Co-production of hydrogen, carbon, electricity, and concrete with carbon dioxide capture

Patent metadata

Field	Value
Publication number	US-2024194916-A1
Application number	US-202218077643-A
Country	US
Kind code	A1
Filing date	Dec 8, 2022
Priority date	Dec 8, 2022
Publication date	Jun 13, 2024
Grant date	—

Abstract

A hydrocarbon feed stream is exposed to heat in an absence of oxygen to the convert the hydrocarbon feed stream into a solids stream and a gas stream. The gas stream is separated into an exhaust gas stream and hydrogen. The carbon is separated from the solids stream as a carbon stream. Electrolysis is performed on a water stream to produce an oxygen stream and hydrogen. The oxygen and a portion of the carbon are combined to generate power and a carbon dioxide stream. At least a portion of the carbon stream, cement, and water are mixed to form a concrete mixture. The concrete mixture can be used to produce ready-mix concrete and precast concrete. Carbon dioxide used for curing the concrete can be sourced from the carbon dioxide stream produced by power generation.

First claim

What is claimed is:

1 . A method comprising:
exposing a hydrocarbon feed stream comprising a hydrocarbon to heat in an absence of oxygen to convert the hydrocarbon feed stream into a solids stream and a gas stream, the solids stream comprising carbon, the gas stream comprising hydrogen; separating the gas stream into an exhaust gas stream and a first hydrogen stream comprising at least a portion of the hydrogen from the gas stream; separating the carbon from the solids stream to produce a carbon stream; performing electrolysis on a water stream comprising water to produce an oxygen stream and a second hydrogen stream, the oxygen stream comprising oxygen, the second hydrogen stream comprising hydrogen; combining at least a portion of the oxygen of the oxygen stream and a first portion of the carbon stream to generate power and a carbon dioxide stream comprising carbon dioxide, wherein a first portion of the generated power is used to perform electrolysis on the water stream; combining a second portion of the carbon stream, a cement stream comprising cement, and water to form a concrete mixture; pressurizing a first portion of the carbon dioxide stream using a second portion of the generated power to form a pressurized carbon dioxide stream, the pressurized carbon dioxide stream in a liquefied or supercritical state; discharging the pressurized carbon dioxide stream and a first portion of the concrete mixture as a ready-mix concrete stream; and curing a second portion of the concrete mixture using a second portion of the carbon dioxide stream to produce a precast concrete stream.

2 . The method of claim 1 , wherein the hydrocarbon feed stream comprises one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof.

3 . The method of claim 2 , wherein the hydrocarbon feed stream comprises hydrogen.

4 . The method of claim 3 , wherein the oxygen and the carbon are combined by a direct carbon fuel cell comprising a solid oxide, and the oxygen and the carbon are combined by the direct carbon fuel cell at an operating temperature in a range of from about 550 degrees Celsius (° C.) to about 900° C.

5 . The method of claim 4 , comprising transferring, by a first waste heat recovery heat exchanger, heat from the gas stream to a buffer fluid.

6 . The method of claim 5 , comprising transferring, by a second waste heat recovery heat exchanger, heat from the buffer fluid to the hydrocarbon feed stream prior to exposing the hydrocarbon feed stream to heat in the absence of oxygen.

7 . The method of claim 1 , comprising flowing, after curing the second portion of the concrete mixture to produce the precast concrete stream, a remaining portion of the carbon dioxide stream to the ready-mix concrete production unit.

8 . The method of claim 4 , comprising transferring, by a first waste heat recovery heat exchanger, heat from the carbon dioxide stream to a buffer fluid.

9 . The method of claim 8 , comprising transferring, by a second waste heat recovery heat exchanger, heat from the buffer fluid to the hydrocarbon feed stream prior to exposing the hydrocarbon feed stream to heat in the absence of oxygen.

10 . The method of claim 4 , comprising sequestering, within a subterranean formation, the carbon dioxide stream generated by the direct carbon fuel cell, such that the carbon dioxide stream is not released to the atmosphere.

