Systems and methods for converting gaseous carbon compounds into carbon-neutral or carbon-negative products

Abstract

A system and method for converting gaseous carbon compounds into carbon-neutral or carbon-negative products. The system and method uses biological processes to metabolize the gaseous carbon compounds. The gaseous carbon compounds include a mixture of CO2 and CH4 from a single source or from two or more different sources. Separate biological processes are combined to process different gaseous carbon compounds. Gaseous carbon compounds produced as a by-product of one biological process are used as a feedstock for, or as part of, another biological process. To assist in minimizing the carbon footprint and enabling an overall carbon-negative profile, a renewable energy system is provided to power the apparatus and equipment of the system and method.

Description

[Technical field]

[0001] Systems and methods are disclosed for converting gaseous carbon compounds into carbon-neutral or carbon-negative products. The gaseous carbon can be derived from one or a combination of sources, including but not limited to fossil fuels, extraction from the atmosphere, or organic waste processing, such as landfill biogas or animal waste. The carbon-neutral or carbon-negative products can include, but are not limited to, animal feed proteins, pharmaceuticals, and high-value chemicals. [Background technology]

[0002] Growing concerns about global warming have led to substantial research on greenhouse gases. It is widely agreed that in order to limit the temperature rise to below 1.5°C, multiple measures must be implemented to reduce the emission of greenhouse gases, especially carbon dioxide and methane, as well as to reduce the current content of greenhouse gases in the atmosphere. While the greenhouse effect of carbon dioxide is well known, methane has a global warming potential (GWP) about 28 times higher than that of carbon dioxide over a 100-year period. The result is that reducing methane emissions from its various sources should not be overlooked. In 2021, the United States, the European Union, and 103 other countries launched the Global Methane Pledge, which intends to reduce global methane emissions by at least 30 percent by 2030 from 2020 levels.

[0003] Research has focused on various methods for utilizing greenhouse gases into valuable products. For example, the Swiss company Climeworks has several operational plants that capture carbon dioxide directly from the atmosphere, with a total annual capacity of 2,000 tons. The captured carbon dioxide is permanently stored through natural underground mineralization. Some companies, such as Carbon Engineering, have developed technologies to convert carbon dioxide into synthetic fuels through multiple reactions. Although methane itself is a valuable energy source, 55-70% of methane emissions come from biogenic sources such as livestock farming, landfills, and wetlands, which cannot be captured and used in the same way as natural gas. In several thermochemical techniques, methane is converted using carbon dioxide as a reducing chemical to produce syngas, an important precursor for a variety of chemicals and fuels. Research has revealed that algae, bacteria, and other microorganisms have huge potential to consume gaseous carbon through photosynthetic or metabolic processes. So far, the economics of greenhouse gas extraction have been an obstacle to large-scale commercially viable operations. Summary of the Invention [Problem to be solved by the invention]

[0004] It is believed that the approach of extracting carbon from gaseous compounds and converting them into commercial products as disclosed therein can assist in keeping global warming to or preferably below the 1.5°C target.

[0005] The above references to the background art do not constitute an admission that such art forms part of the common general knowledge of a person skilled in the art, nor are they intended to limit application of the disclosed systems and methods to any particular form of such systems and methods. [Means for solving the problem]

[0006] In one embodiment, an integrated system for converting gaseous carbon compounds to carbon-neutral or carbon-negative products is disclosed, the integrated system comprising: a source capable of producing a mixture of gaseous carbon feedstock comprising carbon dioxide and methane; a biological methane treatment system containing methane metabolizing microorganisms and supplied with methane from the source, the biological methane treatment system being configured to propagate the methane metabolizing microorganisms and produce carbon dioxide as a by-product; a biological carbon dioxide processing system including a carbon dioxide metabolizing microorganism and supplied with carbon dioxide from a source of a mixture of a gaseous carbon source and said carbon dioxide by-product, the biological carbon dioxide processing system being adapted to propagate the carbon dioxide metabolizing microorganism; a microorganism harvesting and processing system arranged to harvest the propagated microorganisms and produce single cell proteins; Includes:

[0007] In one embodiment, the methane metabolizing microorganism comprises a mesophilic methanotrophic bacterium.

[0008] In one embodiment, the carbon dioxide metabolizing microorganism comprises a mesophilic bacterium.

[0009] In one embodiment, the carbon dioxide metabolizing microorganism includes a cyanobacterium.

[0010] In one embodiment, the carbon dioxide metabolizing microorganism includes a hydrogen-utilizing bacterium.

[0011] In one embodiment, the integrated system includes an air separation unit capable of producing gaseous oxygen, and the integrated system is arranged to supply the gaseous oxygen to one or both of the biological methane treatment system and the biological carbon dioxide treatment system.

[0012] In one embodiment, the integrated system includes a water splitting unit capable of producing gaseous oxygen, and the integrated system is arranged to supply the gaseous oxygen to one or both of the biological methane treatment system and the biological carbon dioxide treatment system.

[0013] In one embodiment, the integrated system includes a water separation unit capable of producing gaseous hydrogen, and the integrated system is arranged to supply the gaseous hydrogen to one or both of the biological methane treatment system and the biological carbon dioxide treatment system.

[0014] In one embodiment, the integrated system includes a cooling system operable to cool one or both of the biological methane treatment system and the biological carbon dioxide treatment system to operate within a predetermined temperature range.

[0015] In one embodiment, the microorganism harvesting and processing system includes a first harvesting system for harvesting microorganisms from the biological methane processing system, a second harvesting system for harvesting microorganisms from the biological carbon dioxide processing system, and a common dryer for drying the harvested microorganisms harvested by both the first and second harvesting systems.

