Process for producing renewable fuel from alcohol

Abstract

Systems, methods, and compositions are disclosed for producing renewable alcohol, converting C1-C5 alcohols into a mixture of C2-C7 olefins to generate a flow for recycling to an alcohol conversion step, creating or separating oligomerization conversions to generate a flow mainly of C4+, oligomerizing the flow into fuel-range olefins to create a flow, and separating the flow into fractions suitable for use as gasoline, jet, and diesel fuels. The disclosure also provides systems, methods, and compositions for bio-ethanol that can be converted to ethylene, followed by a mixture of C3-C8 olefins in a single step.

Description

Technical Field

[0001] Related Applications This disclosure claims priority to U.S. Provisional Patent Application No. 63 / 490,708, filed on March 16, 2023, with the title "Process for production of renewable fuels from Alchohols", the disclosure of which is hereby incorporated by reference in its entirety as if fully set forth herein.

[0002] Field This disclosure relates to systems and methods for producing renewable alcohols, hydrocarbons, and further processing them for the production of transportation fuels such as gasoline, jet fuel, and diesel fuel. This disclosure also relates to a process for converting C1-C5 alcohols to a mixture of C2-C7 olefins for use in the production of transportation fuels. A process for converting bioethanol to ethylene and then in one step to a mixture of C3-C8 olefins is also disclosed.

[0003] Background Art Petroleum is a non-renewable resource, and as a result of its combustion, carbon is released into the environment. There is an increasing demand for the use of biomass sources to replace petroleum as a starting point for the synthesis of fuels, particularly transportation fuels such as gasoline, jet fuel, and diesel fuel (generally referred to herein as fuels or transportation fuels). Due to the increasing availability and cost reduction of biomass-derived alcohols, biomass-derived alcohols are inexpensive and are a renewable feedstock for producing various olefins for use in downstream hydrocarbon production.

[0004] Current biogas production and spent grain treatment technologies are not fully efficient technologies as they produce waste such as proteins that can be used to produce other products, such as animal feed. Further, current technologies cannot address problems caused by high nitrogen concentrations in anaerobic digestion systems. Current integrated systems and processes for improving the yield and efficiency of alcohol production also suffer from inefficiencies and limitations. For example, there is a need for a system that produces a stillage specification with completely efficient and low-cost anaerobic digestion. There is also a need for the production of high energy density fuels such as hydrocarbon fuels or transportation fuels, particularly fuels with low or no carbon footprint (i.e., carbon neutral). Further, there is a need for improved methods for the treatment of renewable alcohols and hydrocarbons for the production of transportation fuels.

[0005] Current technologies that use petroleum fuels, in part, inherently have a high carbon footprint because petroleum fuels are produced by recovering oil from the earth, the fuel is burned in an engine, etc., and ultimately ends up in the atmosphere. The use of biodiesel can also cause problems because biodiesel is not a hydrocarbon, its chemical properties make its fuel properties inferior, and it lowers its blend limit. Renewable diesel, while a commonly used hydrocarbon, is produced from fats, greases, and oils from animals and plants, and there is a relatively low supply considering the high global demand for transportation fuels. Further, by-products produced from sources such as renewable diesel and propane have a low octane rating and a high vapor pressure, and thus have little value for recycling into transportation fuel markets such as the gasoline market or the SAF market to reduce net carbon footprint or net energy use.

[0006] Today, there is a demand for zero or low carbon footprint (i.e., carbon neutral) and negative carbon footprint (i.e., carbon sequestration), high-energy-density transport fuels, such as jet fuel (SAF), diesel fuel, bunker fuel, or gasoline. These fuels can be used in existing assets, can be blended with conventional fuels at a high level, or can be used directly without blending. Fuels such as ethanol have low energy density and blending limits, and are not compatible with existing assets. Existing ethanol production assets were not created to be carbon neutral. Renewable diesel is an example of a high-energy, low-carbon fuel, but its carbon footprint is far higher than zero, renewable diesel is supplied only for the diesel fuel market, and the amount of renewable raw materials for the production of renewable diesel is small compared to the market size and demand.

[0007] To date, the process required to deliver a carbon-neutral, commercially viable transport fuel made from carbohydrates with high energy density has not been identified. As seen in the California Low Carbon Fuel System pathway report, there are no viable carbohydrate-based fuels with high energy density (i.e., over 110,000 BTU / gallon) or hydrocarbon fuels with a zero carbon score.

[0008] Current commercially available ethanol processes rely on distillation and evaporation as part of the operation of the fermentation product recovery unit, and require a large amount of energy, even when heat is integrated to minimize energy consumption. For example, according to a 2016 publication by the Renewable Fuels Association (RFA), a typical ethanol plant uses approximately 26,700 BTU / gallon of process energy (thermal energy + electrical energy) (hereinafter referred to as "external energy") from an external energy source. As used herein, external energy refers to energy sources derived from external ethanol plant limits. Ethanol has a low energy density of 76,300 BTU / gallon, meaning that production process energy accounts for approximately 35% of the output energy. This process energy, natural gas, and grid electricity occupy a large carbon footprint and therefore prevent the process from achieving carbon neutrality. Furthermore, ethanol has an energy density of approximately 65% ​​of that of petroleum gasoline (116,000 BTU / gallon). Therefore, ethanol imposes limitations on the range of vehicle transport, and ethanol cannot be used as jet fuel, diesel fuel, or bunker fuel. Furthermore, the blending ratio in gasoline is limited.

[0009] The process of converting alcohols to hydrocarbon fuels has been moderately successful and has not been commercially implemented for various reasons. The demand for renewable fuels with high energy density is a relatively recent phenomenon. The ability to convert alcohols into transport fuels that meet fuel specifications requiring control of the molecular structure of the product has not been developed until now. Therefore, there has been an unmet demand for a supply of renewable alcohols with a carbon footprint low enough to make the resulting hydrocarbons attractive and commercially viable for use as transport fuels.

[0010] Bio-based alcohols are important versatility chemical products. With the increasing availability and cost reduction of bio-based ethanol, researchers have explored bioethanol as a feedstock for producing a variety of downstream hydrocarbons, including jet fuel and / or diesel fuel. Researchers at Gevo Inc. have developed a fermentation process that facilitates bioisobutanol production, and hereby present a novel pathway to bio-based fuels based on bio-based alcohols and their subsequent conversion.

[0011] Processes for oligomerizing gaseous monoolefins to form gasoline-type hydrocarbons are known and disclosed in the patent documents (U.S. Patents 4,613,719 and 9,688,590). However, there is always a need to develop new oligomerization processes that use more effective and / or less expensive methods.

[0012] The process of oligomerizing olefins is carried out using an acid catalyst such as supported phosphoric acid, and olefin dimers are commonly obtained for gasoline additives after hydrogenation of the dimers (U.S. Patent Nos. 6,689,927 and 6,284,938).

[0013] Examples of using cation exchange resins for oligomerization have been reported. It has been claimed that cation exchange resins can be used for dimerization (U.S. Patent Application Publication No. 20050119111). U.S. Patent No. 5,789,643 taught that oligomerization can be catalyzed by zeolites, alumina, and ion exchange resins. Tetramers or pentamers can also be obtained by oligomerizing a pre-formed dimer with an ion exchange resin (U.S. Patent No. 6,239,321).

[0014] The oligomerization of lower olefins (e.g., C2-C8) from bio-based alcohols to jet fuel and / or diesel fuel using a catalytic conversion process with a first catalyst such as zirconium tungstenide, molybdenum zirconium, or a combination thereof, and a second catalyst such as an acidic ZSM-5 catalyst, has recently been disclosed in U.S. Patent No. 11,078,433 (Gevo Inc.), which is incorporated herein by reference in its entirety.

[0015] This specification provides, in particular, solutions to the above-mentioned and other problems in the art.

[0016] Summary of the Invention This disclosure, in particular, describes a system for producing renewable hydrocarbons. The system includes a fractional distillation subsystem for processing carbohydrate-containing biomass; a fermentation subsystem for converting carbohydrates into fermentation products; a water treatment subsystem for receiving a first portion of the fermentation products; an alcohol concentration subsystem for receiving a second portion of the fermentation products; a hydrocarbon production subsystem for receiving renewable alcohol and producing renewable hydrocarbons; a renewable alcohol and hydrocarbon processing unit for producing transport fuels; and an energy management subsystem for receiving fuel flows from the system and supplying power to the system.

[0017] In some embodiments, one or more of the following features may be included in any viable combination. For example, the fractional distillation subsystem may include at least one of a storage container for storing biomass, a crusher for crushing biomass, a pretreatment container for pretreatment of biomass, a processing container for processing biomass to produce carbohydrates, and a high-temperature short-time (HTST) container for pasteurizing the carbohydrates.

[0018] In some embodiments, the fermentation subsystem may include at least one of a fermenter for converting carbohydrates into fermentation products, a nutrient supply subsystem, a pH adjustment subsystem, and a seed culture growth subsystem.

[0019] In some embodiments, the water treatment subsystem may include at least one of the following: a beer well for receiving a first portion of the fermentation product; a microbial separator for removing microorganisms from the first portion of the fermentation product; a first distillation column for separating the first portion of the fermentation product into alcohol and bottom product; a digester for receiving a portion of the bottom product and producing biogas; and a biogas removal subsystem for removing contaminants from the biogas.

[0020] In some embodiments, the alcohol concentration subsystem may include at least one of the following: a flash tank for separating a condensate from a second portion of the fermentation product; a separation vessel for separating the condensate into a light phase and a heavy phase; an ion exchange vessel for purifying the light phase; a membrane separator for separating the light phase into a high-alcohol holding liquid and a water-rich permeate; a second distillation column for separating water from the high-alcohol holding liquid; and an alcohol storage vessel.

[0021] In some embodiments, the hydrocarbon production subsystem includes a denitrification subsystem for separating nitrogen from alcohol, a dehydration subsystem for converting alcohol to olefin, a hydrocarbon pretreatment subsystem for preparing olefin feedstock, a hydrogen supply subsystem for supplying hydrogen, and a subsystem for supplying olefin feedstock, isooctane fraction, C 12 Alkane fraction, and / or C 16 It may include at least one hydrocarbon processing subsystem for converting to at least one of the alkane fractions.

[0022] In some embodiments, the hydrocarbon processing subsystem may include at least one of a first reactor, a debutanizer, a second reactor, a separator, a first splitter, and / or a second splitter.

[0023] In some embodiments, the energy management subsystem may include at least one of the following: a fuel gas system for distributing fuel gas received from the hydrocarbon processing subsystem; a low-pressure boiler for generating steam; a high-pressure boiler for generating steam; a thermal and power combined unit for generating steam and electricity; a wind turbine for generating electricity; an electric boiler for receiving renewable electricity and heating water to produce steam; a biomass boiler for burning biomass to heat water and produce steam; and / or a steam turbine for generating electricity.

[0024] In some embodiments, the biomass is maize, wheat, and / or sorghum. In some embodiments, the biomass has a negative carbon footprint. In some embodiments, the biomass is cultivated using strip till or no till. In some embodiments, the grinder is a mill. In some embodiments, the biomass is cultivated using agricultural practices that increase soil organic carbon. In some embodiments, the pretreatment vessel may include a recirculating water inlet. In some embodiments, pretreatment of the biomass may include enzymatic pretreatment of the biomass. In some embodiments, the treatment vessel may include a non-fermentable solid product. In some embodiments, the non-fermentable solid product may include dried grain distillate product and / or maize oil product. In some embodiments, a portion of the maize oil product may be used as boiler fuel.

[0025] In some embodiments, the fermentation tank is a continuous fermentation tank. In some embodiments, the fermentation product may contain alcohol. In some embodiments, the alcohol is isobutanol.

[0026] In some embodiments, the seed culture subsystem is configured to supply microorganisms to a fermenter. In some embodiments, the microorganisms are yeast. In some embodiments, the first portion of the fermentation product may contain alcohol. In some embodiments, the first portion of the fermentation product may contain isobutanol. In some embodiments, the first portion of the fermentation product may contain water. In some embodiments, the microbial isolation apparatus may include a centrifuge. In some embodiments, the microbial isolation apparatus may include a filter. In some embodiments, the microbial isolation apparatus may include a sedimentation tank. In some embodiments, the microorganisms are yeast.

[0027] In one aspect of the present disclosure, the first distillation column includes at least one vapor recompression subsystem. In another aspect of the present disclosure, the first distillation column includes at least one mechanical vapor recompression (MVR). In yet another aspect of the present disclosure, the first distillation column includes at least one thermal vapor recompression (TVR).

[0028] In one aspect of this disclosure, the bottom product may include distillation residue. In some embodiments, the digester is an anaerobic digester. In another aspect of this disclosure, the digester is a continuous digester. In another aspect of this disclosure, the biogas removal subsystem may include a scrubber. In another aspect of this disclosure, the contaminant is hydrogen sulfide.

[0029] In some embodiments, a flash tank receives a second portion of the fermentation product from the fermentation subsystem and returns a portion of the second portion of the fermentation product to the fermentation subsystem. In some embodiments, the second portion of the fermentation product is broth, and the dilute isobutanol broth is returned to the fermentation subsystem. In some embodiments, the flash tank operates at atmospheric pressure. In some embodiments, the flash tank operates under vacuum, under reduced pressure below atmospheric pressure. In some embodiments, the flash tank operates at a temperature lower than the temperature of the second portion of the fermentation product received from the fermentation subsystem. In some embodiments, a separation vessel is a liquid / liquid separator for separating the condensate into a light phase and a heavy phase. In some embodiments, the light phase contains a larger amount of alcohol than the heavy phase. In some embodiments, the alcohol is isobutanol, and the liquid / liquid separator forms a two-phase system. In some embodiments, an ion exchange vessel contains an ion exchange resin, receives the light phase from the separation vessel, and removes impurities from the light phase by capturing ions in the ion exchange resin. In some embodiments, the ion exchange vessel receives a caustic solution and regenerates the ion exchange resin by flushing impurities into a beer well.

