Redox reaction facilitated carbon dioxide capture from flue gas and conversion to carbon monoxide

Patent metadata

Field	Value
Publication number	US-2022331736-A1
Application number	US-202017639884-A
Country	US
Kind code	A1
Filing date	Sep 3, 2020
Priority date	Sep 3, 2019
Publication date	Oct 20, 2022
Grant date	—

Abstract

Exemplary reactor systems may include multiple reactors in fluid communication. Oxygen carrier particles comprising a support material and metal oxide can be provided to a first reactor along with flue gas comprising carbon dioxide (CO2). An output of the first reactor is free or substantially free of carbon dioxide (CO2). The oxygen carrier particles can then be provided to one or more reactors in the system along with a hydrocarbon stream and, in some instances, an oxidizing stream. Outlets from these one or more reactors may include hydrogen gas (H2), carbon monoxide (CO), and/or other species, depending upon the content of the hydrocarbon streams and the oxidizing streams.

First claim

1 . A method of operating a reactor system, the method comprising:
providing oxygen carrier particles to a first reactor, the oxygen carrier particles comprising a support material and metal oxide; providing flue gas comprising carbon dioxide (CO 2 ) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO 2 ; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; operating the second reactor at a temperature of 500° C. to 1100° C.; collecting a second reactor gas output comprising hydrogen gas (H 2 ) and carbon monoxide (CO); providing the oxygen carrier particles to a third reactor; providing an oxidizing stream to the third reactor; and collecting a third reactor gas output comprising carbon monoxide (CO).

2 . The method of operating the reactor system according to claim 1 , wherein the oxidizing stream comprises steam (H 2 O) and carbon dioxide (CO 2 ); and
wherein the third reactor gas output further comprises hydrogen gas (H 2 ).

3 . The method of operating the reactor system according to claim 2 , wherein the oxidizing stream further comprises air.

4 . The method of operating the reactor system according to claim 1 , wherein the oxidizing stream comprises an oxide of nitrogen (NO x ) and carbon dioxide (CO 2 ); and
wherein the third reactor gas output further comprises nitrogen (N 2 ).

5 . The method of operating the reactor system according to claim 1 , wherein the metal oxide is an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba).

6 . The method of operating the reactor system according to claim 1 , wherein a metal oxide-metal carbonate solid-phase mixture is formed when the oxygen carrier particles contact the flue gas.

7 . The method of operating the reactor system according to claim 6 , wherein the metal oxide-metal carbonate solid-phase mixture includes one or more carbonates of calcium (Ca), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba).

8 . The method of operating the reactor system according to claim 1 , wherein support material of the oxygen carrier particles comprise silica (SiO 2 ), magnesia (MgO), alumina(Al 2 O 3 ), ceria (CeO 2 ), Titania (TiO 2 ), zirconia (ZrO 2 ), or combinations thereof.

9 . The method of operating the reactor system according to claim 8 , wherein the oxygen carrier particles comprise 20 weight percent (wt %) to 80 wt % support material.

10 . The method of operating the reactor system according to claim 1 , wherein the first reactor is operated at a temperature of 400° C. to 660° C.

11 . The method of operating the reactor system according to claim 10 , wherein the second reactor is operated at a temperature of 800° C. to 1100° C.

12 . The method of operating the reactor system according to claim 1 , further comprising:
providing the oxygen carrier particles to a fourth reactor; providing an air stream to the fourth reactor; collecting a fourth reactor gas output comprising depleted air; and providing the oxygen carrier particles to the first reactor.

13 . The method of operating the reactor system according to claim 1 , further comprising operating a second reactor system, comprising:
providing second oxygen carrier particles to a fifth reactor; providing a second hydrocarbon stream to the fifth reactor; collecting a fifth reactor gas output comprising either hydrogen gas (H 2 ) and carbon monoxide (CO), or hydrogen gas (H 2 ), carbon monoxide (CO), carbon dioxide (CO 2 ) and steam (H 2 O); providing the second oxygen carrier particles to a sixth reactor; providing air to the sixth reactor; collecting a sixth reactor gas output comprising depleted air; and providing heat generated in the sixth reactor to the second reactor.

14 . The method according to claim 1 , further comprising providing the oxygen carrier particles from the third reactor to a riser; and
providing the oxygen carrier particles from the riser to the first reactor.

15 . The method according to claim 1 , wherein the hydrocarbon stream includes coal, biomass, natural gas, shale gas, biogas, petroleum coke, or combinations thereof.

16 . A reactor system, comprising:
a first reactor comprising:
oxygen carrier particles, the oxygen carrier particles comprising a support material and metal oxide;
a flue gas inlet in fluid communication with a flue gas source, the flue gas source providing flue gas comprising carbon dioxide (CO 2 ) to the first reactor; and
a first reactor gas outlet configured to provide outlet gas comprising less than 1 ppb CO 2 ;
a second reactor in fluid communication with the first reactor, the second reactor comprising:
a hydrocarbon stream input in fluid communication with a hydrocarbon source, the hydrocarbon source configured to provide coal, biomass, natural gas, shale gas, biogas, or petroleum coke to the second reactor; and
a second reactor gas outlet configured to provide a second reactor gas output comprising hydrogen gas (H2) and carbon monoxide (CO); and
a third reactor in fluid communication with the second reactor, the third reactor comprising:
an oxidizing stream inlet in fluid communication with an oxidizing gas source comprising one or more of: steam (H 2 O), carbon dioxide (CO 2 ); and
a third reactor outlet gas outlet configured to provide a third reactor gas output comprising carbon monoxide (CO).

17 . The reactor system according to claim 16 , wherein the first reactor is arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed;
wherein the second reactor is arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed; wherein the metal oxide is an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba); and wherein steam (H 2 O) and carbon dioxide (CO 2 ) are co-injected with the hydrocarbon source.

18 . The reactor system according to claim 16 , wherein a metal oxide-metal carbonate solid-phase mixture is formed when the oxygen carrier particles contact the flue gas;
wherein the metal oxide-metal carbonate solid-phase mixture includes one or more carbonates of calcium (Ca), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba); and wherein the oxygen carrier particles further comprise support material comprising silica (SiO 2 ), magnesia (MgO), alumina(Al 2 O 3 ), ceria (CeO 2 ), Titania (TiO 2 ), zirconia (ZrO 2 ), or combinations thereof.

19 . A method of operating a reactor system, the method comprising:
providing oxygen carrier particles to a first reactor, the oxygen carrier particles comprising a support material and metal oxide; providing flue gas comprising carbon dioxide (CO 2 ) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO 2 ; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; providing an oxidizing stream to the second reactor such that the oxidizing stream is counter-current to the oxygen carrier particles; operating the second reactor at a temperature

Assignees

• Ohio State Innovation Foundation

Inventors

• Fan Liang-Shih
• Baser Deven
• Shah Vedant
• Cheng Zhuo

Classifications

• B01D2258/0283

  Flue gases · CPC title

• B01D2255/20738

  Iron · CPC title

• B01D2251/208

  Hydrocarbons · CPC title

• B01D2255/2045

  Calcium · CPC title

• Y02C20/40

  of CO2 · CPC title