[0016] In one embodiment, the integrated system includes a renewable energy system capable of converting energy from one or more renewable energy sources into one or more forms of controlled energy, and one or both of the biological methane treatment system and the biological carbon dioxide treatment system are powered by the controlled energy.

[0017] In one embodiment, one or more of the water splitting unit, the air separation unit, the cooling system, and the microbial harvesting and processing system are powered by the controlled energy.

[0018] In a second aspect, an integrated biological method for converting gaseous carbon compounds to carbon-neutral or carbon-negative products is disclosed, the method comprising: supplying gaseous methane from a first biogas source to a biological methane treatment system capable of growing methanotrophic bacteria and producing carbon dioxide as a by-product; (a) supplying gaseous carbon dioxide from said first biogas source and (b) said carbon dioxide by-product to a biological carbon dioxide treatment system capable of growing carbon dioxide metabolizing bacteria; producing single cell proteins from the propagated methanotrophic bacteria and the propagated carbon dioxide metabolizing bacteria; Includes:

[0019] In one embodiment, providing the gaseous methane from the first biogas source and providing the gaseous carbon dioxide comprises providing biogas comprising a mixture of gaseous methane and gaseous carbon dioxide from the first biogas source to a gas pre-treatment and separation unit and operating the gas pre-treatment and separation unit to provide separate gaseous methane and gaseous carbon dioxide feed streams.

[0020] In one embodiment, the method includes supplying gaseous oxygen to the biological methanation system.

[0021] In one embodiment, the method includes supplying gaseous oxygen to the biological carbon dioxide treatment system.

[0022] In one embodiment, the method includes supplying gaseous hydrogen to the biological carbon dioxide treatment system.

[0023] In one embodiment, the method includes using a hydrogen-utilizing bacterium as the carbon dioxide metabolizing bacterium.

[0024] In one embodiment, the method includes using a cyanobacterium as the carbon dioxide metabolizing bacterium.

[0025] In one embodiment, the method includes supplying one or more nutrients to one or both of the biological methane treatment system and the biological carbon dioxide treatment system.

[0026] In one embodiment, the method includes cooling one or both of the biological methane treatment system and the biological carbon dioxide treatment system to operate within a predetermined temperature range.

[0027] In one embodiment, providing gaseous oxygen includes producing gaseous oxygen from one or both of: (a) an air separation unit; and (b) a water splitting unit.

[0028] In one embodiment, providing the gaseous hydrogen includes operating a water splitting unit to produce the provided gaseous hydrogen.

[0029] In one embodiment, producing the single cell protein comprises harvesting and drying the propagated methanotrophic bacteria and the propagated carbon dioxide metabolizing bacteria.

[0030] In one embodiment, the method includes generating motive power from one or more renewable energy sources and using the generated motive power as operating power for plant and equipment used to enable the performance of the method.

[0031] In a third aspect, a method of animal husbandry is disclosed, the method comprising: producing biogas comprising a mixture of gaseous methane and carbon dioxide from waste materials excreted by the plurality of animals; Converting the biogas into single cell proteins using the method according to the second aspect; feeding said plurality of animals with a feed comprising said single cell protein; Includes:

[0032] In a fourth aspect, a carbon processing system for generating one or more carbon-neutral products is disclosed, the system comprising: a renewable energy system capable of converting energy from one or more renewable energy sources into one or more forms of controlled energy; one or more sources of gaseous carbon compounds; one or more reactant feed streams; a carbon processing plant powered by said controlled energy and configured to convert said gaseous carbon compounds in the presence of said one or more reactants to produce one or more saleable products; Includes:

[0033] In one embodiment of the fourth aspect, the one or more sources of gaseous carbon compounds include a direct air carbon capture system powered by the renewable energy system.

[0034] In one embodiment of the fourth aspect, the one or more sources of gaseous carbon compounds include a methane source.

[0035] In one embodiment of the fourth aspect, the methane source comprises an oil or gas reservoir.

[0036] In one embodiment of the fourth aspect, the methane source comprises coal seam gas.

[0037] In one embodiment of the fourth aspect, the methane source includes biowaste.

[0038] In one embodiment of the fourth aspect, the reactants include one or more of oxygen, hydrogen, and water.

[0039] In one embodiment of the fourth aspect, the carbon processing system includes an air separation unit for producing oxygen, the air separation unit being powered by the renewable energy system.

[0040] In one embodiment of the fourth aspect, the carbon processing system includes a water splitting unit for producing oxygen or hydrogen, the water splitting unit being powered by the renewable energy system.

[0041] In one embodiment of the fourth aspect, the carbon processing system includes a methane pyrolysis unit for producing hydrogen, the methane pyrolysis unit being powered by the renewable energy conversion system.

[0042] In one embodiment of the fourth aspect, the carbon processing plant includes one or more carbon processing units arranged to process the gaseous carbon compounds in the presence of one or more of the reactants to produce the one or more saleable products.

[0043] In one embodiment of the fourth aspect, the one or more carbon processing units include a bioreactor for biologically treating the gaseous carbon compounds.

[0044] In one embodiment of the fourth aspect, the one or more carbon processing units include a separation unit arranged to separate carbon from other elements within the gaseous carbon compound.

[0045] In one embodiment of the fourth aspect, at least one of the carbon processing units is arranged to produce gaseous carbon dioxide, and the carbon capture and processing system is arranged to supply the produced carbon dioxide to at least one other of the carbon processing units.

[0046] In one embodiment of the fourth aspect, the renewable energy system includes a concentrating solar thermal plant that heats a fluid heat transfer and storage medium.