[0030] In some embodiments, the hydrocarbon production subsystem includes an oil and water separator for separating wastewater from the hydrocarbon treatment subsystem, as well as isooctane and C from the hydrocarbon treatment subsystem. 12 Blend, or C 16 The system further includes at least one hydrocarbon storage container for storing at least one of the blends.

[0031] In some embodiments, a denitrification subsystem receives alcohol from an alcohol concentration subsystem. In some embodiments, the alcohol is fuel-grade isobutanol. In some embodiments, a dehydration subsystem receives alcohol from the denitrification subsystem and delivers water and / or purge products to a beer well. In some embodiments, the olefin is a 4-carbon olefin.

[0032] In some embodiments, the hydrocarbon pretreatment subsystem may include at least one of a coalescer for receiving olefins from the dehydration subsystem, an adsorbent for removing unreacted alcohol, water, and nitrogen, and a feedstock receiver.

[0033] In some embodiments, the coalescer receives further wash water and sends wastewater to a surge tank and / or dewatering unit. In some embodiments, the olefin is a C4 olefin. In some embodiments, the unreacted alcohol is isobutanol.

[0034] In some embodiments, a feedstock receiver receives olefins from an adsorbent. In some embodiments, the first reactor is a solid acid-catalyzed oligomerization (e.g., Polynaptha®, a commercially available example) reactor. In some embodiments, the first reactor receives olefins from the feedstock receiver and oligomerizes them into polyolefins. In some embodiments, a debutane column receives polyolefins from the first reactor. In some embodiments, the debutane column recirculates unreacted olefins and / or paraffins back to the first reactor. In some embodiments, the second reactor is a hydrogenation reactor. In some embodiments, the second reactor receives polyolefins from the debutane column. In some embodiments, the second reactor further receives hydrogen from a hydrogen supply subsystem and hydrogenates the polyolefins into C8-C8 16 Convert to alkanes. In some embodiments, the separator separates unreacted olefins and / or paraffins from C8 to C8. 16 Remove from alkanes. In some embodiments, unreacted olefins and / or paraffins contain C4 products. In some embodiments, the separator is C8-C 16Recirculate a portion of the alkane to the second reactor. In some embodiments, the first splitter separates an isooctane fraction from the C8-C 16 alkane.

[0035] In some embodiments, the isooctane fraction may contain about 85 wt%, 90 wt%, 91 wt%, 92 wt%, 93 wt%, 94 wt%, 95 wt%, 96 wt%, 97 wt%, 98 wt%, 99 wt% or 100 wt% C8 alkane, about 1 vol%, 2 vol%, 3 vol%, 4 vol% or 5 vol% olefin, and / or about 2 ppm, 4 ppm, 6 ppm, 8 ppm or 10 ppm sulfur.

[0036] In other embodiments, the isooctane fraction may contain more than 95 wt% C8 alkane, less than 5 vol% olefin, and / or less than 10 ppm sulfur. In some embodiments, the first splitter separates unreacted olefin and / or paraffin from the C8-C 16 alkane. In some embodiments, the unreacted olefin and / or paraffin contains a C4 product. In some embodiments, the second splitter separates a C 12 alkane fraction from a C 18 fraction.

[0037] In some embodiments, the fuel gas system provides fuel gas to a low-pressure boiler. In some embodiments, the fuel gas system provides fuel gas to a high-pressure boiler. In some embodiments, the fuel gas system provides fuel gas to a combustion heater. In some embodiments, the low-pressure boiler is further configured to receive natural gas and / or biogas from an anaerobic digester. In some embodiments, the combined heat and power unit is further configured to receive natural gas and / or biogas from an anaerobic digester. In some embodiments, the low-pressure boiler within the fuel gas system is configured to receive corn oil, biomass, or products from the pyrolysis of biomass as a low-carbon intensity fuel.

[0038] In one embodiment, a process is provided for producing renewable transport fuels, such as gasoline, jet fuel (SAF), and diesel fuel, from renewable C1-C5 alcohols, comprising: a) converting the C1-C5 alcohols into a mixture of C2-C7 olefins to produce a flow A; b) optionally separating a fraction mainly of C2 olefins from flow A to create or separate an oligomerization conversion to produce a flow B mainly of C4+ for recirculation to the alcohol conversion step; c) optionally purifying and combining flow A and / or flow B to produce a flow C suitable for oligomerization to fuel-range olefins; d) oligomerizing flow C to fuel-range olefins to produce a flow D; e) optionally hydrogenating flow D to produce a flow E mainly of paraffin; and f) separating flow E into fractions suitable for use as gasoline, jet fuel, and diesel fuel.

[0039] In another embodiment, a process is provided for producing a renewable alkylate from renewable C1-C5 alcohols, comprising: a) converting the C1-C5 alcohols into a mixture of C2-C7 olefins to produce a stream A; b) optionally separating a fraction mainly of C2 olefins from stream A to create or separate an oligomerization conversion to produce a stream B mainly of C4+ for recycling back to the alcohol conversion step; c) optionally purifying streams A and / or B and combining them with renewable isobutane or petrochemical isobutane to produce a stream C suitable for alkylation; d) subjecting stream C to an alkylation process to produce an unpurified renewable alkylate stream D; and e) optionally purifying stream D to be suitable for direct use as renewable gasoline.

[0040] In yet another embodiment, a process is provided for converting bio-based ethanol into high-octane gasoline fractions and jet fuel fractions, comprising the steps of: a) converting ethanol to ethylene, followed by a one-step conversion to a mixture of C3-C8 olefins; and b) co-oligomerizing the C3-C8 olefins, linear butene and / or fractions thereof with isobutylene to increase branching and thereby provide octane gasoline fractions and jet fuel fractions.

[0041] It should be understood that all combinations of the aforementioned and additional concepts discussed in more detail below (unless such concepts are mutually inconsistent) are considered to be part of the subject matter of the inventions disclosed herein. In particular, all combinations of the subject matter claimed in this disclosure are considered to be part of the embodiments disclosed herein. It should also be understood that terms expressly used herein, which may also appear in any disclosure incorporated by reference, should be given meanings that are most consistent with the specific concepts disclosed herein. [Brief explanation of the drawing]

[0042] [Figure 1] This flowchart shows a low-energy production process consistent with embodiments of the present disclosure. [Figure 2] This is a flowchart of the process for converting carbohydrates to hydrocarbons, consistent with embodiments of the present disclosure. [Figure 3] This flowchart shows an ethanol pretreatment and processing system consistent with embodiments of the present disclosure. [Figure 4] This figure shows the integration of waste heat from alcohol to hydrocarbons with biomass processing, consistent with embodiments of the present disclosure. [Figure 5] This is a process flow diagram showing a typical ethanol distillation system. [Figure 6] This is a process flow diagram showing a conventional triple-effect evaporator used in ethanol purification. [Figure 7]This is a process flow diagram illustrating the use of multiple MVR fans in ethanol purification consistent with embodiments of the present disclosure. [Figure 8] This figure shows an evaporator system integrated with Figure 7, consistent with the embodiments of the present disclosure. [Figure 9] This graph compares the carbon intensity of different petroleum-based fuels and shows the reduction in carbon intensity achieved by producing biofuels using various aspects of low-energy processes. [Figure 10] This is a flowchart showing an isobutanol production process consistent with embodiments of the present disclosure. [Figure 11] This is a flowchart of a carbon-neutral, net-zero energy isobutanol process consistent with embodiments of the present disclosure. [Figure 12] This flowchart shows a continuation of the process in Figure 11, consistent with the embodiments of this disclosure. [Figure 13] This flowchart shows a hydrocarbon pretreatment and processing system consistent with embodiments of the present disclosure. [Figure 14] This figure shows a process for recirculating ETO into a fuel product using C2, consistent with embodiments of the present disclosure. [Figure 15] This figure shows a process consistent with embodiments of the present disclosure, in which ETO is dimerized using C2 to produce a fuel product. [Figure 16] This figure shows an ethanol dehydration and solid acid alkylation process for alkylating the product, consistent with embodiments of the present disclosure. [Figure 17] This figure shows a process including ETO with liquid-acid or ionic liquid alkylation for alkylating the product, consistent with embodiments of the present disclosure. [Figure 18] This graph shows the increase in octane as a result of co-oligomerizing isobutylene with linear butene, compared to blending isooctane.

[0043] Modes for carrying out the invention This specification discloses processes for producing high-energy-density, zero-carbon-footprint hydrocarbon fuels using feedstocks, namely carbohydrates, that are supplied in large quantities worldwide and can be sourced with a zero-carbon footprint. In the systems and processes described herein, carbohydrates (e.g., corn, wheat, and / or sorghum) are converted to hydrocarbons. Generally, the systems and processes achieve net-zero energy use and zero carbon footprint by using low-carbon-footprint carbohydrate feedstocks, feedstock fractionation processes that can be used pre- or post-fermentation to remove most proteins and water-insoluble solids, fermentation processes, biogas production processes using fermentation distillation residues, and alcohol-to-hydrocarbon conversion processes.

[0044] In the systems and processes disclosed herein, the total external process energy requirements are less than approximately 20,000 BTU / gallon, 15,000 BTU / gallon, 10,000 BTU / gallon, 8,000 BTU / gallon, 6,000 BTU / gallon, 4,000 BTU / gallon, and 2,000 BTU / gallon, and the product is at least 100,000 BTU / gallon, 10 These are hydrocarbons with energy densities of 5,000 BTU / gallon, 110,000 BTU / gallon, 115,000 BTU / gallon, 120,000 BTU / gallon, 125,000 BTU / gallon, 130,000 BTU / gallon, 135,000 BTU / gallon, 140,000 BTU / gallon, 145,000 BTU / gallon, or 150,000 BTU / gallon. Therefore, the external process energy is equivalent to 6%, 8%, 10%, or 12% or less of the product energy. This low external process energy requirement, combined with the appropriate selection of carbohydrate feedstock, makes it possible to achieve a zero carbon footprint, i.e., carbon neutrality. Achieving this with ethanol or any other low-energy-density fuel is easier than with other fuels, given the low energy density of low-energy-density fuels. However, there is a demand for fuels with an energy density close to that of petroleum fuels, for example, at least 65%, 70%, 75%, 80%, or 85% of the energy density of petroleum gasoline or jet fuel.

[0045] In the hydrocarbon processes described herein, the hydrocarbon products of any gasoline distillation range provide an octane rating of at least 50, 55, 60, 65, 70, 75, or 80 to ensure an economical blend with other components for producing gasoline. This is in contrast to today's renewable diesel production, which gives by-products (propane) with an octane rating of less than 50, 55, 60, 65, 70, 75, or 80.

[0046] In the processes described herein, carbon intensity (CI) (gCO2e / MJ) is used as a measure of reduced tillage corn feedstock, biogas from distillation residues, and high-energy-density carbohydrate-derived fuels produced using wind power.

[0047] The “Carbon Intensity (CI)” as used herein is calculated based on the industry standard Argonne National Laboratory’s (Argonne) Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET®) Model. However, other CI frameworks, including but not limited to those listed above, may also be used to calculate CI values ​​in this application, including: California Low-Carbon Fuel Standard (CA-GREET3.0), Carbon Offsetting and Reduction Scheme for International Aviation by the UN International Civil Aviation Organization (ICAO CORSIA), Environmental Protection Agency’s Renewable Fuel Standard (EPA RFS), European Renewable Energy Directive (EU REDII), Canadian Clean Fuel Standard (CFS), and carbon reduction regulation used by Brazil (RenovaBio). Argonne’s GREET® model was developed by Argonne with the support of the U.S. Department of Energy (DOE) to consider carbon intensity related to the energy and environmental impacts of fuel and vehicle technologies. Argonne's GREET® model can be applied to all aspects of the fuel supply chain, enabling suppliers, consumers, industry, and regulators to compare greenhouse gas emissions under truly apples-to-apples conditions. Argonne's GREET® model quantifies emissions across the entire lifecycle and is considered superior to other life cycle analysis (LCA) tools available today.Argonne's GREET® models include the Feed-on Carbon Intensity Calculator (FD-CIC) and the Carbon Calculator for Land-Use Change from Biofuels (CCLUB). These models can be downloaded from https: / / greet.es.anl.gov / .

[0048] Described and illustrated herein are systems, equipment, processes, features, and functional processes of carbon-neutral, net-zero energy systems for addressing problems in current systems. The following description includes specific details to provide a complete understanding of the various embodiments. In some examples, well-known structures are not illustrated or described in detail to avoid unnecessarily obscuring the description of the embodiments. Unless the context requires otherwise, the word “comprise” and its variations, e.g., “comprises” and “comprising,” throughout the specification and the subsequent claims should be interpreted as having an open and comprehensive meaning, i.e., “including, but not limited to.” Furthermore, headings provided herein are for convenience only and should not be construed as defining the scope or meaning of the claimed disclosure.

