Industrial carbon dioxide utilization and the management of carbon-rich waste streams, such as rubber dust, coke, and residual biomass, remain critical hurdles for the circular economy. Conventional syngas production often requires significant external hydrogen inputs, which can limit the economic and environmental viability of CO2 recycling.

This work presents a novel integrated process and apparatus designed to synthesize syngas by coupling the Reverse Boudouard reaction with modular hydrogen enrichment.

The technology utilizes a vertical, multi-stage cylindrical reactor. In the primary section, carbonaceous residues react with CO2 to generate carbon monoxide via the [R1] reaction.

[R1] CO2 + C = 2 CO

The system is engineered for high feedstock versatility, accommodating solid materials through auger delivery and fluid or slurry-like wastes via specialized atomizers. The process can operate endothermically or in an autothermal mode; in the latter, selective oxygen injection triggers exothermic oxidation, providing the necessary enthalpy for the Boudouard transition at temperatures typically exceeding 600 – 900° C.

The resulting gas stream is filtered through an integrated dust collector before entering a secondary stage for hydrogen enrichment. This is achieved either through a catalytic Water Gas Shift reaction or via integration with water electrolysis, specifically utilizing Solid Oxide Electrolyser Cells (SOECs). The integration with electrolysis offers distinct operational advantages, including the internal recycling of pure oxygen to sustain the primary reactor's thermal balance and the precise adjustment of stoichiometric ratios. This optimization ensures the production of high-quality syngas tailored for the downstream synthesis of value-added chemicals, such as methanol and dimethyl ether.