[0047] In one embodiment of the fourth aspect, the renewable energy system includes a photovoltaic array for producing electricity to power the carbon capture and treatment system.

[0048] In one embodiment of the fourth aspect, the renewable energy system is arranged to store energy to enable daily operation of the carbon capture and treatment system.

[0049] In a fifth aspect, a method of carbon processing to generate one or more carbon-neutral products is disclosed, the method comprising: Producing energy using renewable energy; providing one or more gaseous carbon compounds to a carbon processing plant; providing one or more reactants to the carbon processing plant; using the produced energy to power at least the carbon processing plant; operating said carbon processing plant to convert said gaseous carbon compounds in the presence of said one or more reactants into one or more saleable carbon-neutral products; Includes:

[0050] In one embodiment of the fifth aspect, providing the one or more gaseous carbon compounds includes providing gaseous carbon dioxide derived from any one or more of: (a) a direct-air carbon capture system powered by the produced energy; (b) fossil fuel production, processing, or combustion; and (c) a by-product or waste product of an industrial process including cement manufacturing or ammonia production.

[0051] In one embodiment of the fifth aspect, providing a gaseous carbon compound includes providing methane to said carbon processing plant.

[0052] In one embodiment of the fifth aspect, providing methane includes providing methane sourced from an oil or gas reservoir.

[0053] In one embodiment of the fifth aspect, providing methane includes providing coalbed sourced methane.

[0054] In one embodiment of the fifth aspect, providing methane includes providing biowaste-sourced methane.

[0055] In one embodiment of the fifth aspect, providing the one or more reactants includes providing one or more of oxygen, hydrogen, and water feed streams.

[0056] In one embodiment of the fifth aspect, supplying oxygen includes supplying oxygen produced by an air separation unit powered by said produced energy.

[0057] In one embodiment of the fifth aspect, supplying oxygen comprises supplying oxygen produced by a water splitting unit powered by said produced energy.

[0058] In one embodiment of the fifth aspect, supplying hydrogen includes supplying hydrogen produced by a water cracking unit or a methane pyrolysis unit powered by the produced energy.

[0059] In one embodiment of the fifth aspect, the method includes forming the carbon processing plant as one or more carbon processing units, each capable of processing the gaseous carbon compound in the presence of one or more of the reactants to produce the one or more saleable products or precursors to saleable products.

[0060] In one embodiment of the fifth aspect, at least one of the carbon processing units is arranged to biologically treat said gaseous carbon compounds.

[0061] In one embodiment of the fifth aspect, at least one of the carbon processing units is a separation unit arranged to separate carbon from other elements within the gaseous carbon compound.

[0062] In one embodiment of the fifth aspect, gaseous carbon dioxide produced as a waste product by a process in said carbon processing plant is supplied back to said carbon processing plant.

[0063] In one embodiment of the fifth aspect, the method comprises operating the renewable energy system as a concentrated solar thermal plant, and the energy produced is thermal energy carried thereby in a flowable heat transfer medium.

[0064] In one embodiment of the fifth aspect, the method includes operating the renewable energy system in a manner such that the produced energy includes electrical energy.

[0065] In one embodiment of the fifth aspect, the method includes storing at least a partial proportion of the produced energy and subsequently using the stored energy to enable daily operation of the carbon capture and treatment system.

[0066] In one embodiment of the fifth aspect, the method includes monitoring and controlling flows of the gaseous carbon compounds and the reactants to the carbon processing units to provide mass balanced amounts of the gaseous carbon compounds and the reactants for processing in each carbon processing unit.

[0067] In a sixth aspect, an integrated system for converting gaseous carbon compounds to carbon-neutral or carbon-negative products is disclosed, the integrated system comprising: a renewable energy system capable of converting energy from one or more renewable energy sources into one or more forms of controlled energy; one or more sources of one or more gaseous carbon compounds; one or more reactant feed streams; a carbon processing plant powered by said controlled energy and configured to convert said gaseous carbon compounds in the presence of said one or more reactants to produce one or more saleable products, said carbon processing plant having a first carbon processing unit capable of producing a first saleable product and a gaseous carbon compound by-product from at least one of said gaseous carbon compounds, and a second carbon unit capable of producing a second saleable product from said gaseous carbon compound by-product; Includes:

[0068] In one embodiment, one or both of the first and second carbon processing units includes a bioreactor that biologically processes the gaseous carbon compounds.

[0069] In one embodiment, the first carbon processing unit is a biological methane processing system comprising methane metabolizing microorganisms and the by-product of the gaseous carbon compounds is carbon dioxide.

[0070] In one embodiment, the methane metabolizing microorganism comprises a mesophilic methanotrophic bacterium.

[0071] In one embodiment, the second carbon processing unit is a biological carbon dioxide processing system comprising a carbon dioxide metabolizing microorganism.

[0072] In one embodiment, the carbon dioxide metabolizing microorganism comprises a mesophilic bacterium.

[0073] In one embodiment, the carbon dioxide metabolizing microorganism includes a cyanobacterium.

[0074] In one embodiment, the carbon dioxide metabolizing microorganism includes a hydrogen-utilizing bacterium.

[0075] In one embodiment, the integrated system includes a third carbon processing unit capable of producing a third saleable product, the third carbon processing unit being a biological carbon dioxide processing system including carbon dioxide metabolizing microorganisms, the carbon dioxide metabolizing microorganisms of the second carbon processing unit including hydrogenotrophic bacteria, and the carbon dioxide metabolizing microorganisms of the third carbon processing unit including cyanobacteria.