[0049] Throughout this specification, any reference to “some embodiments,” “one embodiment,” or “an embodiment” means that the particular features, structures, or characteristics described in relation to that embodiment are included in at least one embodiment. Therefore, the occurrences of the phrases “in some embodiments,” “in one embodiment,” or “in an embodiment” in various parts of this specification do not necessarily all refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Additionally, where used herein and in the appended claims, the singular forms “a,” “an,” and “the” include multiple references unless otherwise explicitly indicated in the context. It should also be noted that the term “or” is generally used to include “and / or” unless otherwise explicitly indicated in the context.

[0050] The word "approximately" preceding a number means a range of plus or minus 10% of that value; for example, "approximately 50" means 45 to 55, and "approximately 25,000" means 22,500 to 27,500. Furthermore, the phrases "approximately less than a certain value" or "approximately greater than a certain value" should be understood in light of the definition of the term "approximately" provided herein.

[0051] C 12+ The oligomers can be used directly in the production of renewable diesel fuel and post-hydrogen renewable jet fuel, such as in the isobutanol / iC4 process.

[0052] Process scheme for low-energy production processes for biofuel production

[0053] A schematic diagram of the low-energy production process 100 is shown in Figure 1. The low-energy production process 100 is sometimes referred to as a net-zero carbon footprint process ("net-zero" or "NZ"). With regard to the raw materials and their selection, certain cultivation practices are now known to enable carbohydrates with a carbon footprint of zero or less. For example, tillage-reduced maize grown at reasonable yields and with little to no irrigation is estimated to have a low or zero carbon footprint.

[0054] Referring to Step 1 in Figure 1, the low-energy production process 100 begins with the preparation of a fermentation feedstock. The fermentation feedstock is a biomass source containing carbohydrates, and when this feedstock is introduced into water to produce a slurry, it may reduce water-insoluble solids and proteins. The carbohydrate source (e.g., high-sugar maize) has been determined to potentially affect the ability to ultimately meet the net-zero energy carbon-neutrality goal. As described in Figure 1, the feedstock is fractionally distilled as needed for the process.

[0055] Step 2 in Figure 1 involves carrying out fermentation to convert carbohydrates into fermentation products. Alternatively, Step 1 can be performed after the process in Step 2.

[0056] Step 3 in Figure 1 includes subjecting the fermentation broth containing the fermentation product to one or more fermentation product separation processes, thereby producing a first stream containing the fermentation product and a second stream consisting of fermentation spent broth. The fermentation product is purified so that it can meet product specifications using one or more energy-efficient processes consistent with the technology described herein. Optionally, the fermentation product is subjected to one or more chemical transformations, in certain embodiments described herein, resulting in one or more hydrocarbons that meet specifications for use in fuels and / or chemicals. A low thermal energy requirement unit operates to recover the fermentation product, including mechanical vapor recompression (MVR) and / or distillation processes and equipment with membranes, filters, or centrifuges, as described herein, thereby enabling an overall production process thermal energy less than the zero-carbon energy generated by the fuel gas system.

[0057] In step 4 of Figure 1, the fermentation product is converted to a hydrocarbon product having an energy density of at least 100,000 BTU / gallon, 105,000 BTU / gallon, 110,000 BTU / gallon, 115,000 BTU / gallon, 120,000 BTU / gallon, 125,000 BTU / gallon, 130,000 BTU / gallon, 135,000 BTU / gallon, 140,000 BTU / gallon, 145,000 BTU / gallon, or 150,000 BTU / gallon by using a combination of dehydration and oligomerization followed by hydrogenation. The thermal output of the oligomerization step can be integrated with a first conversion step, including dehydration, to minimize the total net energy required to convert the alcohol to hydrocarbons and achieve a low-energy process.

[0058] In step 5 of Figure 1, the hydrocarbon products are separated into transport fuels such as jet fuel, diesel fuel, bunker fuel, and / or gasoline distillation range hydrocarbons. The hydrocarbon products produced from the fermentation products are generally C6-C6, which are useful for gasoline, jet, diesel, and / or bunker fuels. 20 It consists of hydrocarbons.

[0059] In step 6 of Figure 1, the distillation residue has a composition that is substantially free of proteins and suspended solids, thereby enabling an efficient and low-cost water treatment system. Specifically, the composition of the distillation residue has the following characteristics: chemical oxygen demand (COD) greater than 40,000, 45,000 COD, 50,000 COD, 55,000 COD, 60,000 COD, 65,000 COD, 70,000 COD, 75,000 COD, 80,000 COD, 85,000 COD, or 90,000 COD; 0.2%, 0.4%, 0. Total suspended solids (TSS) of less than 8%, 1%, 1.2%, or 1.4%; total Kjeldahl nitrogen (TKN) of less than 1000 ppm, 1300 ppm, 1600 ppm, 1900 ppm, 2200 ppm, or 2500 ppm; protein of less than 2000 ppm, 4000 ppm, 6000 ppm, 8000 ppm, 10,000 ppm, or 12,000 ppm.

[0060] Step 7 in Figure 1 may include subjecting the distillation residue to one or more filtration processes to reduce suspended solids and proteins, for example, in order to achieve these specifications. In certain embodiments, Step 7 may be optional depending on the composition.

[0061] In step 8 of Figure 1, the fermented spent broth is subjected to an anaerobic digestion process that, in certain embodiments, produces at least 6,000 BTU, 8,000 BTU, 10,000 BTU, 12,000 BTU, 18,000 BTU, 22,000 BTU, 25,000 BTU, 30,000 BTU, 35,000 BTU, or 40,000 BTU of methane per gallon of hydrocarbon product. This corresponds to at least 6%, 8%, 10%, 12%, 18%, 22%, 25%, 30%, 35%, or 40% of the energy content of the product produced. In some embodiments, the anaerobic digestion process can produce at least 20,000 BTU of methane per gallon of hydrocarbon product, which may correspond to at least 20% of the energy content of the product produced. In some embodiments, the amount of methane produced is at least equal to the required external process energy. Instead of using the methane produced in Step 8 as an energy source, at least a portion of the oil produced during biomass fractional distillation (Step 1) can be used as an energy source to drive the entire production process, or at least a portion of it, resulting in fewer external energy sources required and at least a partial reduction in the overall carbon footprint.

[0062] If at least a portion of this methane is subsequently used as an energy source to drive the entire production process, the need for external energy sources, whether for all or part of the production process, is reduced. For example, in an isobutanol plant with a COD of 82,000 mg / L at 58 mgpy, the methane produced in the anaerobic digester is approximately 233 MMBTU / hour, or 500 MMBTU / day. This corresponds to approximately 2 million MMBTU / year, assuming 24 hours per day and 350 days per year. The total process thermal energy required is approximately 3300 MMBTU / day, excluding the energy needed to dry any part of the solids flow, and approximately 5500 MMBTU / day if 90% of the solids are dried to approximately 88% dry material, with the remainder supplied to the feed market on a wet basis.

[0063] In step 9 of Figure 1, water is produced using the water treatment process. The recovered water can be recycled to the front end of the process.

[0064] In step 10 of Figure 1, one or more boilers can receive the gas outlet of an anaerobic digester (AD) system. In certain embodiments, heat or energy from the AD system produces steam that drives part of the process. Using heat / energy from the AD system also helps reduce the overall external energy requirements of the process.

[0065] Referring to Figure 2, a flowchart is shown illustrating the process of converting carbohydrates to hydrocarbons via isobutanol 1000. Carbohydrates such as corn 1001 are subjected to fractional distillation 1005. Fractional distillation generally refers to the conversion of carbohydrates into their constituent components. The product of fractional distillation 1005 is then used for either feed and food raw materials 1010 (for example, however, other alternative uses 1010 may be available for different biomass) or for isobutanol production 1015. Although described as isobutanol, isobutanol is just one example of a possible alcohol that can be used throughout the process. The product of isobutanol production 1015 can be used for hydrocarbon production 1020 or water treatment 1030. The product of isobutanol production 1015 used for hydrocarbon production 1020 becomes isooctane jet fuel 1025. The product of isobutanol production 1015 used for water treatment 1030 becomes partially biogas 1035. Biogas 1035 and / or natural gas 1055 can be used to create the energy source 1040. Optionally, corn oil and / or biomass may also be used as part of the energy source 1040. In certain embodiments, any corn oil by-products may be sold or otherwise disposed of. The energy source 1040 comprises coagulated biogas, natural gas, corn oil, and biomass. In certain embodiments, the energy 1040 may produce electricity 1050 and steam 1045 using wind power, CHP, electric boilers, or a combination thereof.

[0066] Process scheme for an energy-efficient hydrocarbon production process using ethanol as an alcohol intermediate

[0067] Figure 3 shows a schematic diagram of a low-energy production process well-suited for jet and diesel fuels derived from ethanol intermediates. The selection of feedstock is crucial to ensure that the input feedstocks have a zero or negative carbon footprint.

[0068] Figure 3 is a diagram of the process and equipment 50. The diagram of the process and equipment 50 shows that the fractional distillation and fermentation unit 51 receives carbohydrates 52, such as maize 52. The fractional distillation and fermentation unit 51 produces fermentation broth 53, which is received by the distillation unit 54. The fractional distillation and fermentation unit 51 also outputs maize fiber 55 and maize oil 56. The maize fiber 55 may be supplied to an anaerobic digester (as described elsewhere in this specification). The maize oil 56 may be used as fuel or otherwise discarded. The distillation unit 54 produces alcohol 57, such as ethanol 57, which is received by the dehydration unit 58. The distillation unit 54 produces fusel oil 59, which is mixed with other combustible materials and sent to a boiler or the like. The distillation unit 54 also produces feed by-products 60 and wastewater 61. The dehydration unit 58 dehydrates the alcohol 57 and produces ethylene 62, which is received by the dimerization unit 63. The dewatering unit 58 also produces ethane 64 combined with fusel oil 59 and other combustible materials as well as additional wastewater 61. The dimerization unit 63 produces ethylene 62, a catalyst and / or chemical 65 to facilitate the operation of the dimerization unit 63, as well as C4-C6 olefins 67 and C 8+ Water 66 is received to produce olefin 67. C4-C6 olefin 67 is received by the oligomerization unit 68. The dimerization unit 63 produces a light purge 69 combined with other combustible materials. The dimerization unit 63 also produces by-products including spent caustic agent 70 and additional wastewater 61. The oligomerization unit 68 receives C4-C6 olefin 67, which is then received by the hydrogenation and fractional distillation unit 72. 6+ The oligomerization unit 68 produces olefin 71. The oligomerization unit 68 also produces additional light purge 69 which is combined with other combustible materials. The hydrogenation and fractional distillation unit 72 produces C4-C6 olefin 67 and C 8+ The unit receives olefin 67 and produces transport fuel 73. The hydrogenation and fractional distillation unit 72 also produces light purge 69, which is combined with other combustible materials.

[0069] As disclosed herein, a low carbon intensity (CI) corn or any other low CI carbohydrate, a carbohydrate-rich feedstock, is fed into a process as shown in Figure 3. For example, in the case of corn, the feedstock is simply ground into a powder of the desired particle size before being fed forward. After mixing the powder with hot water and an enzyme (e.g., α-amylase and / or other suitable enzyme), it is fed into a liquefaction system that provides sufficient residence time for the starch in the corn flour to liquefy into polysaccharides. In some embodiments, enzymes such as cellulose-degrading enzymes, cellulases, proteases, pectinases, xylanases, α-L-arabinofuranosidases, and / or phytases can be used. In conventional corn-based ethanol dry mill equipment, heating the corn flour / water mixture before liquefaction is an utilization-intensive process in that a large amount of steam is injected directly into the slurry tank to achieve the target temperature. To help minimize the use of steam and fresh water, hot water from the ethanol distillation system, hot water from the evaporator system, and warm, low-concentration distillation residue (called "backset") are recirculated downstream into the slurry tank. To achieve the target total solids percentage in the slurry tank, additional water is often required. The bottom of the CO2 scrubbing tower is the typical cold water flow supplied to the slurry tank. If anaerobic digestion is used in the project, treated AD effluent can also be supplied to the slurry tank. In some cases, fresh makeup water, such as tap water, can also be supplied to the slurry tank. At these sources, these water flows are relatively cold, increasing the steam load required in the slurry tank. For this low-energy process for producing biofuels, design features are included to use excess heat from other parts of the NZ plant to heat the cold water flow supplying the slurry tank, thereby reducing steam usage to the point where it is only required at startup. Figure 4 shows an example of a heat integration scheme used to preheat the water supplying the slurry tank. Other configurations of Figure 4 for integrating heat generated from one part of the NZ plant into another part are also possible and within the scope of this application.

[0070] Figure 4 shows Figure 75 of the process and equipment for cooking water heating integration. Figure 75 shows one possible equipment and process configuration, etc., which is possible and within the spirit and scope of this technology. In relation to a net-zero carbon footprint plant for producing transport fuel, liquid heated by other processes described elsewhere in this specification is received by a treated water tank 76. The treated water tank 76 contains heated water 77 or treated water 77 for reuse by the plant, thereby saving thermal energy. The treated water 77 may be used directly from the treated water tank 76 or may be further heated and pressurized by one or more heat exchangers 78, which are described further below as exemplary exchangers, the heat exchangers 78 heat the treated water 77 to superheated treated water 79. To ensure safe storage, a slurry heat exchanger 80 uses the heat from the superheated treated water 79 to heat the slurry 81 in a slurry tank 82. The slurry heat exchanger 80 cools and depressurizes the superheated treated water 70 to produce cooking water 83 stored in the cooking water tank 84. The slurry mixer 85 uses the cooking water to combine the cooking water 83 with cornmeal (or similar), buckset (as described elsewhere in this specification), and enzymes to produce slurry 81.