11 . A system comprising:
a hydrocarbon feed stream comprising a hydrocarbon; a pyrolysis chamber configured to receive the hydrocarbon feed stream and expose the hydrocarbon feed stream to heat in an absence of oxygen to convert the hydrocarbon feed stream into a solids stream comprising carbon and a gas stream comprising hydrogen; a gas separation unit configured to receive the gas stream from the pyrolysis chamber and separate the hydrogen from the gas stream to produce an exhaust gas stream and a first hydrogen stream comprising at least a portion of the hydrogen from the gas stream; a carbon separation unit configured to receive the solids stream from the pyrolysis chamber and separate the carbon from the solids stream to produce a carbon stream; a water stream comprising water; an electrolysis unit configured to receive the water stream and electrical power, the electrolysis unit configured to use the electrical power to perform electrolysis on the water stream to produce an oxygen stream comprising oxygen and a second hydrogen stream comprising hydrogen; a power generation unit configured to receive at least a portion of the oxygen stream from the electrolysis unit and a first portion of the carbon stream from the carbon separation unit, the power generation unit comprising a direct carbon fuel cell configured to combine the oxygen from the portion of the oxygen stream and the carbon from the first portion of the carbon stream to generate power and a carbon dioxide stream comprising carbon dioxide, wherein a first portion of the power generated by the power generation unit is provided to the electrolysis unit to perform electrolysis on the water stream; a cement stream comprising cement; a ready-mix concrete production unit configured to receive the cement stream and a second portion of the carbon stream, the ready-mix concrete production unit configured to mix the cement stream, the second portion of the carbon stream, and water to form a concrete mixture, wherein the ready-mix concrete production unit is configured to receive a first portion of the carbon dioxide stream from the power generation unit and a second portion of the power generated by the power generation unit, and the ready-mix concrete production unit is configured to use the second portion of the power generated by the power generation unit to pressurize the first portion of the carbon dioxide stream to form a pressurized carbon dioxide stream, the pressurized carbon dioxide stream in a liquefied or supercritical state, the ready-mix concrete production unit configured to discharge the pressurized carbon dioxide stream and a first portion of the concrete mixture as a ready-mix concrete stream; and a precast concrete production unit configured to receive a second portion of the concrete mixture from the ready-mix concrete production unit and a second portion of the carbon dioxide stream from the power generation unit, the precast concrete production unit configured to cure the second portion of the concrete mixture using the second portion of the carbon dioxide stream to produce a precast concrete stream.

12 . The system of claim 11 , wherein the hydrocarbon feed stream comprises one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof.

13 . The system of claim 12 , wherein the hydrocarbon feed stream comprises hydrogen.

14 . The system of claim 13 , wherein the direct carbon fuel cell comprises a solid oxide electrolyte configured to operate at a temperature in a range of from about 550 degrees Celsius (° C.) to about 900° C.

15 . The system of claim 14 , comprising a first waste heat recovery heat exchanger in fluid communication with the gas stream exiting the pyrolysis chamber and a buffer fluid, the first waste heat recovery heat exchanger configured to transfer heat from the gas stream to the buffer fluid.

16 . The system of claim 15 , comprising a second waste heat recovery heat exchanger in fluid communication with the hydrocarbon feed stream entering the pyrolysis chamber and the buffer fluid, the second waste heat recovery heat exchanger configured to transfer the heat from the buffer fluid to the hydrocarbon feed stream prior

Assignees

• Saudi Arabian Oil Co

Inventors

• Perez Omar David Hurtado
• Katikaneni Sai P

Classifications

• C01B2203/0277

  containing a catalytic decomposition step · CPC title

• C01B2203/043

  Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration · CPC title

• C01B2203/04

  containing a purification step for the hydrogen or the synthesis gas · CPC title

• C01B2203/0405

  Purification by membrane separation · CPC title

• C04B2290/20

  Integrated combined plants or devices, e.g. combined foundry and concrete plant · CPC title