[0076] In one embodiment, the carbon processing plant includes a synthesis gas generation unit capable of producing synthesis gas from the one or more gaseous carbon compounds and by-products of the gaseous carbon compounds.

[0077] In a seventh aspect, a system for converting gaseous carbon compounds to carbon-neutral or carbon-negative products is disclosed, the system comprising: a renewable energy system capable of converting energy from one or more renewable energy sources into one or more forms of controlled energy; one or more sources of methane and carbon dioxide; a synthesis gas generation unit capable of forming synthesis gas from said methane and carbon dioxide, said synthesis gas generation unit being powered by said controlled energy; a syngas conversion unit configured to convert the syngas into carbon-neutral or carbon-negative products; Includes:

[0078] In one embodiment, the syngas conversion unit is a bioreactor capable of fermenting the syngas.

[0079] In one embodiment, the synthesis gas conversion unit is arranged to carry out a thermochemical process to produce hydrocarbons.

[0080] While any other format may fall within the scope of the systems and methods as set forth in the Summary of the Invention, specific embodiments are described below, by way of example only, and with reference to the appropriate Figures, which are included below. [Brief description of the drawings]

[0081] [Figure 1] FIG. 1 is a flow diagram generally illustrating one embodiment of the disclosed system and method for converting gaseous carbon compounds into carbon-neutral or carbon-negative products. [Diagram 2] FIG. 2 is a more detailed flow diagram of the method and system shown in FIG. 1. [Diagram 3]FIG. 1 is a flow diagram of a second embodiment of the systems and methods of the present disclosure, which may be specified as an integrated system and method for converting gaseous carbon compounds to carbon-neutral or carbon-negative products, where the gaseous carbon compounds include a mixture of methane and carbon dioxide generated from a single source. [Figure 4] FIG. 4 is a mass flow diagram for the embodiment shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0082] Next, specific embodiments of the disclosed system and method will be described for illustrative purposes only. The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the scope of the disclosed system and method. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art related to the system and method. In the drawings, it should be understood that like reference numerals refer to like parts.

[0083] The general concepts disclosed herein provide systems and methods for converting gaseous carbon compounds into carbon-neutral or carbon-negative products. The gaseous carbon compounds can be provided from one or more sources. The sources can provide a single gaseous carbon compound, e.g., CO2 or CH4; or a mixture of gaseous carbon compounds, e.g., both CO2 and CH4. Separate biological processes are combined to process different gaseous carbon compounds. Gaseous carbon compounds produced as waste products of one biological process can be used as feedstock for, or as part of, another biological process.

[0084] The systems and methods also contemplate providing feed streams of other reactants such as oxygen, hydrogen, and water to facilitate processing of the gaseous carbon compounds. Processes that consume the gaseous carbon compounds include, but are not limited to, biological reactions such as metabolism / fermentation and / or chemical dissociation. In some embodiments, only biological processes are used to consume the gaseous carbon compounds. To help minimize the carbon footprint and enable an overall carbon negative profile, various embodiments of the disclosed integrated systems and methods can provide renewable energy systems to power the individual processes, systems, and devices.

[0085] FIG. 1 generally illustrates in flow diagram form an embodiment of the disclosed system 10 and associated method 12 for taking gaseous carbon compounds and processing the carbon to produce products of value.

[0086] In the system 10 and method 12, energy from one or more renewable energy sources is converted by the renewable energy system 14 into one or more forms of energy that are controlled and used to power downstream plants, equipment, and processes. For example, the renewable energy system 14 may be arranged to produce both thermal energy and electricity. The energy conversion system 14 may also include energy storage facilities, such as a volume of molten salt or particulate material for storing heat and / or batteries for storing electricity. Depending on the application, the energy storage facilities will be adapted to enable 24 / 7 operation of the system 10.

[0087] One or more gaseous carbon compounds CX are provided to the carbon processing plant 20 by one or more gaseous carbon sources CS. The gaseous carbon compounds can be different compounds / gases, for example, carbon dioxide and methane. The gaseous carbon source CS can include a single source or a combination of sources. The gaseous carbon source can also provide a mixture of two or more different gaseous carbon compounds. For example, the gaseous carbon source CS can include a biogas source that provides a mixture of methane and carbon dioxide (as well as other non-carbon gases such as nitrogen, hydrogen sulfide, and ammonia).

[0088] Energy from system 14 can be used to power one or more of the gaseous carbon sources CS that convert or process materials to produce a stream CX of gaseous carbon compounds. The stream CX is fed to a carbon processing plant 20. The carbon processing plant can have a number of different processing systems that produce a wide range of different products P1-Pn. The different processes within the carbon processing unit are arranged to process different types of gaseous carbon compounds or to perform different processes on gaseous carbon compounds to produce different products P1-Pn. Energy to run the carbon processing plant 20 is provided by the renewable energy system 14.

[0089] Other reactants and / or nutrients may be provided to the carbon processing plant 20 to facilitate or enhance a particular process for producing a particular product P1-Pn. Examples of reactants include one or more of oxygen, hydrogen, nitrogen, and water provided by respective feed streams 24, 26, 27, and 28. The nutrients, when provided, may include macronutrients and / or micronutrients. As described below, one or more of the reactants may be produced by a respective reactant generation unit RU. The unit RU may be powered by a renewable energy system 14.

[0090] The products P1-Pn may include single-cell proteins that can be used as animal feed, artificial meat for human consumption, pharmaceuticals, and high-value chemicals such as ethanol, isopropanol, and palm oil.

[0091] Figure 2 illustrates in more detail the overall system 10. In describing system 10, the use of the same reference numbers as in Figure 1 indicates the same features.