[0071] Anaerobic digesters (ADs) described elsewhere in this specification are optional. Because ADs are optional, they may not be available to produce the effluent flow as shown in the figures. An ethanol reactor creates an ethanol-ethylene purge water flow, and this reactor is optional. The ethanol reactor converts ethanol to ethylene and water. This flow can be used to offset the fresh water supplied to the CO2 scrub tower, or it can be supplied directly to a process water tank as shown in Figure 4. The ethylene dimerized scrub water is C8, C 12 , and C 16In preparation for sending butene to the oligomerization process that produces olefins, it is produced from washing the butene formed from ethylene dimerization. The ethanol-ethylene process receives 190-proof ethanol as feedstock and, for safety reasons, is cooled by a water cooler in this example before entering intermediate storage, although other heat exchangers may be used. The hot 190-proof ethanol is cross-exchanged with cold, fresh feedwater and heated by the hot 190-proof ethanol, thereby saving heat drawn from the hot 190-proof ethanol. The heated water is supplied to the process water tank. The bottom of the stripper column is a relatively clean water stream produced in the production of 190-proof ethanol. If it originates from ethanol distillation, it is warm and supplied directly to the process water tank. The condensate in the evaporator is produced in the process of removing water from low-concentration distillation residue to produce syrup. The syrup is ultimately blended with wet cake and sold as animal feed, or, in some cases, supplied to a dryer to produce DDGS (Dried Grain Distillation Spent Water with Soluble Substances). The evaporator condensate is warm and contains low levels of impurities such as organic acids. The evaporator condensate is supplied directly to the process water tank.

[0072] While the combined water flow in the process water tank is warm, additional heat may be required to achieve the target temperature in the slurry tank. A wide range of cooling services in the ethanol-jet process were evaluated, which use the heat removed by a cooling water cooler exchanger or air cooler exchanger to heat the water leaving the process water tank. Cooling services were evaluated based on cooling load, temperature, operability, and safety. Although other services with higher cooling loads or useful temperature ranges existed, three services that met all criteria, including operability and safety, are shown in Figure 4. Cooling services related to the exothermic reactions produced from ethylene dimerization and butene oligomerization were evaluated, but were ultimately excluded as a heat source for cooking water due to being too cold or safety / operability concerns in controlling the reaction temperature. The three cooling services shown in Figure 4 are arranged to allow the process water to be heated from approximately 67°C to approximately 112°C in three steps. The process water leaving the cross-exchanger, including saturated recirculation from hydrogenation, is above the boiling point of water at atmospheric pressure. The process water is then superheated under back pressure control. To manage process fluctuations, it is necessary to store high-temperature process water in a surge tank, but it is not possible to store the water in a superheated state safely or economically, and some of it vaporizes when stored at atmospheric pressure. Therefore, the flowing superheated process water is cross-exchanged with a circulation loop from the slurry tank to lower the temperature of the process water below its atmospheric boiling point before being supplied to the cooking water tank, which is at atmospheric pressure. As shown in Figure 4, the cooking water tank operates at approximately 95°C. The cooking water is supplied to the slurry tank, where it is combined with cornmeal, buckset, and enzymes. In total, the thermal integration scheme saves at least 33 MMBTU / hour of steam with an annual ethanol capacity of 100 million gallons (anhydrous basis, 8000 hours of annual operation), as shown in Figure 4, which is equivalent to 39 MMBTU / hour with natural gas assuming an 85% boiler efficiency.

[0073] In some cases, the flow after liquefaction may undergo additional processing to reduce the particle size of the corn particles before being supplied downstream. This is advantageous because it helps to release additional corn oil from the corn particles, making more corn oil available for recovery downstream, although energy recovery via corn oil is optional as corn oil can be used in other carbon reduction methods. In the case of this low-energy process for producing biofuels, the corn oil is recovered and used as fuel for boiler systems, which helps to reduce the carbon intensity of the final jet product as well as naphtha and diesel by-products.

[0074] The flow that leaves the liquefied starch is supplied to the fermenter, where it combines with further enzymes and yeast. Fermentation is carried out in the conventional manner. The liquefied starch is simultaneously saccharified to form monosaccharides, which are then consumed by the yeast to form ethanol and CO2 gas. The CO2 gas is exhausted from the fermenter into a scrubbing tower system, which uses water to wash away ethanol or other water-soluble impurities carried by CO2 vapor. Fermentation is carried out in batches. Once a fermentation batch is complete, most of the monosaccharides are gone, leaving a small amount of residual sugar. The ethanol concentration is approximately 13.0% by weight, 13.5% by weight, 14.0% by weight, 14.5% by weight, 15.0% by weight, or 15.5% by weight. Generally, the yeast does not consume the corn fiber, corn oil, corn protein, ash, and other maize components present in the fermenter broth, except for small amounts of nutrients consumed to keep the yeast growing during fermentation. The ethanol, water, yeast, and maize components are transferred to a large surge tank called a beer well. The beer flow flows downstream from the beer well, continuously supplying it to ethanol distillation, where ethanol is recovered, while the water, corn components, yeast, and most of the enzymes are sent downstream to what is known as the total distillation residue.

[0075] Ethanol distillation can be carried out in several ways. In maize ethanol dry mill facilities that produce fuel-grade ethanol, the ethanol distillation system is almost always thermally integrated with the evaporator system in some way to reduce the amount of new vapor required to carry out the process. Figure 5 shows an example of a commercially available technology for distilling fuel-grade ethanol.

[0076] Like all available technologies, the one in Figure 5 has features to facilitate operation. Beer from the beer well is almost always cross-exchanged with the flow away from the liquefaction in the exchanger 101 to preheat the beer on its way to distillation in the beer stripper 102 (or beer distillation column 102), saving the cooling water demand when cooling the liquefied mash before fermentation. Figure 5 shows the vapor of aqueous ethanol 103 removed at the top of the beer stripper 102 and condensed in the first evaporator of the multi-effect evaporator system 104 shown in Figure 6. The heat removed from the aqueous ethanol vapor is used to separate the water vapor from the low-concentration distillation residue in the first evaporator, as shown in Figure 6. The water removed in the first evaporator is used to drive separation in a second effect evaporator, etc. Although evaporation is an energy-intensive process, the schemes shown in Figures 5 and 6 are such that the evaporator system does not require new steam. Figure 6 shows a typical triple-effect evaporator configuration that can be used. Figure 6 shows additional distillation components, including a beer reboiler 105 and a rectification column 106 (rectifier distillation column 106), where the condensed aqueous ethanol 103 is vaporized again by the rectification column 106 and used to supply heat to the beer reboiler 105. The rectifier top distillate condenser 107 uses the cooler product of the beer reboiler 105 to further condense the product into 190 proof ethanol 108. A fusel oil washing and separation unit 109 is used by the rectification column 106 and provides a fusel output 110 which is combined with the 190 proof ethanol 108 in this example. A side stripper 111 (side distillation column 111) is driven by fresh steam 112 in a side stripper boiler 113 and provides additional energy to the system 114.

[0077] Figure 7 provides a more detailed illustration of an exemplary embodiment of the multi-effect evaporation system 104. The multi-effect evaporation system 104 receives aqueous ethanol vapor 103 and low-concentration distillation residue from the distillation residue separation described elsewhere in this specification. Although the multi-effect evaporation system 104 is shown as comprising three evaporators 120, 121, and 122, more or fewer evaporators are possible depending on cost, design, and recovery constraints. The condensed aqueous ethanol output 103 is supplied to the rectification column 106. Energy-saving improvements over the distillation system shown in Figure 5, consistent with the technology of this application I, are shown in Figure 7 below. In particular, it has been found that by condensing the top distillate vapor from the rectification column 106, the pressure and temperature of the top distillate vapor / liquid can be heated using one or more pumps, such as the illustrated mechanical vapor recompression fan. The pressure can be such that the condensed top distillate steam from the rectifier column 106 operates at a higher pressure and temperature, and 190 proof ethanol can power the beer reboiler 105. Since the beer reboiler 105 has a considerable load, this heat integration conserves new steam and reduces the overall external energy required by the NZ plant. The problem associated with condensing the steam at the top of the beer stripper column 102 before feeding it to the rectifier column 106 is that a large portion of the feed to the rectifier needs to be revaporized in order to drive the ethanol to the top of the rectifier column 106. The energy for revaporization comes from the large amount of new steam 112 used in the side stripper boiler 113.

[0078] For this lower-energy process for producing biofuels, it is desirable to reduce the use of all new steam and natural gas as much as possible, so even schemes like those in Figures 5 and 6 offer opportunities for energy reduction. For this low-energy process for producing biofuels, a scheme like the one shown in Figure 7 can be developed. Figure 7 shows a possible configuration, but other configurations are also within the spirit and scope of this application.

[0079] Figure 7 shows a distillation system with an MVR fan; see the beer column 3195 with an MVR fan in Figure 11 below. The MVR fan shown in Figure 7 can be considered a mechanical vapor recompression (MVR) system 123. Figure 7 has some similar components to the distillation system in Figure 5, and the similar components will not be described again. As shown in Figure 7, aqueous ethanol 103 is supplied directly to the rectification column 106. The vapor from the top of the rectification column 106 is drawn out by a series of MVR fans 124 1~I The MVR system 123 is supplied with five MVR fans 124. 1~5The MVR fan 124 increases the pressure and temperature of the vapor from the top of the rectification column 106 to drive the beer reboiler 105. The discharge from the beer reboiler is supplied to a multi-effect finish evaporator 125, which replaces the multi-effect evaporation system 104 described above. A draw trap (not shown) in the rectification column 106 is used to draw 190-proof ethanol 108 directly from the rectification column 106, removing fermentation byproducts that are problematic in the ethanol dehydration and purification reaction from the flow of 190-proof ethanol 108. The 190-proof ethanol 108 is drawn from a draw tray located one or more steps below the top of the rectification column (note that the column used in the context of this application may also be a distillation column). This allows acetaldehyde to accumulate in the top distillate of the rectifier column, away from the 190-proof ethanol, and be purged in a light purge flow as shown in Figure 7. Acetaldehyde is preferable to keep away from 190-proof ethanol because it can form undesirable byproducts such as CO2 during the ethanol dehydration reaction. As shown in Figure 7, the fusel flow is not combined again with the 190-proof ethanol 108 flow, as in conventional maize dry mill plants producing fuel-grade ethanol. The fusel oil flow contains high concentrations of C4 and C5 alcohols. These C4 and C5 alcohols react in the ethanol dehydration reaction to form their respective monoolefins. These olefins are ultimately removed from the ethylene produced along with other oxygenation byproducts and then burned as fuel to offset other heating needs in the process. Since fusel has a higher calorific value as fuel before being converted to olefins, fusel is not combined with 190-proof ethanol to produce biofuels in this low-energy process. Table 1 below shows examples of fusel oil flow and light purge compositions as shown in Figure 7.

[0080] [Table 1]

[0081] Combining light purging with a fusel can offset the project's heat demand of 27 MMBTU / hour (higher calorific value). Burning corn oil as fuel provides another 62 MMBTU / hour (higher calorific value) for steam production.

[0082] The ethanol distillation in this low-energy process for producing biofuels differs from that which can be done in some ways by conventional maize ethanol dry mills. As shown in Figure 7, one distinct difference is the addition of an MVR system 123, which centers around five MVR fans 124 arranged in series between the top distillate vapor of the rectification column 106 and the beer reboiler 105. The MVR system 123 mechanically compresses the vapor and, at the same time, increases its pressure by raising its temperature to a more useful range so that the vapor condenses at a higher temperature. This effect makes the latent heat of condensation of the vapor available to drive something like a beer column reboiler, as shown in Figure 7. At least three, four, and five or more MVR fans are shown because both the temperature and pressure increases of the entire MVR fan are within the range of 11°C and 6.5 psi, respectively. For the vapor to have a condensation range with a temperature higher than that at the bottom of the beer column is operating, a total pressure rise of 20 psi, 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi or higher is considered preferable across the entire fan. The temperature rise across the entire fan is controlled by injecting high-proof liquid from the rectifier pump into the supply section to each fan. In one embodiment, the total number of MVR fans is preferably 5. A single MVR fan offers advantages. In general, certain embodiments of the art include at least 3 MVR fans. Other embodiments of the art include 5 or fewer MVR fans. Yet another embodiment of the art provides 3 to 5 MVR fans.

[0083] The exemplary system configuration shown in Figure 7 provides five MVR fans to raise the pressure and temperature of the rectifier column top distillate steam to a useful range that can be used to operate the beer stripper reboiler.

[0084] For example, as shown in Figure 7, the 5-stage MVR has been found to be the most cost-effective way to obtain the required thermal energy savings for reasons such as the following: i.MVR uses hydrocarbon ethanol to drive the reboiler of a beer stripper. ii. As MVR increases, costs rise. iii. If the MVR is low, energy is not supplied at the desired pressure. iv. The cost of one compressor is approximately three times the cost of five MVRs. v. The thermal energy savings are at least about 7,327 BTU / gallon for ethanol, or at least about 11,780 BTU / gallon for hydrocarbons (based on 100 mmGPY of ETOH and 62.2 mmGPY of hydrocarbons).

[0085] The added water stripper absorbs the hydraulic load from the bottom of the rectification column, reducing the hydraulic load on the beer stripper column. This allows for a smaller beer stripper size (diameter), making it possible to manufacture the column in the factory and transport it to the site. This results in significant cost savings compared to columns manufactured on-site.

