Method for the preparation of synthesis gas

Abstract

Method for the preparation of synthesis gas by combining electrolysis of water, autothermal reforming and heat exchange reforming of a hydrocarbon feed stock.

Claims

1. Method for the preparation of synthesis gas comprising the steps of: (a) preparing a separate hydrogen containing stream and a separate oxygen containing stream by electrolysis of water and/or steam; (b) providing a hydrocarbon feedstock; (c1) steam reforming a part of the hydrocarbon feedstock from step (b), and/or a second hydrocarbon feedstock, by indirect heat transfer with part or all of an autothermal reformed gas leaving step (d), to obtain a steam reformed gas stream, and mixing the steam reformed gas stream with the autothermal reformed gas downstream of step (d); or (c2) heat exchange steam reforming a part or all of the hydrocarbon feedstock from step (b), by indirect heat transfer with part or all of an autothermal reformed gas leaving step (d), to obtain a steam reformed gas, and introducing the steam reformed gas into an autothermal reformer in step (d) to obtain the autothermal reformed gas for use in step (c2); (d) producing, as an exit gas in an autothermal reformer, the autothermal reformed gas for use in step (c1) or step (c2) by autothermal reforming a part of the hydrocarbon feedstock from step (b) or at least a part of the steam reformed gas from step (c2), with at least a part of the separate oxygen containing stream from step (a); (e) introducing at least part of the separate hydrogen containing stream from step (a) into the mixed heat exchange reformed gas and autothermal reformed gas downstream step (c1) or into the autothermal reformed gas downstream step (d) to obtain a synthesis gas comprising hydrogen, carbon monoxide and carbon dioxide; and (f) withdrawing a synthesis gas.

2. The method of claim 1, wherein carbon dioxide is added to the hydrocarbon feedstock upstream of the autothermal reformer or downstream step (c1) or (c2) or downstream of step (d).

3. The method of claim 2, wherein the carbon dioxide is added in an amount to provide a module (M=(H.sub.2CO.sub.2)/(CO+CO.sub.2) in the synthesis gas prepared in step (d) in the range from 1.9-2.2.

4. The method of claim 1, wherein the hydrocarbon feedstock comprises natural gas, methane, LNG, naphtha or mixtures thereof either as such or pre-reformed and/or desulfurized.

5. The method of claim 1, wherein the electrolysis of water and/or steam in step (a) is powered at least in part by renewable energy.

6. The method of claim 1, wherein the synthesis gas prepared in step (f) is, in a further step, converted to a methanol product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a system for carrying out the method of the present invention, in which a heat exchange reformer is arranged in series with an ATR.

(2) FIG. 2 shows a system for carrying out the method of the present invention, in which a heat exchange reformer is arranged in parallel with an ATR.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(3) In the series heat exchange solution, shown in FIG. 1, part or all the hydrocarbon feedstock is directed to the heat exchange reformer in which steam reforming takes place. The remaining part of the hydrocarbon feedstock can bypass the heat exchange reformer and be directed to the autothermal reformer.

(4) Typically, the gas leaving the heat exchange reformer in series will be at or close to equilibrium at a temperature of 550-800 C. The exit gas from the heat exchange reformer in series is then directed to the ATR. Part or all of the exit gas from the ATR is used as heat source in the heat exchange reformer by heat exchange to drive the endothermic steam reforming reaction.

(5) In the parallel solution of the heat exchange reformer, shown in FIG. 2, part of the hydrocarbon feedstock and/or a second hydrocarbon feedstock is directed to the ATR and the remaining hydrocarbon feed stock and/or a second hydrocarbon feed stock to the heat exchange reformer.

(6) In the heat exchange reformer in the parallel concept part or all the exit gas from the ATR is utilized as heat source in the heat exchange reformer by heat exchange to drive the endothermic steam reforming reaction.

(7) The gas leaving the catalyst in the heat exchange reformer may optionally be mixed with part or the entire the exit gas from the ATR before the latter is used as heat source. Alternatively, the exit gas from the heat exchange reformer and the exit gas from the ATR can be mixed downstream the heat exchange reformer.

(8) The feed stocks to the ATR and to the heat exchange reformer may have different compositions, e.g different steam to carbon ratios.

(9) Irrespective of whether a parallel or a series concept of the heat exchange reformer is used, the operating parameters, the amount of hydrogen from the electrolysis unit added in step (e) and the heat exchange reformer design can in principle be adjusted to give a module M of the desired value of 1.9-2.2 or preferably 2.0-2.1, in particular when using the synthesis gas for the preparation of methanol.

(10) In general, the feed stock to the heat exchange reformer and ATR suitable for use in the invention comprises natural gas, methane, LNG, naphtha or mixtures thereof either as such or pre-reformed and/or desulfurized.

(11) The amount of hydrogen addition can be tailored such that when the hydrogen is mixed with the process gas generated by the reforming steps, the desired value of M (between 1.90 and 2.20 or preferably between 2.00 and 2.10) is achieved.

(12) In some cases, the amount of hydrogen from the electrolysis step may be too high to provide a module in the desired range. In this case part of the hydrogen may be used for other means.

(13) Alternatively, the module can additionally be adjusted to the desired value by addition of essentially pure carbon dioxide to the hydrocarbon feed stock and/or to the synthesis gas, and/or upstream the autothermal reformer.

(14) Thus, in an embodiment of the invention, essentially pure carbon dioxide is added to the hydrocarbon feed stock upstream of the autothermal reformer or downstream step (c1) or (c2) or downstream of step (d).

(15) In all of the above cases, the feed stock may initially be subjected to the steps of purification (including desulphurization) and adiabatic pre-reforming as mentioned above.

(16) The hydrocarbon feed stock may further comprise hydrogen and/or steam as well as other components.

(17) The electrolysis can be performed by various means known in the art such as by solid oxide based electrolysis or electrolysis by alkaline cells or polymer cells (PEM).

(18) If the power for the electrolysis is produced (at least in part) by sustainable sources, the CO2-emissions from the plant per unit of product produced is reduced.

(19) The invention can further be employed for producing synthesis gas for other applications where it is desirable to increase the hydrogen concentration in the feed gas and where part of the oxygen needed for synthesis gas production is favorably produced by electrolysis.