[0092] The renewable energy system 14 can provide energy to all plants and equipment in the system 10. Additionally, the energy system 14 can be arranged to provide different forms of energy to different plants and equipment in the system 10. For example, in one embodiment, the energy system 14 can include a concentrated solar thermal (CST) plant that heats a flowing fluid heat transfer and storage medium, such as molten salt, in a temperature range between, for example, 500° C. and 700° C. Alternatively, or in addition, the renewable energy system 14 can include one or a combination of one or more of an array of photovoltaic cells, a wind turbine, and a geothermal source.

[0093] The carbon source CS in Figure 1 is shown in Figure 2 as three different sources of gaseous carbon compounds. They are: a direct air carbon capture system (DAC) 16 powered by a renewable energy system 14; A carbon dioxide source 31, which may include a supply of carbon dioxide as a by-product or waste product of an industrial process, such as cement production or an ammonia plant, or the combustion of hydrocarbons; A methane source 36 which may include methane as biogas produced by the processing of hydrocarbons or generated by the decomposition of organic waste. In the case where the methane source is a biogas source, in addition to methane, the source 36 will also provide gaseous carbon dioxide which can be processed by the treatment plant 20.

[0094] The direct air carbon capture system 16 may use a carbon absorbent material such as zeolite. The zeolite may be arranged in different banks that are heated and cooled at different times. At relatively low temperatures, the carbon absorbent material captures carbon dioxide from the air. Upon heating, the captured carbon dioxide is released from the carbon absorbent material at a substantially higher concentration than in the air. By appropriately controlling the heating and cooling cycles of the different banks of zeolite or other carbon absorbent material, a relatively constant carbon dioxide feed stream 18 may be produced.

[0095] The heated molten salt from the energy system 14 can be circulated directly through the carbon-from-air capture system 16 to heat the zeolite and liberate carbon dioxide. When the energy system 14 includes a CST plant, the system 10 can also include a storage tank (not shown) for the heated molten salt to allow continuous circulation during the daily cycle. Alternatively, electric heaters powered by photovoltaic cells and / or electricity from wind turbines and / or geothermal sources can be used to heat the zeolite.

[0096] The renewable energy system 14 may also provide electrical energy to the carbon processing plant 20 and other equipment of the system 10. This may be accomplished in a number of different ways. For example, a heat transfer medium may be used to heat water to produce steam, which in turn drives a turbine connected to a generator to produce electrical energy, which is stored in an on-site battery. Alternatively or in addition, the renewable energy system 14 may also include a photovoltaic array to charge the battery. Current from the battery may be used to power other sections of the plant and equipment items of the system 10, including the carbon processing plant 20, on a 24 / 7 basis.

[0097] The system 10 includes an air separation unit (ASU) 30 that receives air from an air collection system 33, and a water splitting unit (WSU) 32, which may be in the form of, for example, an electrolyzer. Both the ASU 30 and the WSU 32 may be powered by electricity from the renewable energy system 14. The ASU 30 separates the air into its main components, primarily oxygen and nitrogen. The ASU 30 may be based on any known technology, such as cryogenic air separation, membrane separation, and pressure swing absorption. The oxygen from the ASU 30 constitutes or is added to the oxygen feed stream 24 for the carbon processing plant 20. The nitrogen and other gases produced by the ASU 30 may be released to the atmosphere. Alternatively, if desired, the nitrogen may be handled and / or used in a number of different ways, including capture and optional liquefaction as a further saleable product, or distribution as a feed stream 27 to and utilization in a section or plant 20 of the system 10.

[0098] WSU 32 is powered by electricity from renewable energy system 14 and is capable of producing gaseous hydrogen and oxygen. The oxygen produced by WSU 32 is added to oxygen feed stream 24. The hydrogen produced by WSU 32 is provided to carbon processing plant 20 as hydrogen feed stream 26.

[0099] A water source 34 provides water that forms a water feed stream 28. The feed stream 28 provides water to both the WSU 32 and the carbon processing plant 20.

[0100] Methane source 36 provides methane for methane feed stream 22. Methane source 36 may hold or supply methane from one or more of a hydrocarbon reservoir, coal seam gas, or biogas, for example from municipal or other organic waste. If methane source 36 is a biogas source that produces both methane and carbon dioxide, the carbon dioxide can be added to other CO2 feed streams or can itself form a CO2 feed stream for treatment plant 20, as described in more detail in the embodiments below.

[0101] In this embodiment, the carbon processing plant 20 includes five separate carbon processing units 20a, 20b, 20c, 20d, and 20e. In any particular embodiment of the system 10, the carbon processing plant can include different combinations of units 20a, 20b, 20c, 20d, and 20e. This depends on the source CS and the desired products provided or available. By way of non-limiting example, the carbon processing plant 20 in a particular embodiment can include (a) units 20a and 20b, (b) units 20a and 20c, (c) units 20a, 20b, and 20c, (d) units 20a, 20d, and 20e, (e) units 20d and 20e, or all of 20a, 20b, 20c, 20d, and 20e.

[0102] Carbon processing unit 20a is a bioprocess that utilizes methanotrophic bacteria to oxidize methane. Oxygen is also supplied to unit 20a to facilitate the oxidation of methane. An example of a biologically derived product of this bioprocess, P1, is a single cell protein that can be used as an animal feed, such as, but not limited to, pig feed or fish feed. A by-product of the reaction is carbon dioxide. This carbon dioxide is added to carbon dioxide feed stream 18 for use in other areas of the carbon processing plant, such as, but not limited to, processing unit 20b. This provides an integrated aspect of system 10 and method 12, since the gaseous carbon by-product from one process is consumed in another process that converts the gaseous carbon by-product to a carbon neutral / carbon negative product.