[0086] Another method involves generating low-pressure steam from evaporator condensate or boiler water to drive an auxiliary reboiler for the water stripper, reducing the natural gas heat load by approximately 1,884 BTU / gallon with ethanol or approximately 3,028 BTU / gallon with hydrocarbons.

[0087] The top distillate steam from the rectification column 106 is partially condensed in the beer reboiler 105. Additional heat can be recovered after the beer reboiler 105 by the multi-effect finishing evaporator 125, which is shown in more detail in one exemplary configuration in Figure 8.

[0088] Figure 8 also shows the low-concentration distillation residue concentrated in syrup. The mechanical vapor recompression (MVR) evaporator 126 uses a single MVR fan 127 to increase the water vapor pressure and temperature from the drawout from the MVR evaporator 126 to produce heat and expel water from the low-concentration distillation residue being fed to it. The discharge from the single MVR fan 126 is used for reflux in the distillation system. The multi-effect finish evaporator 125 is shown together with three finish evaporators 127, 128, and 129. The first finish evaporator 127 receives the output of the beer reboiler 105. As can be understood from Figure 8, the steam and condensate configuration of the MVR evaporator 126 and the multi-effect finish evaporator 125 is designed to recover / save as much energy as possible to reduce the overall carbon footprint of the NZ plant in which it is incorporated.

[0089] The medium-concentration distillation residue produced from the MVR evaporator 126, with a solid content of approximately 35% to 45% by weight, is sent to the corn oil separation system 130, where corn oil is removed by centrifugal separation. Optionally, the distiller corn oil produced by corn oil separation may be consumed by the NZ plant as energy to reduce the plant footprint. Alternatively, the distiller corn oil may be disposed of using other carbon-reducing methods.

[0090] The medium-concentration distillation residue is then sent in this exemplary configuration to finish evaporators 127 and 128, where the product of the beer reboiler 105 is used to provide heat for removing the remaining water, achieving a syrup solids content of approximately 45% by weight or 45% by weight.

[0091] The product from the beer reboiler 105 is used to increase the syrup solids content by the finishing evaporators 127 and 128. This allows for better wetcake solids for shipment and sale, and reduces the energy in the rotary dryer by approximately 1.8 MMBTU / hour.

[0092] The condensed rectifier vapor is then returned to the rectifier top distillate tank 131. The contents of the rectifier top distillate tank 11 can be used as reflux injection into the rectifier column 106 to facilitate the distillation process.

[0093] Thermal integration in ethanol and hydrocarbons results in energy reductions of approximately 3,446 BTU / gallon for ethanol and approximately 5,540 BTU / gallon for hydrocarbons.

[0094] Another feature evident from Figures 7 and 8 is that, in this exemplary embodiment, the disclosed scheme improves efficiency because the beer stripper steam 103, which is aqueous ethanol 103, is not condensed before being supplied to the rectifier. This feature eliminates the need for a large amount of new steam 112 for the side stripper boiler 113 to revaporize the feedstock to the rectifier column 106. The scheme in Figure 7 integrates the evaporator system into a thermal integration strategy. After the beer reboiler 105, a portion of the top distillate of the rectifier column 10 is still steam. The condensation load of this residual steam is used to drive the multi-effect finish evaporator 125, which is part of the evaporator system that produces syrup. Figure 8 shows an exemplary configuration of the multi-effect finish evaporator 125 scheme that integrates the top distillate of the rectifier column 106 in Figure 7 into the multi-effect finish evaporator 125.

[0095] The scheme in Figure 8 uses an MVR fan 127 to drive the MVR evaporator 126, removing some of the water from the low-concentration distillation residue. One advantage of the MVR fan 127 is that it increases the overall efficiency of the evaporator and does not require new steam in exchange for electricity from a renewable source such as wind power. The supply of the low-concentration distillation residue to the evaporator system begins from the bottom of the beer column 102, as shown in Figure 7, as the distillation residue as a whole, as shown in Figure 8. The total distillation residue is processed by a system to remove most of the insoluble solids (also known as suspended solids) from the liquid. This typically involves some type of centrifugation. The two flows resulting from the separation of the total distillation residue are called the low-concentration distillation residue and the wet cake. Examples of the flows and compositions of the total distillation residue, low-concentration distillation residue, and wet cake are shown in Table 2. These correspond to an anhydrous ethanol capacity of over 100 million gallons per year (8,000 operating hours per year).

[0096] [Table 2]

[0097] In many cases, a portion of the low-concentration distillation residue is recycled back into the slurry tank to mix with incoming cornmeal, cooking water, and enzymes. This recycled low-concentration distillation residue is called backset. Backset offers several functions. It helps reduce the plant's freshwater usage and reduces the size and utility associated with the evaporator system. Backset also provides nutrients that are utilized by the yeast during fermentation, ensuring that the yeast is healthy and functions quickly and efficiently.

[0098] Figure 8 shows the low-concentration distillation residue being supplied to the MVR evaporator 126. A constant circulation of the thickened distillation residue is pressurized from the bottom to the top of the evaporator. The supply of low-concentration distillation residue mixes with this recirculating flow as it moves to the top of the evaporator. This type of evaporator is called a downward-flowing membrane evaporator because the feed material supplied to the top is distributed across an array of tubes. The distillation residue flows as a membrane inside the tubes and is heated by the hot steam flowing outside the tubes. As the steam moves down the tubes, it evaporates from the low-concentration distillation residue and can separate from the liquid at the bottom of the evaporator. In Figure 8, the steam separated from the distillation residue at the bottom is supplied to the MVR fan 127, which compresses the steam and forces it to flow across the outside of the tubes, and most of the steam condenses as it heats the distillation residue inside the tubes. It is assumed that no new steam is needed in the MVR fan 127 to operate the multi-effect finish evaporator 125. The distillation residue stream produced in MVR evaporator 126 contains approximately 35% by weight or approximately 45% by weight of total solids. This concentration is necessary to remove distilled corn oil from the distillation residue stream between MVR evaporator 125 and finish evaporators 127, 128, and 129. The process for removing distilled corn oil typically involves adding a chemical that acts as a deemulsifier to the distillation residue, followed by centrifugation. Corn oil, which is less dense than water, can be separated quickly and efficiently under the high relative centrifugal force imposed by centrifugation.

[0099] In this low-energy process for producing biofuels, distilled corn oil is used as fuel to power the boiler system.

[0100] The medium-concentration distillation residue, de-oiled from the oil separation block in Figure 8, is sent to finish evaporators 127, 128, and 129. The heat driving the first finish evaporator 127 is supplied by the product of the beer reboiler 105. In this case, the distillation residue circulates upward through the tubes and returns downward in the same manner as the MVR evaporator 126 described above, except that the high-proof rectifier vapor supplied to the shell side of the first finish evaporator 127 condenses as it transfers heat to the distillation residue through the tube walls. The steam separated at the bottom of the first finish evaporator 127 is used to drive the second finish evaporator 128. The concentrated distillation residue produced by the second finish evaporator 128 is called syrup and is mixed with wet cake from the total distillation residue isolate. The wet cake can be sold as is as animal feed and is called soluble substance-added wet grain distillation residue (WDGS). The wet cake can also be dried and subsequently sold as animal feed called soluble substance-added dried grain distillate (DDGS). The steam from the second finishing evaporator 128 is condensed and mixed with the other cooking water flow used in the slurry tank (see Figure 4). Table 3 below compares the energy consumption of the conventional ethanol distillation and evaporation system shown in Figures 5 and 6 with that of the system with energy reductions shown in Figures 7 and 8.

[0101] [Table 3]

[0102] As is evident from Table 3, steam demand is dramatically reduced by approximately 86.5% when using an MVR-based system. Furthermore, if we consider MVR power requirements to be the same units as steam, it is not a one-to-one trade-off between steam and electricity. MVR achieves an energy reduction of approximately 67% compared to not relying on conventional heat sources.

[0103] In the disclosed low-energy process for producing biofuels, all electricity demand is met by renewable electricity generated from wind power. It is also feasible to use other forms of renewable electricity, such as solar, nuclear, or hydroelectric power. In the disclosed low-energy process for producing biofuels, the heat load typically met by natural gas can be met by a fuel stream generated in-situ by the process itself, or by a fuel stream from a blend of natural gas with a net carbon intensity of 0 and renewable natural gas.

[0104] The disclosed low-energy processes for producing biofuels for jet fuel, naphtha, and renewable diesel products have marketability and value as renewable fuels due to their lower carbon intensity compared to conventional petroleum-based counterparts. These low-energy processes for biofuel production are designed to produce liquid transport fuels with a carbon intensity of approximately 45 or less, using methods defined by the California Air Resources Board (CARB) Low Carbon Fuel Standard (LCFS). Figure 9 shows a comparison of the carbon intensity of different petroleum-based fuels and the reduction in carbon intensity achieved by using various embodiments of this low-energy process to produce biofuel designs, ultimately achieving a carbon intensity of approximately 45 or less for liquid transport fuel products.

[0105] Figure 10 shows the isobutanol process and system 2000. At the start of the isobutanol process and system 2000, a storage container 2001, e.g., a corn bin, contains carbohydrates, e.g., corn or high-sugar corn, which may be sent to a grinder such as a hammer mill 2005, or alternatively, a low-concentration distillation residue 2040 of carbohydrates may be subjected to a low-concentration distillation residue high-temperature short-time (HTST) treatment 2045. Referring to the carbohydrates sent to the grinder, it then proceeds to a slurry tank 2010, followed by a liquid tank 2015, followed by a processing tank 2020. The product of the processing tank 2020 undergoes separation such as a feed and oil separation 2025 to produce final products such as corn oil and animal feed 2030 for storage, as well as waste that is recycled back into the process via mash HTST 2035, etc.

[0106] Referring to the low-concentration distillation residue 2040, this is subjected to the low-concentration distillation residue HTST 2045 before being used in the isobutanol yeast growth 2050. The product of the isobutanol yeast growth 2050, along with the product of the mash HTST 2060, is sent to a fermentation unit such as the isobutanol fermenter 2055. The product of the isobutanol fermenter 2055 is sent to the modified GIFT column 2065, where some is recycled back to the isobutanol fermenter 2055 or sent to the beer well 2090. Anything not recycled back from the modified GIFT column 2065 to the isobutanol fermenter 2055 / beer well 290 is sent to the liquid / liquid separator 2070. The product of the beer well 2090 is sent to the first distillation column 2085, such as the beer column 2085. The product of distillation column 2085 is fed to liquid / liquid separator 2070, and the product of distillation column 2085 is fed to filter unit 2115. Liquid / liquid separator 2070 produces the heavy phase 2075 and the light phase 2080. The heavy phase 2075 liquid is returned to beer column 2085 for reflux operation, etc. The light phase 2080 liquid is sent through membrane 2100 to impurity removal 2095 for filtration, etc., and then to light phase removal unit 2105. Light phase removal unit 2105 produces fuel-grade isobutanol 2110 for storage or hydrocarbon processing. The product from beer column 2085 fed to filter unit 2115 is combined with the product of light phase removal unit 2105 and filtered in filter unit 2115, and optionally a filter may be provided before beer column 2085. The products of filter 2115 are sent to anaerobic digester 2120. The high-protein product 2125 from filter 2115 can be used as animal feed, recycled as fermentation nutrients, or disposed of in other ways. The anaerobic digester 2120 produces biogas 2130, which can be sent to a boiler in another subsystem, and water 2135, which is recycled to other subsystems.

[0107] Figure 11 is a flowchart of the isobutanol production process and system 3000, which in a particular embodiment corresponds to a net-zero production plant that corresponds to the technology of this application for producing transport fuel. The flowchart of the isobutanol production process and system 3000 includes systems and subsystems having a specific structure that collectively represents the NZ plant that corresponds to the technology of this application. The specific structure, process, and features of the NZ plant are described in relation to one or more of the identified subsystems, but the specific structure, process, and features may be distributed across other subsystems of the NZ plant or included in other subsystems of the NZ plant without departing from the scope of this technology. The isobutanol production process and system 3000 includes a fractional distillation subsystem 3002, a fermentation subsystem 3003, a water treatment subsystem 3004, and an alcohol concentration system 3006. The products from these subsystems are combined with the subsystems shown in Figure 12 to create an entire carbon-neutral, zero-net-energy production plant using the described processes and equipment.

[0108] In the fractional distillation subsystem 3002, recirculated water 3001 is fed into the cooker 3005 to produce cooking water 3010. Furthermore, carbohydrates such as corn 3030 are moved through the receiving and storage system 3035, and then through the grinder 3025 to produce ground corn 3020. The ground corn 3020 and cooking water 3010 are put into slurry pretreatment 3015 along with added enzyme 3045. The resulting slurry 3050, along with biogas 3035, enters the purified sugar process 3055. The purified sugar process 3055 has a dryer vent to the atmosphere 3060 and produces products 3070 such as dried grain distillate (DDG) and corn oil for storage and loadout 3075, and sugar / mash 3080 for the mash HTST 3085 processor which processes the sugar / mash 3080. Next, the sterile mash 3090 from mash HTST3085 is placed into the fermentation subsystem 3003.

[0109] The fermentation subsystem 3003 contains sterile air 3135 and air from a CO2-rich vent collection header 3095. The CO2-rich air is washed by a scrubbing tower 3100 of the CO2-rich exhaust system, and the resulting air is exhausted to the atmosphere 3105.

