Vertical Stacked Fluidized Bed Reactors for CO2 Purification
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Solution Overview
Problem
Conventional chemical-looping combustion reactors, particularly those using iron-based oxygen carriers, face inefficiencies in controlling multi-stage reduction reactions, leading to incomplete oxygen release and limited throughput due to their large size and horizontal configuration, which restricts the effective capture and purification of CO2.
Innovation Solution
The implementation of an interconnected fluidized bed system with vertically stacked reduction reactors and an oxidation reactor, allowing for precise control of each stage of the reduction reaction, reducing the overall footprint, and incorporating heat exchangers to enhance performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fluidized-bed reactors are used for multi-stage reduction reaction, then the reactor can process the reaction, but the reactor size becomes large and cannot effectively control the three-stage reduction reaction
Solution Approach 1:
The patent divides the conventional single large fluidized-bed reactor into three separate smaller fluidized-bed reactors, each dedicated to one specific reduction stage (Fe2O3 to Fe3O4, Fe3O4 to FeO, FeO to Fe). This segmentation allows precise control of each reaction stage while reducing the volume of each individual reactor unit.
Solution Approach 2:
The patent transitions from a horizontal arrangement of reactors to a vertical stacked configuration, utilizing the vertical dimension to organize the three reduction reactors and oxidation reactor. This dimensional change reduces the horizontal footprint while maintaining the multi-stage reaction capability.
2Area of stationary object
If conventional horizontal connection of reactors is used, then the reaction process can be maintained, but the footprint of the overall structure is large and vertical space is not effectively used
Solution Approach 1:
The patent reconfigures the reactor arrangement from horizontal connection to vertical stacking, utilizing the vertical dimension to reduce the horizontal footprint. The three reduction reactors and oxidation reactor are stacked vertically with interconnections, effectively using vertical space while maintaining high throughput capability.
Solution Approach 2:
The patent implements a nested vertical structure where the three reduction reactors and oxidation reactor are stacked one above another, with each reactor connected to the next through vertical channels. This nested arrangement maximizes space utilization and reduces the overall footprint.
3Productivity
If oxygen carrier is not completely reduced in conventional reactors, then the reaction can proceed, but the throughput is limited and fuel may not be reacted completely
Solution Approach 1:
By dividing the reduction process into three separate reactors, each optimized for a specific reduction stage, the system ensures complete oxygen release. Each reactor maintains optimal conditions for its specific stage, preventing incomplete reduction that limits throughput in conventional single-reactor systems.
Solution Approach 2:
The patent establishes continuous circulation of the oxygen carrier through the three reduction reactors and back to the oxidation reactor. This continuous action ensures that the oxygen carrier is completely reduced and regenerated, maintaining high throughput without compromising the completeness of oxygen release.
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 configuration enables complete oxygen release, high-purity CO2 production, and hydrogen generation while reducing the structural footprint, achieving high-volume throughput, operational efficiency, and low costs by optimizing the use of vertical space and allowing for geometric flexibility in each reduction reactor.
Implementation Method 1
the first stage reduction reaction is processed to obtain a gas comprising CO2 and steam while reduce Fe2O3 to ferroferric oxide (Fe3O4); the second stage reduction reaction is processed with a hydrocarbon fuel to obtain a gas comprising CO2 and steam while reduce Fe3O4 to iron oxide (FeO); the third stage reduction reaction is processed with a hydrocarbon fuel to obtain a gas comprising CO2 and steam while reduce FeO to iron (Fe)
Implementation Method 2
an oxidation reaction is processed with air to obtain a gas comprising nitrogen and oxygen and turn Fe to Fe2O3
Implementation Method 3
set a heat exchanger between various adjacent reduction reactors in the vertically-connecting structure for improving overall performance
Data Source
AI summary
An apparatus of hydrocarbon fuel reactors separates and purifies carbon dioxide (CO2). Interconnected fluidized beds are applied in chemical-looping combustion. A multi-stage reduction reaction is processed with iron-based oxygen carriers. Three reduction stages using the iron-based oxygen carriers are accurately and completely controlled. Each of the three stages is separately processed in an individual space. Oxygen in the iron-based oxygen carriers can be fully released. High-purity CO2 is obtained. Hydrogen can be produced as an option. Horizontal connection of three reduction reactors is changed into vertical one. An oxidation reactor is further connected. Thus, the whole structure occupies less area and effectively uses vertical space. Not only small space is effectively used; but also high-volume capacity is obtained. Each of the reactors has better geometry flexibility. The tandem reactor in each layer has less geometric influence and limitation. Therefore, each of the reactors can be resized on its own.