[0103] The carbon processing unit 20b is a bioprocess that utilizes hydrogenotrophic bacteria to consume the hydrogen, oxygen, and carbon dioxide present in the water to produce a second, different biological derived product P2 in the form of single cell protein that can be used as animal feed, including pig feed and fish feed.

[0104] The carbon processing unit 20c is a bioprocess that produces photosynthetic cyanobacteria from light, carbon dioxide, and water. It is possible to extract high-value products P3 from the cyanobacteria in a controlled environment. Examples of high-value products include pharmaceuticals (e.g., anti-cancer drugs), nutritional supplements (e.g., dietary supplements), food additives, and animal feed in the form of single-cell proteins.

[0105] Carbon processing units 20d and 20e are used in combination to produce product P4, which are high value chemicals such as ethanol and isopropanol.

[0106] The carbon processing unit 20d is a syngas generation unit. It converts carbon dioxide and methane, provided by the feed streams 18 and 22, respectively, in the presence of optional oxygen, to produce a syngas, which is a mixture of hydrogen, carbon and its oxides, water, and residual methane. The unit 20d can be a reforming reactor that uses heat produced from energy from the energy conversion system 14. The downstream syngas conversion unit 20e converts the syngas into high-value chemicals P4. In one example, the unit 20e can be a bioreactor that ferments the syngas, resulting in the production of high-value chemicals such as ethanol and isopropanol. Alternatively, the unit 20e can perform a thermochemical process to produce hydrocarbons, such as a Fischer-Tropsch-like process. Additional hydrogen from a hydrogen supply, steam 26, can be provided to the unit 20e and used to adjust the ratio of carbon monoxide to hydrogen in the feed steam from the unit 20d.

[0107] It should be noted that some of the products or by-products of some of the carbon processing units 20a-20e are used by the other carbon processing units. For example, carbon monoxide and hydrogen produced by unit 20d are provided as inputs to unit 20e. Carbon dioxide produced by unit 20a can be combined with carbon dioxide from the direct air intake system 16 and provided to carbon processing units 20b, 20c, and 20d.

[0108] The system 10 and method 12 include a control system having various sensors, gas detectors, flow controllers, and valves to control the flow rates, volumes, and pressures of the carbon dioxide, methane, oxygen, hydrogen, and water feed streams 18, 22, 24, 26, and 28, respectively, and to ensure optimal stoichiometric and / or mass balance of the feed streams to each of the carbon processing units 20a-20e in the carbon processing plant 20. The control system is also provided to monitor and control the renewable energy system 14 for the production and storage of energy and distribution of energy to the various plants, systems, and facilities of the system 10.

[0109] Figures 3 and 4 are diagrams of an integrated biological carbon processing system 10 and method 12 for converting gaseous carbon compounds to carbon-neutral or carbon-negative products. In describing this embodiment, the same reference numbers are used to designate the same systems or processes as were used in describing the first embodiment shown in Figures 1 and 2. A renewable energy system 14 provides the motive power for system 10 and method 12 in the same manner as described in connection with the first embodiment.

[0110] In this embodiment, a single mixed gaseous carbon source CS is provided. The source may take the form of a biogas source. The source CS produces a gaseous feed stream CX as a mixture of gaseous carbon compounds, specifically methane and carbon dioxide. The feed stream CX may also contain other gases, such as nitrogen, hydrogen sulfide, and ammonia. The feed stream CX is fed to a gas pre-treatment and separation unit 50. The unit 50 removes non-carbonaceous gases in the feed stream and separates the mixed gaseous carbon compounds into a high purity methane feed stream 22 and a carbon dioxide feed stream 18.

[0111] In this embodiment, all processing of gaseous carbon compounds is carried out biologically in an integrated biological treatment plant 20. The treatment plant 20 includes a biological methane treatment / conversion system 20a and a biological carbon dioxide treatment / conversion system 20b. The treatment systems 20a, 20b use different microorganisms for the treatment of their respective feed gases. A methane feed stream 22 is fed to the biological methane treatment / conversion system 20a. The system 20a is in the form of a bioreactor having methane-feeding microorganisms, such as methanotrophs, that metabolize methane as a carbon source. At the same time, the carbon dioxide feed stream 18 is fed to the biological carbon dioxide treatment / conversion system 20b, which consumes the carbon dioxide. One example of this is a bioreactor containing hydrogenotrophic bacteria.

[0112] Unconsumed methane and carbon dioxide produced thereby from process / system 20a are recycled back to gas pretreatment and separation unit 50 via conduit 52. In this manner, carbon dioxide produced as a by-product by process 20a is used as a feed input to process 20b.

[0113] The system 10 includes first and second harvesting systems HS1 and HS2 and a single cell protein (SCP) processing system 54, which together form a microorganism harvesting and processing system. The microorganisms grown in the process 20a are harvested by the first harvesting system HS1 as a first single cell protein source. The microorganisms grown in the process 20b are harvested by the second harvesting system HS2 as a second product source, also in the form of single cell protein. Both of these harvested single cell proteins are processed in the single cell protein (SCP) processing system 54, which may include precipitating the proteins in a precipitating tank to achieve a paste-like consistency and a rotating drum to collect the paste. The single cell protein (SCP) processing system 54 also includes a common dryer for drying the paste. Drying is performed while the paste is in the drum. The paste may be dried to a desired moisture content, for example 6%-8%, and then converted into a single cell protein powder that forms the final product P of the system 10 and method 12.

