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5,767,165 34 to produce carbon monoxide and thereafter reacting the hydrogen produced in the natural gas thermal decomposition step with the carbon monoxide in a catalyized reaction in a methanol synthesis reactor to form methanol. A thirdembodimentofthepresentinventioninvolvesthe stepofreformingaportionofthenaturalgasfeedstockwith carbon dioxide to produce carbon monoxide and hydrogen which constituents are then provided to a methanol synthesis reactor along with the hydrogen gas produced in the meth ane decomposition step. where the carbon monoxide and hydrogen are combined in a catalyzed reaction to produce methanol. It will be clear to those skilled in the art that the thermal energy necessary to cause the thermal decomposition of the naturalgasinsteponeintheabovedescribedprocessmay IS be provided in any of the known manners. but it is most commonly provided by ?re combustion of natural gas in accordance with the following reaction: 2. This thermal decomposition step yields elemental carbon (in solid form) and large amounts of hydrogen gas and is described by the following reaction: ThecarbonproducedinthisMDR 2isremovedforotheruse or sale. In the second step of the process. the hydrogen gas producedintheMDR 2isfedintothemethanolsynthesis reactor (MSR) 4 where itis combined with carbon dioxide in a catalyzed reaction to produce me?ranol as follows: Methanolresultingfromthisprocessissynthesizedfrom carbon dioxide and hydrogen. as detailed in reaction 8 above. rather than by the more conventional combination of hydrogen and carbon monoxide (in a 2:1 molar ratio). As can be seen this reaction produces carbon dioxide. However. since the process of the present invention also consumes carbon dioxide and in fact does so in an amount greater than that produced by the above reaction 5. the use of the present process results in the reduction of carbon dioxide produced by the methanol producing process. In addition. if hydrogen gas produced by methane decompo sition is substituted as the fuel in the process or if an alternative non-fossil fuel method of supplying thermal energy (e.g. solar energy or nuclear energy to ?re methane decomposition reactor is employed. for the decomposition step. the production of carbon dioxide in the process of the present invention is further reduced. An alternate embodiment of the present invention is 20 showninFIG.2.Inthisembodiment.agasi?cationstep6 is added between the methane decomposition step and the methanol synthesis step. In this additional step. a portion of theelementalcarbonproducedintheMDR 2isreactedin the carbon gasi?cation reactor 6 with carbon dioxide to 25 producecarbonmonoxideinaccordancewiththefollowing reaction: The carbon monoxide is then reacted with the hydrogen gas (in a ratio of 1 mole carbon monoxide and 2 moles hydrogengas)producedintheMDR 2toformmethanol.as follows: In yet another embodiment of the present invention. as depicted in FIG. 3. the step of reforming a portion of the natural gas feedstock with carbon dioxide in a reforming reactor 8 is undertaken. the chemical reaction being as Thecarbonproducedintheprocessiseithersequestered 35 or used as a materials commodity and is not burned as fuel. When methanol is used as an alternative transportation fuel in automotive engines or as a clean stationary power plant fuel. the methanol combustion reaction is as follows: (6) follows: As indicated. carbon dioxide isproduced However. since carbon dioxide recovered from a fossil fuel burning power plant is used in the synthesis of methanol according to The carbon monoxide and hydrogen produced in this step reaction(4)above.thenetcarbondioxideproducedinthe45 maythenbecombinedwiththehydrogenproducedinthe systembecomesnearzerowhenmethaneisusedasafuelto heat the methane decomposition reaction of step one of the process or is zero when hydrogen is used as a fuel. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a simpli?ed schematic process flow chart of the process of the present invention. FIG. 2 is a schematic process ?ow chart showing an alternate embodiment of the present invention. FIG. 3 is a schematic process flow sheet showing another alternate embodiment of ?re present invention. FIG. 4 is the schematic ?ow chart of FIG. 1 showing a hydrogen gas recycle stream. DETAILED DESCRIPTION OF THE PRESENT INVENTION Referring to FIG. 1. an embodiment of the overall process is shown which may be divided into two principal sections: thermal decomposition. and methanol synthesis. As shown. in the thermal decomposition step. methane (CH4) isfedintothemethane decompositionreactor(MDR) Still another embodiment of the present invention is SO shown in FIG. 4. In this embodiment. a portion of the hydrogenproducedintheMDR 2isdivertedforuseasafuel forprovidingthethermalenergyrequiredbytheMDR 2.By eliminating the use of natural gas as the fuel. ?re amount of carbondioxideproducedby?reoverallprocessisreducedto 55 zero.Furthermore.sincetheMDR 2produceshydrogenin an amount in excess of that needed to supply the thermal energyforreaction6andthestoichiornetricamountrequired byreaction8above(thereactiontakingplaceintheMSR 4 informingme?ianol)theCO2 emissionsisreducedtozero witharelativelysmallreductioninthemethanolproduction of the entire process. As indicated above. itis clear that there must be a source ofthermalenergytocausethedecompositionofthemethane intheMDR 2.Asalsodescribedabove.thisismosttypically 65 providedbyburningmethaneorhydrogengas.However.in accordance with the present invention. molten salts or mol tenmetaltechnologymay beusedadvantageouslyemployed MDR 2andfedintotheMSR 4whereinmethanolis produced in accordance with the catalyzed reaction 10 above.PDF Image | CONVERTING NATURAL GAS AND CARBON DIOXIDE TO METHANOL
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