Method for the production of synthetic fuels

Abstract

A method for producing synthetic fuels is provided. The process can involve the reaction of metals with water to liberate hydrogen, which can attack the feedstock molecules and with elevated temperature and pressure, reform the feedstocks into liquid fuels. These can be used as is or refined and used as gasoline, diesel fuel, aircraft fuel or burned to produce heat for uses such as generating electricity. The process can be environmentally friendly, producing no net greenhouse gases.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority to provisional application No. 60 / 927,552, the contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]Wood and coal have been a principle source of fuel for hundreds of years. In modern times, petroleum has become a primary commodity for the generation of energy. Petroleum has had the advantages of relatively low cost and ease of transportation and storage because of its liquid consistency. Further, petroleum is readily amenable to fractionation and conversion into a variety of valuable industrial products such as fuels, building products, chemical intermediates and the like.[0003]International developments have led to increase in the price of this crude oil. The consumption of petroleum has been increasing exponentially and concomitantly the readily available world petroleum supply has diminished. Governments and industrial concerns are dedicating increased attention to al...

AI Technical Summary

Benefits of technology

[0017]In a preferred embodiment of the invention, the chemical reactions take place in an organic liquid phase. The hydrocarbon output of reactions in accordance with the invention can be recycled and use as the organic liquid, such as that combined with the initial feedstock, to ensure a substantially air free system and to assist in the downsizing of the feedstock solids. The recycled hydrocarbon output is at elevated temperature. Thus, the recycled stream aids in the initial elevation of feedstock temperature and reduces instances of charring. Recycling the output can also lead to branched chain hydrocarbons, which tend to increase octane or cetane ratings.

[0019]Preferred reactors are in the form of horizontal tubes. The tubes are preferably formed of steel. The tubes are capable of containing liquid at over 700° F. and 500 psig. An internal screw is used to move the reactants in plug-flow, through the reactor at controlled speeds. Electrical heating elements on the reactor surfaces advantageously control the temperature of the reactors. Measuring the temperature and viscosity at the output can provide valuable feedback for controlling the heating elements and screw speed. It is the believed that the metal powders in the slurry react with the water in the feed stream to yield metal oxides and hydrogen. At the temperatures involved, ranging from over about 250° F. to 450° F. and above, the free hydrogen is believed to attack bonds in the feed material and thereby reduce the size of the feedstock molecules and promote the liquefication of the feed stream. Increasing the temperature, either in the same or in a separate reactor, further breaks down the feed material into small chain hydrocarbon radicals, advantageously 3, 6, and 9 carbons in length. Molecular size can be adjusted by controlling the temperature, reactor time and the amount of metal added. As the reaction proceeds, the metal powder can be substantially converted into sufficient oxide powder to act as a surface catalyst for the polymerization of the short chain hydrocarbon radicals into hydrocarbons of selected lengths. By adjusting reaction temperatures, at least 80% if not substantially all of the output can be gasoline, diesel fuel or aircraft fuel. Alternatively, the output can be refined (or otherwise purified or separated) to one of these fuels. In another embodiment of the invention, the output can be blended as more than least 5% or 10% with one of these fuels. The resulting product can be used as is or further refined or purified. It can also be advisable to employ a mechanism, such as a shockwave producer, to break up any relatively long chain hydrocarbons, such as waxes, that might be in the final product.

Problems solved by technology

The feedstock can comprise scrap rubber, plastic and / or organic matter or other materials that are not particularly well suited for use as fuels in their existing state.

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