[0114] The biological processes 20a and 20b may be aided or otherwise facilitated by the addition of feedstocks, including, but not limited to, hydrogen, oxygen, water, ammonia, and nutrients, via a feedstock system 56. The feedstock system 56 includes an air separation unit 30 that produces gaseous oxygen, a water splitting system 32 that produces gaseous hydrogen and gaseous oxygen, and a nutrient system 58. An air collection system 33 provides air to the air separation system 30. A water source 34 (which may be, for example, a water supply) provides water to the water splitting system 32. The nutrient system 58 may provide macronutrients and / or micronutrients. The micronutrients may include, but are not limited to, cobalt, manganese, iron, zinc, chlorine, boron, and vitamins. The macronutrients may include, but are not limited to, phosphorus, potassium, and nitrogen. Each of the systems in the feedstock system 56 is powered by a renewable energy system 14.

[0115] Auxiliary systems 62 are provided to assist in maintaining the operation of the integrated biological treatment plant 20. The auxiliary systems 62 may include a cooling system 64, a cleaning-in-place system 66, and a wastewater treatment system 68. The cooling system 64 operates to remove heat generated by the metabolic processes 20a, 20b. The cooling system 64 maintains temperatures within the reactors used in the processes 20a, 20b within the optimum activation range of the respective mesophilic bacteria. In one example, the cooling system may be in the form of a water jacket surrounding each reactor. The cooling system may provide different operating temperatures for each reactor for the processes 20a and 20b. Temperature control may be provided by an electrically controlled thermoregulator powered by the renewable energy system 14.

[0116] The cleaning-in-place system 66 is used to periodically or on-demand clean the reactors used to carry out the processes 20a, 20b. It may, for example, deliver water and / or steam and / or various chemicals to clean and sanitize the bioreactors, including removing biofilm or other residues. A wastewater treatment system may treat water from one or more of the cleaning-in-place system 66, the SCP treatment system 54, and the plant 20.

[0117] The size of the bioreactor used in processes 20a, 20b is determined based on the gas supply and the amount of carbon dioxide that is recycled from process 20a to unit 50 via conduit 52.

[0118] 4, provided for illustrative purposes only, is a mass flow diagram for system 10, method 12 for a single mixed biogas source CS producing 10 tons per day (tpd) of mixed methane and carbon dioxide in a weight ratio of about 38:62. 3.8 tpd of methane and 6.2 tpd of carbon dioxide are fed from the gas pretreatment and separation unit to respective reactors carrying out processes 20a and 20b. In addition, process 20a produces about 4.1 tpd of CO2 as a by-product, which is provided to process 20b as additional feedstock.

[0119] Air and water are supplied at approximately 15.2 tpd and 16.1 tpd, respectively, to produce the mass flows of oxygen and hydrogen required to support the processing of methane and carbon dioxide. Methane processing / conversion system 20a receives 3.5 tpd of oxygen from air separation unit 30 and 7.7 tpd of oxygen from water splitting unit 32, which also supplies 6.6 tpd of oxygen and 1.8 tpd of hydrogen to carbon dioxide processing / conversion system 20b. These mass flows produce approximately 2.3 tpd of single cell protein by system 20a and approximately 5.8 tpd of single cell protein by system 20b. Nitrogen and other gases produced by the air separation unit are output at a rate of approximately 11.7 tpd and processed by processing unit 70. This may include, for example, capturing the nitrogen as a gas or liquefying the nitrogen, which can then be sold to a third party.

[0120] Methanotrophs, cyanobacteria, and hydrogenotrophs can all be considered mesophilic bacteria that operate optimally in a temperature range of about 15°-45° C. The processes and material flows in the embodiments of system 10 and method 12 can be carried out at atmospheric pressure. The doubling rate of the bacteria under these conditions can vary between 2-8 hours.

[0121] The system and method described with reference to figures 3 and 4 is well suited for livestock production, e.g. pig farming, as a closed-loop biogas processing system with the capacity to produce animal feed material, i.e. single cell protein, derived from animal waste. It is a carbon negative process as it consumes the greenhouse gases methane and carbon dioxide that would otherwise be released by the decomposition of waste and uses renewable energy as its power source.

[0122] As will be apparent from the above description, the embodiment shown in Figures 3 and 4 is a substantial subset of the system shown in Figures 1 and 2 for producing single cell proteins using bioprocesses 20a, 20b, and / or 20c, renewable energy system 14, and air and water inputs feeding air separation unit 30 and water splitting unit 32, respectively. System 10 of Figures 3 and 4 can be augmented or modified by the addition of carbon processing units 20d and 20e, and / or additional sources of gaseous carbon compounds.

[0123] While exemplary embodiments have been presented in the above detailed description, it is to be appreciated that a vast number of variations exist. For example, in the system 10 shown and described in connection with Figures 3 and 4, the bioprocess used to consume carbon dioxide is carried out by hydrogenotrophic bacteria. However, alternatively, or indeed in addition, the bioprocess can include the previously described process 20c that utilizes photosynthetic cyanobacteria to consume gaseous carbon dioxide to produce high value products, such as pharmaceuticals (e.g., anticancer drugs), nutritional supplements (e.g., dietary supplements), and food additives in the presence of water. In another variation, in addition to or as an alternative for the WSU 32, the system 10 can include a methane pyrolysis unit for the purpose of hydrogen gas production. Similarly, the gaseous carbon dioxide feed stream 18 may utilize or otherwise be supplied with gaseous carbon compounds from one or more of a number of sources, including, but not limited to, DAC 16; an acid gas removal unit of a liquefied natural gas processing plant; fossil fuel production, processing, or combustion; and by-products or waste products of industrial plants, such as, but not limited to, cement manufacturing plants and ammonia production plants. Additionally, embodiments of the system 10 and method 12 may be provided as an add-on facility to any existing industrial production plant that produces gaseous carbon compounds as a by-product or waste product to produce additional valuable products. When used in this manner, it may also extend the capacity of a renewable energy system to power the industrial production plant, thus further assisting in reducing the carbon footprint of the plant. In another variation of the system described with reference to Figures 3 and 4, the microbial harvesting and processing system may include separate processing systems 54, rather than a common processing system 54, for each of the harvesting systems HS1 and HS2. It should also be recognized that the exemplary implementations of the systems and methods are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way.Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing exemplary embodiments of the disclosed systems and methods.