[0110] Sterile mash 3090 received from fractional distillation subsystem 3002 is placed in the fermentation 3110 structure together with nutrients 3115 and pH adjuster 3120. Furthermore, recirculated water 3250 is led to distillation residue sterilization 3255, and the resulting sterilized distillation residue 3260 is placed into growth 3265 together with nutrients 3280, pH adjuster 3290, and microorganisms 3275 from a microbial growth unit 3270, e.g., yeast seeding system 3270, e.g., yeast cream 3275. Growth 3265 produces starter culture 3285. Starter culture 3285 is supplied to fermentation 3110 together with the above components. The fermentation 3110 unit produces at least a first part and a second part. The second part of the fermentation 3110 unit includes at least fermentation broth 3125. The first portion of the fermentation unit 3110 comprises at least a diluted beer 3165 (or alcohol 3165), such as isobutanol beer 3265. The fermentation broth 3125 is provided to the modified / enhanced GIFT 3140 of the alcohol concentration subsystem 3006 described later.

[0111] A portion of the diluted beer 3165 from fermentation 3110, such as diluted isobutanol beer 3165, can be used for water recovery in the water treatment subsystem 3004 described below. A portion of the diluted beer 3165 can be used by the alcohol concentration system 3006, as described later. However, prior to water recovery or alcohol concentration, the beer well 3170 receives the diluted beer 3165. HC water from the dehydration unit 3175 and intermittent heavy component purging from the dehydration unit 3180 are supplied to the beer well 3170 to create beer 3185 (or undiluted beer 3185). The beer 3185 moves through a beer column with MVR 3195 in the yeast isolation unit 3190, for example, an isobutanol (IBA) beer column with MVR 3195. The beer column with MVR 3195 receives the pH adjuster 3205. The beer column containing the obtained MVR3195 condensate is sent to the alcohol concentration subsystem 3006 via the light phase / light phase separation unit 3215, for example, the IBA light phase / light phase separation unit 3215. The heavy phase 3210 from the light phase / light phase separation unit 3210 is recycled back into the beer column containing MVR3195. The beer column containing MVR3195 produces BC bottom 3245, which is used for distillation residue sterilization 3255. A portion of the BC bottom 3245 is used in the water treatment subsystem 3004, which is described below.

[0112] The alcohol concentration system 3004 receives fermentation broth 3125 from the fermentation subsystem 3003. The enhanced GIFT 3140 receives the fermentation broth 3125. The enhanced GIFT passes back and forth between cold water 3145 and hot water 3150 between the GIFT chiller 3155. The enhanced GIFT 3140 produces dilute broth 313, such as IBA dilute broth 3130, which is supplied to the fermentation subsystem 3110 and the GIFT condensate 3160. Separation units 3125, such as the IBA light phase / light phase separation unit 3215, receive the GIFT condensate 3160 and produce, among other things, light phase IBA 3220 toward the ion exchanger 3225, as well as heavy phase 3210 which is received by the beer column having the MVR 3195 described above. The ion exchanger 3225 may be upstream or downstream of a dry membrane 3300, such as an IBA membrane 3300. Caustic agent 3230 is added to the ion exchanger 3225, and the resulting impurities 3235 are, if applicable, recycled to the beer well 3170. IBA 3240 from the ion exchanger 3225 also travels through the IBA membrane 3300 to create a water-rich permeate 3306 that is recycled to the IBA light phase / light phase separator 3215 and an IBA-rich retention liquid 3305 that is sent to the IBA light phase column 3310. The IBA light phase column 3310 produces fuel-grade IBA 3315, which can be sent to the IBA storage unit 3340 before being sent to the HC unit as fuel-grade IBA 3345. The light phase column top distillate 3320 from the IBA light phase column 3310 is supplied to the anaerobic digester (AD) 3350 of the water treatment subsystem 3004 described later. The alcohol concentration subsystem 3006 may include a CO2 lean exhaust collection header 3325 that is exhausted to the atmosphere 3335 via a scrubbing tower 3330 of the CO2 lean exhaust system.

[0113] As described above, the water treatment subsystem 3004 receives BC bottom 3245 from the fermentation subsystem 3003 and the light phase column top distillate 3320 from the alcohol concentration subsystem 3006 in AD3350. AD3350 also uses the wastewater from the HC unit 3375 to produce crude biogas 3355, recovered water 3380, and remove waste 3370. The removed waste is disposed of, for example, by being sent to wetlands or land use. The crude biogas 3355 is sent to the biogas H2S removal unit 3360 to produce biogas 3365 which can be sent to LP broilers, CHP units, DDG dryers, combinations thereof, etc. The recovered water 3380 is sent to the recirculated water treatment unit 3385 to produce recirculated water 3390.

[0114] Figure 12 shows the hydrocarbon production process 4000. The hydrocarbon production process 4000 includes a hydrocarbon production subsystem 4002 and an energy management subsystem 4003. The hydrocarbon production process and system 4000 also provides certain auxiliary components and processes that may or may not be specifically incorporated into the hydrocarbon production subsystem 4002 and the energy management subsystem 4003. The hydrocarbon production process and system 4000 is linked with the isobutanol process and system 3000 to form part of a carbon-neutral, net-zero energy overall process and plant. The hydrocarbon production subsystem 4002 takes feedwater 4001, including recirculated water from other subsystems such as the recirculated water 3390 described above, into the hydrogen supply system 4005 to form hydrogen 4010. Furthermore, fuel-grade IBA 4050, including IBA from another subsystem, e.g., fuel-grade IBA 3345 described above, undergoes nitrogen removal 4045 to produce IBA 4040. The dewatering unit 4035 receives IBA 4040 and produces hydrocarbon water 4055 and intermittent heavy purge 4060, which are sent to beer wells such as the beer well 3170 described above. The dewatering unit 4035 also produces feedstock 4030, e.g., C4 olefin 4030, to the hydrocarbon pretreatment 4025. The hydrocarbon pretreatment leads out olefin feedstock 4020 and wash water 4065, which may, if applicable, be used in the various systems described herein. The olefin feedstock 4020, along with the hydrogen 4010 described above, is sent to the hydrocarbon treatment unit 4015. The hydrocarbon treatment unit 4015 produces hydrocarbon wastewater 4120, which is sent to the hydrocarbon oil-water separator 4130 to create hydrocarbon wastewater 4135, which is sent to the AD3350 described above. The hydrocarbon processing unit 4015 also produces hydrocarbon vent product 4070 which leaves the hydrocarbon production subsystem 4002 via the fuel gas system 4075 to produce fuel gas 4080, as described later, and the vent product may be supplied to the PSV header 4095 and subsequently received by the flare 4100 system. Furthermore, the hydrocarbon processing unit 4015 also processes isooctane 4115 and C 12 ~C16 Jet fuel 4110 is produced, and both are sent to hydrocarbon storage and discharge port 4125. Then isooctane 4140 and C 12 ~C 16 Jet fuel 4145 can be obtained from hydrocarbon storage and discharge ports 4125.

[0115] The aforementioned fuel gas system 4075 also supplies fuel gas 4080 to the combustion heater 4085 and the HP boiler 4090, where fuel gas 400 is used.

[0116] Excess fuel gas 4105 from the fuel system 4075 may be supplied to the energy management subsystem 4003 via the LP boiler 4155, as long as excess fuel gas is present. The LP boiler 4155 also takes in renewable natural gas 4150, biogas 4160 from the AD3355 mentioned above, and natural gas 4165 from the utility system, as needed. The CHP unit 4170 takes in biogas 4160, natural gas 4165 as needed, and maize oil from fractional distillation, if applicable. The products of the LP boiler 415 and the CHP unit 4170 create LP steam 4175. The LP steam 4170, which may be a steam header, can receive input from the biomass boiler / turbine 4195 and the electric boiler 4180, and the electric boiler 4180 can be powered using renewable energy sources. Renewable energy sources include wind power 4190, photovoltaic panels (not shown), or energy produced by the turbine of a biomass boiler / turbine 4195. The hydrocarbon production process and system 4000 also includes several auxiliary systems and processes. For example, the hydrocarbon production process and system 4000 includes, among other things, an exhaust gas collection and volatile organic compound (VOC) reduction unit 4210 that draws in air from an IBA vent 4200 and a dryer vent 4205. Other components of the hydrocarbon production process and system 4000 include a combustible steam recovery tank 4215, nitrogen 4220, plant and equipment air 4225, raw water treatment 4230, reverse osmosis (RO) water 4235, cooling water 4240, sewage and pumps 4245, a clean-in-place (CIP) unit 4250, washing water 4255, chemicals 4260, and fire extinguishing water 4265. The hydrocarbon pretreatment unit 4025 and the hydrocarbon treatment unit 4015 are described in more detail in Figure 13.

[0117] Figure 13 shows more detail of the hydrocarbon pretreatment 4025 and hydrocarbon treatment unit 4015 as hydrocarbon pretreatment and treatment scheme 5000, describing their features, processes, and structure. First, the wash water column / coalesser 5010 receives wash water 5001 and C4 olefin feedstock 5005. The wash water column / coalesser 5010 feeds the hydrocarbon wastewater surge tank or dewatering unit (TBC) 5015, as well as the IBA water and nitrogen adsorbent 5020. The IBA water and nitrogen adsorbent 5020 is fed to the feedstock receiver 5025 before being combined with C4 olefin recycled material 5045, debutane column recycled material 5040, and splitter bottom recycled material 5120. The polynaphtha reactor 5030 receives the above combination and feeds the product to the debutane column 5035. The product of the debutane column 5035 enters the debutane column recirculated product 5040, or is combined with C4 raffinate recirculation for RVP control 5055, hydrogen 5060 consisting of 99.999 mol% H2, and hydrogenated liquid recirculated product 5080, and enters the total hydrogenation reactor 5065.

[0118] The total hydrogenation reactor 5065 supplies the separator 5070 and the hydrogenated liquid recirculation 5080, which produce reactor purge 5075, part of which is supplied to the total hydrogenation reactor 5065 (above), and part of which is supplied to the splitter 5085. The reactor purge 5075, the products of the splitter 5085, and the C4 olefin recirculation 5045 are combined to produce the C4 raffinate product into fuel gas 5050. The products of the separator 5070 that are not used as hydrogenated liquid recirculation 5080 are received by the splitter 5085, which supplies the splitter 5085 back to the debutane column recirculation 5040, and C 12 ~C 16 This creates the splitter bottom recirculated material 5120 and isooctane 5110 that are supplied to the splitter 5090. 12 ~C 16 Splitter 5090 is C 12 Blend or jet fuel 5105 or C 12 / C 16Create jet fuel 5115. Furthermore, the first C 12 Blend 5095 contains isooctane 5110 and C 12 It can be made from a blend or jet fuel 5105, and the second C 12 Blend 5100 is C 12 Blend or jet fuel 5105 and C 12 / C 16 It can be produced from jet fuel 5115.

[0119] ETO with C2 recirculation into fuel products

[0120] Figure 14 is a process flow and equipment diagram 135 illustrating the equipment, process, features, and functions according to a specific embodiment of the present technology. Referring to step 1 of Figure 14, ethanol, fusel oil, or a combination thereof is supplied to the ETO dehydration unit 136. The ETO dehydration unit 136 processes the feedstock to convert the ethanol and / or fusel oil into ethylene and other light olefins. Next, the ethylene distillation column 137 distills the ethylene. The ethylene is recycled as shown in the diagram, and C 3+ The olefin is fed to the aromatic distillation column 138, but alternatively, propylene can be removed by distillation as a chemical product, C 4+ The olefins are supplied to aromatic distillation 138. Alternatively, all C2 and C 4+The olefin can be recycled to the ETO dehydration unit 136 to produce propylene in higher yield, in which case steps 3 and 4 below are not present in Figure 14. Ethane is purged from the ethylene recirculation flow and used as a low carbon intensity (CI) fuel gas. The ETO process inherently maximizes thermal efficiency and reduces the energy requirements of auxiliary systems by combining dehydration (endothermic) and conversion to light olefins (exothermic) into a single-unit process, thereby reducing the total energy requirements compared to the conventional two-step process of ethanol dehydration to ethylene followed by ethylene dimerization to butene. This, coupled with the large exothermic effect from hydrogenation, results in a low CI net thermal energy surplus in the ETJ that can be used to meet part of the thermal demand for ethanol production and replace the use of natural gas.

[0121] In step 2 of Figure 14, aromatic and heavy olefins are removed from the light olefin stream as a purification step prior to oligomerization. The aromatic stream is then sold as gasoline blend stock, mainly C 3+ The aromatic top distillate, composed of olefins, is supplied to the oligomerization unit 139.

[0122] In step 3 of Figure 14, C 3+ The olefin is supplied to the oligomerization unit 139 and reacted in the reaction tower 140, mainly by C 6+ It is converted to olefin. The light olefin in the effluent of reaction tower 140 is recycled, C 6+ The olefin is supplied to the hydrogenation unit 141. The splitting column 142 purges the light paraffins used as low-CI fuel gas from the recirculation flow. Optionally, to increase the octane number of the gasoline product, the straight-chain butene can be separated before oligomerization, isomerized to isobutene and then supplied to oligomerization, or separately dimerized to isooctene.

[0123] In step 4 of Figure 14, the mixed olefins are fed to hydrogenator 141 along with hydrogen and converted to paraffin. The hydrogen is produced by electrolysis powered by electricity generated by a wind turbine and / or solar panels. Splitting column 142 purges the light paraffin and excess hydrogen from the recirculation flow, which are used as low-CI fuel gas. The paraffin mixture is separated into a light phase, gasoline, sustainable aviation fuel (SAF), and diesel products by distillation in splitting column 142. This separation can be performed before hydrogenation if specific olefin products are desired.

