Integrated Water Electrolysis And Parallel Reforming For Synthesis Gas
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Solution Overview
Problem
Existing steam reforming processes for synthesis gas production are large and require significant heat and oxygen, which is typically produced by costly cryogenic air separation units (ASU), while the hydrogen and carbon monoxide yields are imbalanced, and there is a need to reduce CO2 emissions and improve hydrogen efficiency.
Innovation Solution
Combining tubular steam reforming with autothermal reforming, electrolysis of water to generate oxygen, and optional heat exchange reforming to produce synthesis gas, eliminating the need for ASU and optimizing hydrogen and carbon dioxide levels for methanol synthesis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cryogenic air separation unit (ASU) is used to produce oxygen for autothermal reforming, then oxygen supply is ensured, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines the oxygen production function into the electrolysis unit that also produces hydrogen, eliminating the separate ASU. The electrolysis unit simultaneously generates hydrogen for methanol synthesis and oxygen for autothermal reforming, reducing overall system complexity while ensuring reliable oxygen supply.
Solution Approach 2:
The electrolysis unit is designed to serve multiple functions: producing hydrogen for methanol synthesis and generating oxygen for autothermal reforming. This multi-functional approach replaces the dedicated ASU, reducing device complexity while maintaining oxygen supply reliability.
2Device complexity
If tubular steam reformer size is reduced, then device complexity decreases, but hydrogen production capacity is insufficient
Solution Approach 1:
The patent merges tubular steam reforming with autothermal reforming in a combined reformer system. The autothermal reforming section provides additional hydrogen production capacity through partial oxidation reactions, allowing the overall system to meet hydrogen demands with a more compact configuration than traditional large-scale tubular reformers.
Solution Approach 2:
The patent changes the operational parameters by introducing partial oxidation reactions alongside steam reforming. This creates a synergistic effect where the exothermic oxidation reactions provide heat for the endothermic steam reforming, enabling higher hydrogen production density in a smaller reactor volume.
3Device complexity
If electrolysis is integrated to produce oxygen for ATR, then ASU is eliminated, but energy consumption increases
Solution Approach 1:
The patent combines hydrogen production and oxygen production in a single electrolysis unit, and integrates both products into the reforming process. The oxygen from electrolysis feeds the autothermal reforming section, creating a synergistic system where the energy input for electrolysis is offset by the valuable oxygen product that enables efficient hydrocarbon conversion.
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
Reduces the size and cost of steam reformers, optimizes hydrogen production, lowers CO2 emissions, and enhances hydrogen efficiency by integrating electrolysis and heat exchange reforming, while achieving desired hydrogen-to-carbon monoxide ratios for methanol synthesis.
Implementation Method 1
separating a hydrogen-containing stream and an oxygen-containing stream from water and/or steam in an electrolysis unit
Implementation Method 2
steam reforming a first part of the hydrocarbon feed stock from step (a) in a tubular steam reformer to a tubular steam reformed gas comprising hydrogen, carbon monoxide and carbon dioxide
Implementation Method 3
autothermal reforming a second part of the hydrocarbon feed stock in an autothermal reformer with at least part of the oxygen containing stream obtained in step (b) to an autothermal reformed gas stream comprising hydrogen, carbon monoxide and carbon dioxide
Implementation Method 4
a part of the feedstock can be heat exchange reformed in a heat exchange reformer downstream the tubular steam reformer and/or the tubular steam reformed gas can be additionally heat exchange reformed to reduce fuel consumption
Data Source
AI summary
Method for the preparation of synthesis gas combining electrolysis of water, tubular steam reforming and autothermal reforming of a hydrocarbon feed stock in parallel.