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Energy efficient system and process for the continuous production of fuels and energy from syngas

a technology of energy efficiency and system, applied in the direction of combustible gas production, combustible gas purification/modification, chemical production, etc., can solve the problems of low efficiency of systems, high cost, environmental protection, etc., and achieve the effect of maximizing the carbon and energy conversion potential and efficiency of the associated components or subsystems

Inactive Publication Date: 2010-07-15
GREYROCK ENERGY INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0016]The present invention is an integrated system with processes configured to generate liquid fuels, electricity and heat from carbonaceous fuel sources. The preferred system combines and maximizes the carbon and energy conversion potential and efficiency of the associated components or subsystems to produce a system for the co-production of fuels and electricity from syngas. The process can produce liquid fuels and electricity from carbonaceous feedstock at net thermal energy efficiencies of greater than 40-50%, which are significantly higher than fuel synthesis or electricity generation alone.
[0017]Some of the other advantages of the present invention over the prior art include simplified process steps through the real-time monitoring of gas composition before and after the catalyst reactor, monitoring of process conditions (such as temperature, pressure and gas flow velocity) optimization of hydrogen / carbon monoxide gas composition using a hydrogen generator, the use of neural network algorithms and kinetic / thermodynamic models with feed-back control, for process optimization, and the use of chemical species (e.g. methane) that are relatively catalytically non-reactive to generate electricity and heat. This simplified system optimizes fuel, electricity and heat production, resulting in high net energy efficiencies and system flexibility.

Problems solved by technology

The worldwide demand for energy and transportation fuels is growing rapidly as fossil energy sources become more depleted, expensive, and environmentally problematic.
Such generation systems have modest efficiencies and contribute to the global emissions of nitrogen oxides, sulfur oxide, carbon dioxide, and particulate matter.
Furthermore, in some coal combustion plants, only a third of the energy value of the coal is actually converted into electricity and the rest is lost as waste heat.
Even though there are many technologies that are capable of changing energy fuels from one form to another, existing energy conversion systems have limited efficiencies and notable waste.
Part of this challenge is to develop low cost and scalable systems that can achieve high energy conversion efficiencies.
Since these reformers require elevated pressures and temperatures, additional external energy is needed, resulting in lower thermal energy efficiency for the production processes.

Method used

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  • Energy efficient system and process for the continuous production of fuels and energy from syngas
  • Energy efficient system and process for the continuous production of fuels and energy from syngas
  • Energy efficient system and process for the continuous production of fuels and energy from syngas

Examples

Experimental program
Comparison scheme
Effect test

example 1

Production of Syngas and Fuels

[0093]In Example 1, a pyrolysis / steam reforming system is operated in the absence of oxygen or air to produce syngas with an average molar composition of 35% H2, 28% CO, 18% CO2 and 18% CH4 (Table 1).

[0094]Continuous Gas Analyzers (22 and 64) in FIG. 1 and FIG. 2, specifically mass spectrometers in this example, are used to obtain real-time measurements by monitoring the molecular peaks of the gas-phase species listed in Table 1 before (BC) and after the catalyst reactors (AC). The syngas generator for this example utilizes pyrolysis / steam reforming thermochemical process in the absence of oxygen or air. Since nitrogen has the same nominal mass as carbon monoxide (m / e: 28) and oxygen has the same nominal mass as methanol (m / e: 32), the presence of nitrogen and oxygen could cause an error in the quantitative measurement of carbon monoxide and methanol. Therefore, the initial concentrations of the gas-phase species, listed under FPS Operation (Initial Con...

example 2

Production of Methanol

[0101]In order to demonstrate the production of one liquid product and electricity with the system shown schematically in FIG. 2, the catalyst of the reactor 28 was selected to produce methanol. The catalyst used in the synthesis reactor 28 was a Cu—Zn based catalyst used for methanol synthesis. Table 3 shows the operating conditions for this system including catalyst pressure, reactor temperature, CO conversion, and selectivity. In addition, Table 3 summarizes the resulting outputs and efficiencies for this system with a syngas input of 500,000 SCF per hour. The productivity of the plant is shown for three different recycle rates (0%, 75%, and 90%) to demonstrate the range of operating conditions and product mixes.

[0102]It can be seen that the synthesis of liquid fuels alone gives lower (9%-37%) thermal conversion efficiencies that are particularly pronounced at lower recycle rates. The combined production of fuel and electricity also provides a higher thermal...

example 3

Production of Mixed Alcohols

80% Ethanol, 15% Methanol, 5% C3+Alcohols

[0103]This example uses a multi-layered catalyst combination based on a promoted Cu—Zn and a promoted Group VIII metal catalyst to produce a mixture of alcohols containing primary ethanol.

[0104]Table 4 shows the operating conditions for this system including catalyst pressure, reactor temperature, CO conversion, and selectivity. In addition, this table summarizes the resulting outputs and efficiencies for this system with a syngas input of 500,000 SCF per hour. The productivity of the plant is shown for three different recycle rates (0%, 75%, and 90%) to demonstrate the range of operating conditions and product mixes.

[0105]The productivity and efficiency for the production of ethanol and electricity seen in Example 3 is similar to that shown Example 2 for a product stream with a higher energy density. This product stream of ethanol may be more suitable for fuel applications or more desirable for economic reasons.

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Abstract

A system and apparatus is provided that maximizes mass and energy conversion efficiencies in an integrated thermochemical process for the conversion of fossil fuel or renewable biomass to synthesis gas. The system combines gasification, catalytic conversion of gas to liquid, electricity generation, steam and chilled water generation with a system controller to maximize the conversion efficiency from syngas to merchantable products over the efficiency of syngas alone burned as a fuel. A clean synthesis gas stream is introduced into a catalytic reactor that utilizes specially formulated catalysts to generate liquid fuel from CO and H2 while concentrating CH4 and other combustible, but non-reactive gases in the syngas product stream. The methane rich stream is introduced into an engine for the production of electricity and heat while the unreacted CO and H2 can be recycled to produce additional liquid fuel. Excess heat can be used for other co-located processes and facilities.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority from U.S. provisional application Ser. No. 60 / 882,755 filed on Dec. 29, 2006, incorporated herein by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]Not ApplicableINCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC[0003]Not ApplicableBACKGROUND OF THE INVENTION[0004]1. Field of the Invention[0005]This invention pertains generally to an improved energy efficient process for the continuous, co-production of liquid fuels, electricity and heat from syngas, and more particularly to a system and method which integrates thermochemical syngas production, catalytic conversion processes and electricity and heat production systems in a manner that maximizes the thermal energy efficiency for the conversion of carbonaceous materials to electricity and liquid fuels.[0006]2. Description of Related Art[0007]The worldwide demand for energy and transportation fue...

Claims

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Application Information

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IPC IPC(8): C10J3/00
CPCC10K3/026Y02E50/32B01J23/78B01J23/80B01J27/051C07C29/1518C10J3/00C10J3/723C10K3/00C10K3/06C10G2/32F02C3/28C10J2300/0916C10J2300/093C10J2300/0976C10J2300/1609C10J2300/1618C10J2300/1621C10J2300/165C10J2300/1659C10J2300/1665C10J2300/1671C10J2300/1684C10J2300/1693C10J2300/1823F05D2220/75F05D2260/80B01J23/10Y02E50/18Y02E50/12C07C31/04C07C31/08Y02E50/10Y02E50/30Y02P20/00Y02P20/145Y02P20/52
Inventor SCHUETZLE, DENNISHURLEY, RONALD G.SCHUETZLE, ROBERT W.
Owner GREYROCK ENERGY INC
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