and simplifies operation while ensuring reaction completeness through optimized catalyst and conditions
Solution Approach 2:
The tri-reforming process is designed to be self-sufficient by generating its own heat through exothermic partial oxidation reactions, which provides the necessary temperature for the endothermic steam reforming and dry reforming reactions. This internal heat generation eliminates the need for external heating systems and complex temperature control apparatus, reducing operating costs while maintaining reliable reaction completion
3Quantity of substance
If conventional reforming processes are used, then syngas can be produced, but carbon dioxide is released into the atmosphere contributing to the greenhouse effect
Solution Approach 1:
The patent recovers carbon dioxide that would otherwise be emitted as waste by incorporating it as a reactant in the dry reforming reaction. The CO2 is converted into useful syngas components (CO and H2) through reaction with the hydrocarbon feedstock over the tri-reforming catalyst. This transforms carbon dioxide from a harmful emission into a valuable reaction material, reducing greenhouse gas emissions while maintaining syngas production quantity
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 process reduces the number of reaction steps, decreases carbon dioxide generation, and lowers production costs by integrating syngas synthesis and DME production into a single step while maintaining high productivity and selectivity.
Implementation Method 1
simultaneously subjecting a feedstock mixture including C1-C4 hydrocarbons, carbon dioxide and water vapor, and an oxidant, to CO2 dry reforming and steam reforming, in the presence of a tri-reforming catalyst
Implementation Method 2
subjecting the syngas to methanol synthesis and methanol dehydration in the presence of a hybrid catalyst, to obtain a reaction product gas mixture including DME
Implementation Method 3
methane gas and oxygen are reacted at a high temperature to induce the combustion reaction. At this time, the temperature required for the reaction is maintained using the combustion heat generated
Implementation Method 4
carbon dioxide and methane gas are reacted to produce hydrogen and carbon monoxide, which is referred to as CO2 dry reforming. Since this process is an endothermic reaction, it functions to decrease the temperature of the reactor
Data Source
AI summary
Disclosed herein is a process for the preparation of dimethylether from hydrocarbons, including tri-reforming a feedstock mixture comprised of hydrocarbons, carbon dioxide and water vapor in the presence of a tri-reforming catalyst, to prepare a syngas, which then undergoes gas-phase direct synthesis into dimethylether in one step in the presence of a hybrid catalyst. According to the process of this invention, three main processes among typical syngas preparation processes are simultaneously performed, and then, the syngas thus obtained is prepared into dimethylether through a direct reaction in one step, thereby decreasing the apparatus cost and operation cost. In addition, all of the carbon dioxide separated and recovered from the unreacted material and by-products may be reused as reaction material, thus decreasing the generation of carbon dioxide and reducing the material cost.