[0124] In the following claims and the preceding description, unless the context requires otherwise due to express language or necessary implication, the terms "comprises" and variations thereof such as "comprises" or "comprises" are used in an open sense, in other words, they specify the presence of the recited features in various embodiments of the systems and methods disclosed herein, but do not preclude the presence or addition of further features.

Claims

Claim 1 An integrated system for converting gaseous carbon compounds into carbon-neutral or carbon-negative products, comprising: one or more units for producing each reactant; one or more sources of carbon dioxide and methane; a biological methane treatment system containing methane-metabolizing microorganisms and supplied with methane from the one or more sources and the one or more reactants, the biological methane treatment system propagating the methane-metabolizing microorganisms and producing carbon dioxide as a by-product; a biological carbon dioxide treatment system containing carbon dioxide-metabolizing microorganisms and supplied with carbon dioxide from the one or more sources, the by-product carbon dioxide, and the one or more reactants, the biological carbon dioxide treatment system propagating the carbon dioxide-metabolizing microorganisms; a microorganism harvesting and processing system that harvests the methane-metabolizing microorganisms propagated by the biological methane treatment system and the carbon dioxide-metabolizing microorganisms propagated by the biological carbon dioxide treatment system and produces single-cell protein; a control system for controlling the flow of carbon dioxide, methane, and the reactants to the biological methane treatment system and the biological carbon dioxide treatment system to provide a mass-balanced amount of carbon dioxide, methane, and reactants for the processes carried out in each of the biological methane treatment system and the biological carbon dioxide treatment system; An integrated system comprising the above. Claim 2 further comprising a renewable energy system for converting energy from one or more renewable energy sources into one or more forms of controlled energy, wherein the biological methane treatment system, the biological carbon dioxide treatment system, and the one or more units for producing each reactant are powered by the controlled energy, the integrated system according to claim 1. Claim 3 The control system is further provided to monitor and control the renewable energy system for energy production, storage, and energy distribution to the one or more units for producing the respective reactants of the biological methane treatment system and the biological carbon dioxide treatment system. The integrated system according to claim 2.

4. One of the units for producing the respective reactants is an air separation unit for producing gaseous oxygen, and the integrated system is provided to supply the gaseous oxygen to one or both of the biological methane treatment system and the biological carbon dioxide treatment system. The integrated system according to claim 1.

5. One of the units for producing the respective reactants is a water separation unit for producing additional gaseous oxygen, and the integrated system is provided to supply the additional gaseous oxygen to one or both of the biological methane treatment system and the biological carbon dioxide treatment system. The integrated system according to claim 1.

6. The water separation unit produces gaseous hydrogen, and the integrated system is provided to supply the gaseous hydrogen to the biological carbon dioxide treatment system. The integrated system according to claim 5.

7. A cooling system for cooling one or both of the biological methane treatment system and the biological carbon dioxide treatment system to operate within a predetermined temperature range. The integrated system according to claim 1.

8. The microorganism harvesting and treatment system includes a common dryer for drying the products produced by the biological methane treatment system and the biological carbon dioxide treatment system, and the products are the single cell protein. The integrated system according to claim 1.

9. The one or more sources of carbon dioxide and methane include (a) separate sources of carbon dioxide and methane respectively, or (b) a source that produces a mixture of carbon dioxide and methane. The integrated system according to claim 1.

10. The methane-metabolizing microorganisms include mesophilic methane-assimilating bacteria. The integrated system according to claim 1.

11. The carbon dioxide-metabolizing microorganisms include mesophilic bacteria. The integrated system according to claim 1.

12. The integrated system according to claim 11, wherein the carbon dioxide-metabolizing microorganism includes cyanobacteria.

13. The integrated system according to claim 12, wherein the carbon dioxide-metabolizing microorganism includes hydrogen-utilizing bacteria.

14. A cooling system operable to cool one or both of the biological methane treatment system and the biological carbon dioxide treatment system to operate within a predetermined temperature range, The integrated system according to claim 2, wherein the cooling system and the microorganism harvesting and treatment system are powered by the controlled energy.

15. An integrated system according to claim 1, including at least a first carbon treatment system, wherein the secondary product of carbon dioxide is supplied to the first carbon treatment system, and the first carbon treatment system produces synthesis gas.

16. The integrated system according to claim 15, including a second carbon treatment system provided downstream of the first carbon treatment system for converting the synthesis gas into high-value chemicals.

17. The integrated system according to claim 16, wherein the second carbon treatment system includes a bioreactor provided for fermenting the synthesis gas to form the high-value chemicals.

18. The integrated system according to claim 16, wherein the second carbon treatment system is provided for performing a thermochemical process.

19. The integrated system according to claim 1, wherein the one or more sources of methane and carbon dioxide are one or more sources of a mixture of carbon dioxide and methane.

Images