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Caphenia GmbH
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Caphenia - 3-in-1 Zone Reactor

Caphenia - 3-in-1 Zone Reactor

Caphenia GmbH offers a pioneering technological innovation through its CAPHENIA process, which efficiently combines three distinct sub-processes into one system to produce high-quality synthesis gas. The unique 3-in-1 zone reactor of CAPHENIA is at the core of this technology, allowing precise control over chemical reactions. Unlike traditional methods requiring multiple reactors and units, Caphenia’s approach reduces complexity and cost, while significantly increasing efficiency. The process begins with a high-temperature plasma zone that breaks down methane into carbon aerosol and hydrogen. The subsequent Boudouard zone utilizes the high thermal energy to convert carbon aerosol and CO2 into carbon monoxide. Finally, the hetWGS zone ensures that the remaining carbon aerosols react with water vapor to produce a synthesis gas composed of carbon monoxide and hydrogen, which can be tailored flexibly. This highly efficient method requires less electricity and can produce synthetic fuels rapidly in large quantities with up to 92% CO2 reduction compared to fossil fuels. These synthetic fuels exhibit a higher degree of purity and minimal sulfur dioxide emission, positioning the Caphenia process as a front-runner in sustainable fuel technology.

PBR-500

Active power plasma torch: 250 kW
Syngas production: 1280 tpa
Potential fuel production: 500 tpa • 1,875 l/day
CO2 consumption: 607 tpa
Methane consumption: 332 tpa
Electricity consumption: 3.9 MWh/t
Diameter (Ø): 2 m

PBR-5K

Active power plasma torch: 2500 kW
Syngas production: 12,800 tpa
Potential fuel production: 5000 tpa • 18,750 l/day
CO2 consumption: 6,070 tpa
Methane consumption: 3,320 tpa
Electricity consumption: 3.9 MWh/t
Diameter (Ø): 2 m

PBR-50K

Active power of plasma torch: 25 MW
Syngas production: 128,000 tpa
Potential fuel production: 50,000 tpa • 187,500 l/day
CO2 consumption: 60,700 tpa
Methane consumption: 33,200 tpa
Electricity consumption: 3.9 MWh/t
Diameter (Ø): 6.3 m

1. Plasma zone

The key technology of the CAPHENIA process is the high temperature plasma process. At a temperature of about 2000°C, methane (CH4) is broken down into a carbon aerosol (C) and hydrogen (H2).

2. Boudouard zone

In the Boudouard zone, the carbon aerosol (C) is combined with carbon dioxide (CO2) and converted into carbon monoxide (CO). This conversion is based on the well-known Boudouard reaction, which takes place at temperatures of around 1000°C. In this reaction process, the high thermal energy of the gas from the plasma zone is fully utilised and converted into chemical bonding energy.

The CO2 can come from biogas, CO2 air separation (Direct-Air-Capture/DAC) or CO2 flue gas separation (Carbon-Capture-and-Usage/CCU).

3. hetWGS zone

In the heterogeneous water gas shift zone (hetWGS), the remaining carbon aerosols (C) react with added water vapour (H2O) to form carbon monoxide (CO) and hydrogen (H2). The composition of the synthesis gas (CO + H2) can be flexibly controlled.

The CAPHENIA process achieves an industry-leading efficiency due to the successive process reactions in the 3-in-1 zone reactor.

4. Synthesis gas converter

The synthesis gas is the starting material for a large number of products. In fuel production, synthetic fuels are produced in a synthesis gas converter.

Synthetic fuels are not only climate-friendly, but also have a significantly higher degree of purity than fossil fuels. When they are burned, significantly less sulfur dioxide and fine dust are produced.

The CAPHENIA process has a selectivity of 100%. There are no by-products and therefore no energetic losses.

When it comes to producing syngas, the CAPHENIA process achieves a record efficiency of 86%. This is made possible by the intelligent design of the 3-in-1 zone reactor and the 100% selectivity.

Synthetic fuels from the CAPHENIA process have a CO2 reduction of up to 92% compared to fossil fuels. This brings the CAPHENIA process closer to CO2 neutrality than any other fuel production route.

100%
Selectivity

86%
Efficiency

92%
CO2-reduction