[0124] System-wide measures to further reduce the system's CI score include the use of electricity produced by wind turbines and / or solar panels, and the use of surplus thermal energy and / or produced fuel gases for upstream processing and / or heating of utilities.

[0125] ETJ NZ1 HC Ethanol Specification

[0126] HC ethanol was developed to reduce the cost of producing pure ethanol to supply HC units. This process requires two to three additional distillation columns (approximately $10 million to $20 million) and about 3,000 to 4,000 BTU / gallon of ethanol.

[0127] This process allows for the removal of dewatering equipment and energy.

[0128] Through testing, we developed appropriate ethanol concentrations (e.g., minimum ethanol content of approximately 85%, 86%, 87%, 88%, 89%, or 90% by weight, and maximum water content of approximately 10%, 11%, 12%, 13%, 14%, or 15% by weight) to find the most energy-efficient concentration for HC equipment and to enable the removal of contaminants that would cause catalyst lifespan and product quality issues: i. Reducing contaminant levels to prevent acid formation in the HC process, which can lead to serious corrosion problems or require more expensive metallurgy (2-3 times the cost), ii. Reducing contaminant levels to prevent loss of catalytic activity. iii. Reduction in contaminant levels to prevent loss of catalytic activity and formation of by-products that may cause product quality problems, and iv. This involves selecting an appropriate ethanol concentration to prevent nitrogen concentration in the ethanol from destroying the catalyst. a. Water concentration affects the level of contaminants in ethanol.

[0129] Furthermore, pure ethanol increases CI.

[0130] ETO involving C2 dimerization into fuel products

[0131] Figure 15 is a process flow and equipment diagram showing the apparatus, process, features, and functions according to a specific embodiment of the present technology. Referring to step 1 of Figure 15, ethanol is supplied to the ETO dehydration unit 146, which converts ethanol, fusel oil, or a combination thereof into ethylene and other light olefins. The ethylene distillation column 147 distills the ethylene supplied to the dimerization unit 148, while C 3+ The olefin is supplied to the aromatic distillation unit 149, but alternatively, propylene can be distilled off as a chemical product, C 4+The olefins are fed to aromatic distillation. Ethane is purged from the distilled ethylene stream and used as a low-CI fuel gas. The ETO process inherently maximizes thermal efficiency and reduces the energy requirements of auxiliary systems by combining dehydration (endothermic) and conversion to light olefins (exothermic) into a single-unit process, thereby reducing the overall energy requirements compared to the conventional two-step process of ethanol dehydration to ethylene followed by ethylene dimerization to butene. This, coupled with the significant heat generated from hydrogenation, results in a low-CI net thermal energy surplus in the ETJ that can be used to meet some of the thermal demands of ethanol production and replace the use of natural gas.

[0132] In step 2 of Figure 15, the distilled ethylene stream is supplied to the dimerization unit 148, mainly C 4+ It is converted to olefin. The light paraffin is purged and used as a low CI fuel gas. 4+ The olefin stream is distilled, and oligomerization unit 150 is C 4+ The olefin flow is received. The C8+ flow is the lighter C from oligomerization unit 150. 6+ It is supplied directly to the hydrogenation unit 151 along with the flow of olefins. 4+ Olefins are C as described below. 3+ It can be combined with olefins.

[0133] In step 3 of Figure 15, C from ethylene distillation column 147 3+ The olefins are distilled by the aromatic distillation column 149. Heavy olefins are removed from the stream of light olefins in this step. The aromatic distillation column 149 is mainly C 3+ It supplies a stream of light olefins available as a gasoline blend stock composed of olefins, and the above C 4+ It is supplied to the oligomerization unit 150 along with the olefin.

[0134] In step 4 of Figure 15, C from aromatic distillation column 149 3+The olefins from the olefin and dimerization unit 148 are fed to the oligomerization unit 150 and reacted in the reaction tower 152, mainly by C 6+ It is converted to an olefin. The light olefin in the flow of reaction tower 152 is recycled, C 6+ The olefin is supplied to the hydrogenation unit 151. The splitting column 153 receives the output from the hydrogenation unit 151, and the light paraffin is purged from the recirculation flow and used as a low CI fuel gas. If necessary, to increase the octane number of the gasoline product, the straight-chain butene can be separated before oligomerization, isomerized to isobutene and then supplied to oligomerization, or separately dimerized to isooctene.

[0135] In step 5 of Figure 15, the mixed olefins are supplied to the hydrogenation unit 151 along with hydrogen and converted to paraffin. Hydrogen can be produced by electrolysis powered by electricity produced by a wind turbine and / or solar panels. The light paraffin and excess hydrogen are purged from the recirculation flow by the splitting column 153 and used as low CI fuel gas. The paraffin mixture is also separated by the splitting column 153 into light, gasoline, SAF, and diesel products. This separation can be performed before hydrogenation if specific olefin products are desired.

[0136] System-wide measures to further reduce the system's CI score include the use of electricity produced by wind turbines and / or solar panels, and the use of surplus thermal energy and / or produced fuel gases for upstream processing and / or heating of utilities.

[0137] Ethanol dehydration and solid acid alkylation for alkylation of the product

[0138] Figure 16 is a process flow and equipment diagram showing the apparatus, process, features, and functions according to a specific embodiment of the present technology. Referring to step 1 of Figure 16, ethanol, fusel oil, or a combination thereof is supplied to the first dehydration unit 156 to dehydrate the ethanol, fusel oil, or a combination thereof with ethylene and C 2+ It can be converted to other light olefins such as olefins. At the same time, isobutanol is fed to a second dehydration unit 157, which produces an olefin stream that is received by the aromatic distillation column 158 to produce isobutylene. Hydrogenation unit 159 converts C from the first dehydration unit 156 2+ It produces isobutane by combining light olefins and isobutane. Alkylation unit 160 is C 2+ It receives light olefins and isobutane. 2+ Light olefin and isobutane streams are available as gasoline blend stocks, primarily C 2+ The aromatic top distillate flow, composed of olefins, is supplied to the alkylation unit 160.

[0139] In step 2 of Figure 16, isobutane is produced from the low-CI isobutanol (IBA) production described herein, followed by dehydration to isobutylene and then hydrogenation to isobutane. It is worth noting that renewable isobutane can also be produced from a variety of feedstocks, including ethanol. Alternatively, fossil isobutanes can be used, although they typically have a higher CI score.

[0140] In step 3 of Figure 16, the alkylation unit 160 produces the alkylate gasoline product. The final distillation column 161 separates the light paraffin from the alkylate gasoline. The light paraffin is purged and used as a low CI fuel gas, and the isobutane is recycled back into the process.

[0141] System-wide measures to further reduce the system's CI score include the use of electricity produced by wind turbines and / or solar panels, and the use of surplus thermal energy and / or produced fuel gases for upstream processing and / or heating of utilities.

[0142] ETO with liquid acid or ionic liquid alkylation for alkylation of the product

[0143] Figure 17 is a process flow and equipment diagram 165 illustrating the apparatus, process, features, and functions according to a specific embodiment of the present technology. Referring to step 1 of Figure 17, ethanol, fusel oil, or a combination thereof is supplied to an ETO dehydration unit 166 that converts the ethanol, fusel oil, or combination thereof into ethylene and other light olefins. An ethylene distillation column 167 converts the output of the ETO dehydration unit 16 into ethylene and C 3+ Distilled into olefins. The first aromatic distillation column 168 is C 3+ Olefins are received. In some cases, ethylene is dimerized mainly to butene and then C after the first aromatic distillation column 168. 3+ It may be mixed with an olefin flow.

[0144] In step 2 of Figure 17, the first aromatic distillation column 168 is C 3+ Removes aromatic and heavy olefins from light olefin flows, such as olefin flows. Aromatic flows are available as gasoline blend stocks and are mainly C 3+ The aromatic top distillate flow, composed of olefins, is supplied to the alkylation unit 169 below.

[0145] In step 3 of Figure 17, isobutane is produced from the low CI IBA production described herein and received by the isobutanol dehydration unit 170. A second aromatic distillation column 171 produces isobutene, which is received by the hydrogenation unit 172 to produce isobutane. It is worth noting that renewable isobutane can also be produced from a variety of feedstocks, including ethanol. Alternatively, fossil isobutanes can be used, although they typically have a higher CI score.

[0146] In step 4 of Figure 17, C 3+ Olefins (light olefins from aromatic distillation column 168) are combined with isobutane from hydrogenation unit 172, and alkylation unit 169 receives the combination to produce alkylate gasoline products. Reaction column 173 produces light paraffins, which are purged and used as low-CI fuel gas, and the isobutane is recycled back into the process. Reaction column 173 also produces alkylate gasoline.

[0147] System-wide measures to further reduce the system's CI score include the use of electricity produced by wind turbines and / or solar panels, and the use of surplus thermal energy and / or produced fuel gases for upstream processing and / or heating of utilities.

[0148] High-octane gasoline and jet fuel fractions

[0149] Bio-based ethanol can be converted to ethylene, followed in a single step to a mixture of C3-C8 olefins. The resulting C3-C8 olefins, linear butene, and / or fractions can be co-oligomerized with isobutylene derived from bio-based isobutanol, increasing the branching rate to the extent that the mixture of high octane and jet fuel fractions is maximized. While it is well known that increased branching results in high-octane fuel, it was surprising to find that the addition of large amounts of isobutylene resulted in a significantly higher octane number compared to a simple blend of more branched paraffin compounds after oligomerization. Figure 18 shows the increase in octane as a result of co-oligomerizing isobutylene with linear butene compared to blending with isooctane.

[0150] Therefore, oligomerization of mixtures of isobutylene and / or linear butene derived from isobutanol and ethanol, respectively, results in higher octane gasoline and jet fuel fractions compared to oligomerization of linear butene followed by a blend of isooctane to increase the octane number. Furthermore, parallel or co-configured fermentation of isobutanol and ethanol yields remarkable synergistic effects and cost savings in terms of nutrient reduction, dilution of toxic impurities, and energy savings. An exemplary oligomerization reaction step involves oligomerizing a mixture of isobutylene and a stream of linear olefin using a suitable acidic catalyst at 80°C to 260°C and a pressure of 250 psig to 500 psig.

[0151] One-step oligomerization conditions: Reactor temperature T=175℃, WHSV=1.7, Feed material: 14% isobutylene, 55% linear butene (n-butene, cis / trans-2-butene), 31% pentene mixture; P=250 psig; Catalyst mixture: Zirconia tungstate + ZSM5 zeolite (Si / Al=55).

[0152] Table 4 shows the selectivity of the oligomers.

[0153] [Table 4]

[0154] Isobutylene / linear C4 + linear C5 ratio = 0.16.

[0155] Actual RON measurement of the hydrogenated C8 fraction = 96.6.

[0156] Oligomerization of linear C4 + linear C5 without isobutylene.

[0157] Actual RON measurement of the hydrogenated C8 fraction = 72.7.

[0158] The specific examples presented herein are illustrative and should not be construed as limiting the scope of the claims.

[0159] The detailed explanations provided above are given solely for the purpose of clarifying understanding, and since the modifications are obvious to those skilled in the art, no unnecessary limitations should be inferred from them.

[0160] While described in relation to its specific embodiment, the principles described herein are subject to further modification, and it will be understood that this application is generally intended to cover any modifications, uses, or adaptations that deviate from this disclosure, such as those that follow the principles disclosed herein and that are included in known or customary practices within the art to which the Art relates, and that can be applied to the following essential features described in the appended claims.

[0161] Any disclosures, including claims, figures, and / or drawings, of patents, patent applications, and publications cited herein are incorporated herein by reference in their entirety.

[0162] Exemplary aspects / embodiments

[0163] Certain embodiments / models of the subject matter described above, including those listed below, may be useful on their own or in combination with one or more other embodiments listed below. Furthermore, although the subject matter is disclosed with reference to the specific embodiments and claims listed below, many modifications, changes, and alterations are possible to the described embodiments / models without departing from the scope and scope of the disclosure. Thus, the disclosure is not limited to the described embodiments, models, and claims, but is intended to have the entire scope as defined by the language of the disclosure and its equivalents. Although the art has been described with reference to its specific embodiments / models, it should be understood by those skilled in the art that various modifications can be made and equivalents can be substituted without departing from the true spirit and scope of the disclosure. Furthermore, many modifications can be made to adapt specific circumstances, materials, substance compositions, processes, and / or process steps to the purpose, spirit, and scope of the disclosure. All such modifications are intended to fall within the scope of the appended claims.

