Systems and methods for production and separation of hydrogen and carbon dioxide

Patent metadata

Field	Value
Publication number	US-12240758-B2
Application number	US-202418762336-A
Country	US
Kind code	B2
Filing date	Jul 2, 2024
Priority date	Nov 9, 2017
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

The present disclosure relates to systems and methods useful for providing one or more chemical compounds in a substantially pure form. In particular, the systems and methods can be configured for separation of carbon dioxide from a process stream, such as a process stream in a hydrogen production system. As such, the present disclosure can provide systems and method for production of hydrogen and/or carbon dioxide.

First claim

The invention claimed is:

1. A process for hydrogen production, the process comprising:
reacting a hydrocarbon feed stream and oxygen into a reactor unit to form a product gas stream comprising H 2 +CO;
passing the product gas stream comprising H 2 +CO through a steam generating boiler to add steam to the product gas stream comprising H 2 +CO;
converting the product gas stream comprising H 2 +CO in at least one reactor to form a stream comprising H 2 +CO 2 ;
heating the hydrocarbon feed stream against one or both of the product gas stream comprising H 2 +CO and the stream comprising H 2 +CO 2 in one or more heat exchangers;
heating a hydrocarbon fuel stream against a gas turbine exhaust stream in the one or more heat exchangers and outputting the heated hydrocarbon fuel stream to a gas turbine to produce power;
processing the cooled stream comprising H 2 +CO 2 in a first pressure swing adsorber to provide a first product stream formed of substantially pure hydrogen and also provide waste gas steam comprising CO 2 ;
compressing the waste gas stream comprising CO 2 in a compressor;
passing a vapor phase stream depleted in CO 2 plus additional steam through a catalytic CO shift reactor to provide a cooled compressed waste gas stream; and
processing the cooled compressed waste gas stream in a second pressure swing adsorber to provide a second product stream formed of substantially pure hydrogen and a second low pressure waste gas stream,
wherein an overall ratio of H 2 product divided by H 2 +CO present in the product gas stream is greater than about 97%.

2. The process of claim 1 , further comprising transferring of excess heat from the product gas stream comprising H 2 +CO to an external process using one or more heat exchangers.

3. The process of claim 1 , further comprising outputting one or both of a waste fuel gas stream and steam generated in the hydrogen production system using one or more lines.

4. The process of claim 1 , further comprising one or more lines configured for delivery of at least part of the product stream formed of substantially pure hydrogen as fuel to a gas turbine.

5. The process of claim 1 , wherein reacting the hydrocarbon feed stream and the oxygen comprises receiving a steam stream in addition to the hydrocarbon feed stream at an inlet to a POX or ATR reactor producing a product stream comprising H 2 +CO.

6. The process of claim 1 , wherein reacting the hydrocarbon feed stream and the oxygen comprises receiving a stream of oxygen in addition to the hydrocarbon feed stream at a partial oxidation (POX) reactor.

7. The process of claim 1 , wherein reacting the hydrocarbon feed stream and the oxygen comprises receiving a steam stream and a stream of oxygen in addition to the hydrocarbon feed stream at a catalytic auto-thermal reactor (ATR).

8. The process of claim 1 , wherein reacting the hydrocarbon feed stream and the oxygen comprises receiving one of a stream of oxygen in addition to the hydrocarbon feed stream at a partial oxidation (POX) reactor and a steam stream and a stream of oxygen in addition to the hydrocarbon feed stream at a catalytic auto-thermal reactor (ATR) and also comprises receiving at least a portion of the stream comprising H 2 +CO from the POX reactor or the ATR in addition to the hydrocarbon feed stream at a gas heated reformer (GHR).

9. The process of claim 1 , further comprising cooling the product gas stream comprising H 2 +CO and for forming steam at a steam generating boiler.

10. The process of claim 1 , wherein reacting the hydrocarbon feed stream and the oxygen comprises receiving a low pressure preheated feed air stream in addition to the hydrocarbon stream at an ion transport membrane (ITM) partial oxidation reactor.

11. The process of claim 1 , further comprising transferring heat from an external heat source to at least the hydrocarbon feed stream at a super-heater heat exchanger.

12. The process of claim 1 , the reactor unit is a combined pressure vessel that includes at least a partial oxidation zone and a catalytic steam plus hydrocarbon zone.

13. The hydrogen production system of claim 12 , wherein the partial oxidation zone is at a bottom portion of the combined pressure vessel, the catalytic steam plus hydrocarbon zone comprises open-ended tubes in a middle zone of the combined pressure vessel, and the combined pressure vessel further includes a waste heat boiler heat exchanger at a top portion thereof.

14. The process of claim 1 , further comprising:
separating the waste gas stream comprising CO 2 into a vapor phase stream depleted in CO 2 and a liquid product stream concentrated in CO 2 in a low temperature separation unit, wherein at least 50 mol % of the CO 2 in the waste gas stream comprising CO 2 is separated into the liquid CO 2 product stream;
passing the vapor phase stream depleted in CO 2 through a compressor followed by the catalytic CO shift reactor together with the additional steam;
compressing the second low pressure waste gas stream from the second pressure swing adsorber;
passing a first portion of the vapor phase stream depleted in CO 2 through the one or more heat exchangers to combine with the hydrocarbon feed stream via a first line; and
passing a second portion of the vapor phase stream depleted in CO 2 to the gas turbine exhaust stream for heating the hydrocarbon fuel stream in the one or more heat exchangers via a second line.

15. The process of claim 14 , wherein the low temperature separation unit is a cryogenic separation unit.

16. The process of claim 14 , further comprising compressing the waste gas stream comprising CO 2 at the low temperature separation unit.

17. The process of claim 16 , further comprising drying the waste gas stream comprising CO 2 after the compression at the low temperature separation unit.

18. The process of claim 16 , further comprising cooling the waste gas stream comprising CO 2 by one or both of heat exchange and expansion at the low temperature separation unit.

19. The process of claim 16 , passing the waste gas stream comprising CO 2 through a mass transfer column at the low temperature separation unit.

Assignees

• 8 Rivers Capital Llc

Inventors

• Rafati Mohammad
• Allam Rodney John

Classifications

• Y02C20/40

  of CO2 · CPC title

• F25J2200/70

  Refluxing the column with a condensed part of the feed stream, i.e. fractionator top is stripped or self-rectified · CPC title

• B01D2259/65

  Employing advanced heat integration, e.g. Pinch technology · CPC title

• F25J2200/40

  Features relating to the provision of boil-up in the bottom of a column · CPC title

• C01B3/00

  Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen; Reversible storage of hydrogen (production of water-gas or synthesis gas from solid carbonaceous material C10J) · CPC title