Methods, systems and apparatus for carbon capture, utilization and storage
There are provided CCUS systems and methods having gas-to-liquid systems and processes, e.g., for processing flare gas to methanol. In these systems an air-breathing engine reformer produces a syngas intermediate that is further converted to methanol in a downstream synthesis step. The CCUS system has a CO 2 separator that receives a gas-phase stream and separates this stream into two streams, a CO 2 -rich stream and a CO 2 -depleted stream. The CCUS systems may further have a hydrogen separator that receive a gas-phase stream and separates that stream into a hydrogen-rich stream and a hydrogen-depleted stream. The CO 2 -rich stream can be used for use in EOR, storage or both.
1 . A gas-to-liquid system comprising a primary synthesis loop configured for operation at a pressure above about 30 bar, the system further comprising:
a. a means for providing a high-pressure process stream containing CO 2 , after (i) condensation and collection of a liquid product, (ii) collection of an easily condensable product or (iii) both products; wherein the products comprise one or more of as methanol, ethanol, mixed alcohols, ammonia, dimethyl-ether F-T liquids;
b. a CO 2 separator, wherein the CO 2 separator is configured to operate based on mechanical separation of a condensed-phase, a solid, a liquid, or a solid and liquid, CO 2 ; and,
c. a means for capturing a CO 2 -rich stream for use, sequestration or both.
2 . The system of claim 1 , comprising a means to recycle of a CO 2 -depleted stream to a downstream synthesis process or an upstream reformer.
3 . The system of claim 1 , wherein the high-pressure, process stream comprises at least one of a gas-phase effluent of the product condensation and collection step or a retentate of a hydrogen separation step.
4 . The system of claim 1 , wherein the CO 2 separator is for syngas ratio adjustment; thereby eliminating the need for a hydrogen separation step; and further comprising a splitter and purge stream.
5 . The system of claim 1 , wherein a CO 2 -depleted stream is at high-pressure and the system is configured to recycle the CO 2 -depleted stream to a downstream synthesis process without substantial recompression.
6 . The system of claim 1 , comprising a means for the mechanical separation of a condensed phase CO 2 using expansion; and wherein the means comprises at least one of a turbo-expander, a valve to promote condensation deposition or both via a cooling effect of gas expansion.
7 . The system of claim 1 , comprising a means for the use of one or more recuperating heat exchangers to pre-cool a gas to a turbo-expander and promote melting of a dispersed-phase, solid CO 2 .
8 . The system of claim 1 , comprising a pump configured to compress a dispersed-phase, solid CO 2 , a slurry containing solid and liquid CO 2 , or both prior to melting.
9 . The system of claim 1 , comprising a means for re-injection of a liquid CO 2 at a well site for one or more of sequestration and enhanced oil recovery.
10 . The system of claim 1 , comprising a means for inlet air separation or syngas nitrogen rejection to reduce the amount of nitrogen carried through the process and therefore increase the CO 2 concentration, reducing the energy intensity and capital cost of the carbon capture.
11 . The system of claim 1 , an engine-based reformer configured to provide power to perform the separation.
12 . The system of claim 1 , wherein the gas-to-liquid plant is a small-scale system.
13 . The system of claim 1 , comprising a syngas engines.
14 . The system of claim 1 , having a scale of from 80,000 scfd to 3,000,000 scfd.
15 . The system of claim 1 , having a scale of from 20,000 scfd to 100,000 scfd.
16 . The system of claim 1 , having a scale of from 250,000 scfd to 25,000,000 scfd.
17 . The system of claim 1 , having a scale of from less than 25,000,000 scfd.
18 . The system of claim 1 , having a scale of from less than 10,000,000 scfd.
19 . The system of claim 1 , having a scale of from less than 5,000,000 scfd.
20 . A gas-to-liquid system comprising a primary synthesis loop configured for operation at an operation pressure, the system further comprising:
a. an infeed line in fluid communication with a source of a high-pressure stream comprising CO 2 ;
b. a first recuperator in fluid commination with the infeed line;
c. a turbo expander in fluid communication with the first recuperator;
d. a CO 2 separator in fluid communication with the turbo expander; the CO 2 separator comprising a first outlet and configured to provide a CO 2 -depleted stream of gas from the first outlet;
e. a line placing the first outlet of the CO 2 separator in fluid communication with the first recuperator, whereby a CO 2 -depleted stream of gas is used to cool the high-pressure stream comprising CO 2 .
21 . The system of claim 20 , wherein the source of the high-pressure stream comprising CO 2 comprises a retentate from a hydrogen separator.
22 . The system of claim 20 , where in the operating pressure is above about 30 bar.
23 . The system of claim 21 , where in the operating pressure is above about 30 bar.
24 . A gas-to-liquid system comprising a primary synthesis loop configured for operation at an operation pressure, the system further comprising:
a. an infeed line in fluid communication with a source of a high-pressure stream comprising CO 2 ;
b. a first recuperator in fluid commination with the infeed line;
c. a second recuperator in fluid communication with the first recuperator;
d. a turbo expander in fluid communication with the second recuperator;
e. a CO 2 separator in fluid communication with the turbo expander; the CO 2 separator comprising a first outlet and configured to provide a CO 2 -depleted stream of gas from the first outlet; the CO 2 separator comprising a second outlet and configured to provide a CO 2 -rich stream of material from the second outlet;
f. a line placing the first outlet of the CO 2 separator in fluid communication with the first recuperator, whereby a CO 2 -depleted stream of gas is used to initially cool the high-pressure stream comprising CO 2 ;
g. a line placing the second outlet of the CO 2 separator in fluid communication with the second recuperator, whereby the CO 2 -rich stream of material is used to further cool the high-pressure stream comprising CO 2 ; and,
h. a line placing the second recuperator in fluid with a CO 2 storage, transfer or both device, whereby the CO 2 -rich stream of material is stored, transferred or both.
25 . The system of claim 24 , wherein the source of the high-pressure stream comprising CO 2 comprises a retentate from a hydrogen separator.
26 . The system of claim 24 , where in the operating pressure is above about 30 bar.
27 . The system of claim 26 , where in the operating pressure is above about 30 bar.