[0164] Examples of embodiments of this technology are described below. 1. A system for producing renewable hydrocarbons, A fractional distillation subsystem for processing biomass containing carbohydrates, A fermentation subsystem for converting carbohydrates into fermentation products, An alcohol concentration subsystem for receiving the second part of the fermentation product, A hydrocarbon production subsystem for receiving alcohol and producing renewable hydrocarbons, and an energy management subsystem for receiving fuel flow from the system and supplying power to the system, for reducing the energy demand or CI of ethanol and / or fuel, a) A water treatment subsystem for receiving the first portion of the fermentation product, b) Combustion of light oxygenated materials, fusel oils, vegetable oils, biomass or derivatives, and / or hydrocarbon by-products. c) Utilization of hot water sources and waste heat from fermentation and hydrocarbon production systems for biomass processing at moderate temperatures. d) Use of an alcohol purification system that pressurizes the top distillate of a rectification column using a mechanical vapor recompression (MVR) system, wherein the condensation of the top distillate provides heat to a beer stripping boiler and produces purified alcohol suitable for conversion to hydrocarbons, and e) A low-concentration distillation residue evaporation system that utilizes the heat from a partially condensed flow of 190-proof ethanol from the top distillate of the rectifier column and the MVR system to produce a syrup with a dry solids content of at least about 35% to at least about 45%, without the application of additional vapor. An energy management subsystem further comprising at least one of the following: A system equipped with these features. 2. The fractionation subsystem is Storage containers for storing biomass, A crusher for crushing biomass, Pre-treatment container for pre-treating biomass, A processing container for processing biomass to produce carbohydrates, and High-temperature short-time (HTST) containers for pasteurizing carbohydrates The system according to embodiment 1, further comprising at least one of the following. 3. The system according to embodiment 2, wherein the biomass is corn. 4. The system according to embodiment 2, wherein the biomass has a negative carbon footprint. 5. The system according to embodiment 2, wherein biomass is cultivated using furrowing or no-till farming. 6. The system according to embodiment 2, wherein the grinder is a mill. 7. The system according to embodiment 2, wherein the pretreatment container includes a recirculation water inlet. 8. The system according to embodiment 2, wherein the pretreatment of biomass includes pretreatment of biomass with enzymes. 9. The system according to embodiment 2, wherein the processing container contains a non-fermentable solid product. 10. The system according to embodiment 9, wherein the non-fermentable solid product comprises dried grain distillate product and / or corn oil product. 11. The fermentation subsystem, Fermentation tanks for converting carbohydrates into fermentation products, Nutrient supplementation subsystem, pH adjustment subsystem, and Spawn culture proliferation subsystem A system according to any of the preceding embodiments, comprising at least one of the above. 12. The system according to embodiment 11, wherein the fermentation tank is a continuous fermentation tank. 13. The system according to embodiment 11, wherein the fermentation product contains alcohol. 14. The system according to embodiment 13, wherein the alcohol is isobutanol. 15. The system according to embodiment 11, wherein the seed culture subsystem is configured to supply microorganisms to a fermenter. 16. The system according to embodiment 15, wherein the microorganism is yeast. 17. The water treatment subsystem, A beer well to receive the first part of the fermentation product. A microbial isolation device for removing microorganisms from the first part of the fermentation product. A first distillation column for separating the first part of the fermentation product into alcohol and bottom product, A digester to receive some of the bottom products and produce biogas, and Biogas removal subsystem for removing contaminants from biogas A system according to any of the preceding embodiments, comprising at least one of the above. 18. The system according to embodiment 17, wherein the first portion of the fermentation product contains alcohol. 19. The system according to embodiment 17, wherein the first portion of the fermentation product contains isobutanol. 20. The system according to embodiment 17, wherein the first part of the fermentation product contains water. 21. The system according to embodiment 17, wherein the microbial isolation apparatus includes a centrifuge. 22. The system according to embodiment 17, wherein the microbial isolation device includes a filter. 23. The system according to embodiment 17, wherein the microbial isolation apparatus includes a sedimentation tank. 24. The system according to embodiment 17, wherein the microorganism is yeast. 25. The system according to embodiment 17, wherein the first distillation column includes a vapor recompression subsystem. 26. The system according to embodiment 17, wherein the first distillation column includes mechanical vapor recompression (MVR). 27. The system according to embodiment 17, wherein the first distillation column includes a thermal vapor recompression (TVR). 28. The system according to embodiment 17, wherein the bottom product includes distillation residue. 29. The system according to embodiment 17, wherein the digester is an anaerobic digester. 30. The system according to embodiment 17, wherein the digester is a continuous digester. 31. The system according to embodiment 17, wherein the biogas removal subsystem includes a scrubbing tower. 32. The system according to embodiment 17, wherein the pollutant is hydrogen sulfide. 33. The alcohol concentration subsystem, A flash tank for separating the condensate from the second part of the fermentation product. A separation container for separating condensates into light and heavy phases. Ion exchange vessel for purifying the light phase, A membrane separator for separating the light phase into a high-alcohol holding liquid and a water-rich permeate. A second distillation column for separating water from the high-alcohol holding liquid, and Alcohol storage containers A system according to any of the preceding embodiments, comprising at least one of the above. 34. The system according to embodiment 33, wherein a flash tank receives a second portion of the fermentation product from the fermentation subsystem and returns a portion of the second portion of the fermentation product to the fermentation subsystem. 35. The system according to embodiment 33, wherein the second part of the fermentation product is broth, and the dilute isobutanol broth is returned to the fermentation subsystem. 36. The system according to embodiment 33, wherein the flash tank operates at atmospheric pressure. 37. The system according to embodiment 33, wherein the flash tank operates under vacuum and reduced pressure below atmospheric pressure. 38. The system according to embodiment 33, wherein the flash tank operates at a temperature lower than the temperature of the second portion of the fermentation product received from the fermentation subsystem. 39. The system according to embodiment 33, wherein the separation vessel is a liquid / liquid separator for separating the condensate into a light phase and a heavy phase. 40. The system according to embodiment 39, wherein the light phase contains a larger amount of alcohol than the heavy phase. 41. The system according to embodiment 40, wherein the alcohol is isobutanol and the liquid / liquid separator forms a two-phase system. 42. The system according to embodiment 33, wherein the ion exchange container contains an ion exchange resin, receives the light phase from the separation container, and removes impurities from the light phase by capturing ions in the ion exchange resin. 43. The system according to embodiment 42, wherein the ion exchange container receives a caustic solution and regenerates the ion exchange resin by flushing impurities into the beer well. 44. The hydrocarbon production subsystem, Denitrification subsystem for separating nitrogen from alcohol, Dehydration subsystem for converting alcohol to olefin, Hydrocarbon pretreatment subsystem for preparing olefin feedstocks, A hydrogen supply subsystem for providing hydrogen, and Olefin supply raw materials, isooctane fraction, C 12 Alkane fraction, and / or C 16 Hydrocarbon processing subsystem for conversion to at least one of the alkane fractions The system according to embodiment 33, comprising at least one of the following. 45. The hydrocarbon production subsystem, Oil and water separator for separating wastewater from hydrocarbon treatment subsystems, and Isooctane from hydrocarbon processing subsystem, C 12 Blend, or C 16 Hydrocarbon storage container for storing at least one of the blends The system according to embodiment 44, further comprising at least one of the following. 46. ​​The system according to embodiment 44, wherein the denitrification subsystem receives alcohol from the alcohol concentration subsystem. 47. The system according to embodiment 46, wherein the alcohol is fuel-grade isobutanol. 48. The system according to embodiment 44, wherein a dehydration subsystem receives alcohol from a denitrification subsystem and delivers water and / or purge products to a beer well. 49. The system according to embodiment 44, wherein the olefin is a tetracarbon olefin. 50. The hydrocarbon pretreatment subsystem, Coalescer for receiving olefins from the dehydration subsystem, Adsorbent for removing unreacted alcohol, water, and nitrogen, as Raw material receiver The system according to embodiment 44, comprising at least one of the following. 51. The system according to embodiment 50, wherein the coalescer further receives the washing water and sends the wastewater to the surge tank and / or dewatering unit. 52. The system according to embodiment 50, wherein the coalescer further receives the washing water and sends the wastewater to the surge tank and / or dewatering unit. 53. The system according to embodiment 50, wherein the olefin is a C4 olefin. 54. The system according to embodiment 50, wherein the unreacted alcohol is isobutanol. 55. The system according to embodiment 50, wherein the supply material receiver receives olefin from the adsorbent. 56. The hydrocarbon processing subsystem, First reactor, Debutane Tower, Second reactor, separator, The first splitter, and / or Second splitter The system according to embodiment 44, comprising at least one of the following. 57. The system according to embodiment 56, wherein the first reactor is a polynaphtha reactor. 58. The system according to embodiment 56, wherein the first reactor receives olefin from a feedstock receiver and oligomerizes the olefin to form a polyolefin. 59. The system according to embodiment 56, wherein a butane-removing column receives polyolefins from the first reactor. 60. The system according to embodiment 56, wherein a butane-removing column recirculates unreacted olefins and / or paraffins to the first reactor. 61. The system according to embodiment 56, wherein the second reactor is a hydrogenation reactor. 62. The system according to embodiment 56, wherein a second reactor receives polyolefins from a butane-removing column. 63. The second reactor receives further hydrogen from the hydrogen supply subsystem and hydrogenates the polyolefin to C8~C 16 The system described in embodiment 56, which converts to an alkane. 64. The separator is C8~C 16 The system according to embodiment 56 for removing unreacted olefins and / or paraffins from alkanes. 65. The system according to embodiment 64, wherein the unreacted olefin and / or paraffin comprises the C4 product. 66. Separator is C8~C 16 A system according to embodiment 56, wherein a portion of the alkanes is recycled to a second reactor. 67. The first splitter separates the isooctane fraction from C8 to C8. 16 A system according to embodiment 56 that separates from alkanes. 68. The system according to embodiment 67, wherein the isooctane fraction comprises about 85% by weight, 90% by weight, 91% by weight, 92% by weight, 93% by weight, 94% by weight, 95% by weight, 96% by weight, 97% by weight, 98% by weight, 99% by weight or 100% by weight of C8 alkanes, about 1 volume%, 2 volume%, 3 volume%, 4 volume% or 5 volume% of olefins, and / or about 2 ppm, 4 ppm, 6 ppm, 8 ppm or 10 ppm of sulfur. 69. The system according to embodiment 67, wherein the isooctane fraction contains more than 95% by weight of C8 alkanes, less than 5% by volume of olefins, and / or less than 10 ppm of sulfur. 70. The first splitter is C8~C 16 The system according to embodiment 56 for removing unreacted olefins and / or paraffins from alkanes. 71. The system according to embodiment 70, wherein the unreacted olefin and / or paraffin comprises the C4 product. 72. The second splitter is C 12 Alkane fraction C 18 The system according to embodiment 56, which separates from the fraction. 73. The energy management subsystem, A fuel gas system for distributing fuel gas received from the hydrocarbon processing subsystem. Low-pressure boiler for generating steam, High-pressure boiler for generating steam, A thermal and power combined unit for generating steam and electricity. Wind turbines for generating electricity, Electric boilers that receive renewable electricity and heat water to produce steam. A biomass boiler for burning biomass to heat water and produce steam, and / or Steam turbines for generating electricity A system according to any of the preceding embodiments, comprising at least one of the above. 74. The system according to embodiment 73, wherein the fuel gas system provides fuel gas to a low-pressure boiler. 75. The system according to embodiment 73, wherein the fuel gas system provides fuel gas to a high-pressure boiler. 76. The system according to embodiment 73, wherein the fuel gas system provides fuel gas to a combustion heater. 77. The system according to embodiment 73, wherein a low-pressure boiler is further configured to receive natural gas and / or biogas from an anaerobic digester. 78. The system according to embodiment 73, wherein a thermal and power combined unit is further configured to receive natural gas and / or biogas from an anaerobic digester. 79. A system for producing renewable alcohol, A fractional distillation subsystem for processing biomass containing carbohydrates, A fermentation subsystem for converting carbohydrates into fermentation products, An alcohol concentration subsystem for receiving at least a portion of the fermentation product, An energy management subsystem that receives fuel flow from the system and supplies power to the system, in order to reduce the energy demand or CI of alcohol, a) A water treatment subsystem for receiving the first portion of the fermentation product, b) Combustion of light oxygenated materials, fusel oils, vegetable oils, biomass or derivatives, and / or by-products. c) Use of an alcohol purification system that pressurizes the top distillate of a rectification column using a mechanical vapor recompression system, wherein the condensation of the top distillate of the rectification column provides heat to a beer stripper boiler, and d) A low-concentration distillation residue evaporation system that utilizes heat from a partially condensed flow of 190-proof ethanol from the top distillate of the rectifier column and a mechanical vapor recompression system to produce a syrup with a dry solids content of at least about 35% to at least about 45% without the application of additional vapor. An energy management subsystem comprising at least one of the following: A system equipped with these features. 80. A process for producing renewable transport fuels, such as gasoline, jet fuel, and diesel fuel, from renewable C1-C5 alcohols, a) A step of converting C1-C5 alcohols into a mixture of C2-C7 olefins to produce flow A, b) Depending on the case, a step to separate the fraction mainly of C2 olefins from flow A for recirculation to the alcohol conversion step, to create or separate the oligomerization conversion, and to generate flow B mainly of C4+, c. Depending on the circumstances, the steps include purifying and combining flow A and / or flow B to create flow C suitable for oligomerization to fuel range olefins, d. The step of oligomerizing flow C to create fuel-range olefin and creating flow D, e. Depending on the circumstances, the step of hydrogenating flow D to create a paraffin-based flow E, f. A step of separating flow E into fractions suitable for use as gasoline, jet fuel, and diesel fuel. A process that includes this. 81. The process according to embodiment 80, comprising the step of separating a fraction mainly of C2 olefins from stream A for recirculation to an alcohol conversion step to create or separate an oligomerization conversion and generate a stream B mainly of C4+. 82. The process according to embodiment 80, comprising the step of purifying and combining flow A and / or flow B to create flow C suitable for oligomerization to fuel range olefins. 83. The process according to embodiment 80, comprising the step of hydrogenating flow D to create a flow E mainly of paraffin. 84. A process for producing renewable alkylates from renewable C1-C5 alcohols, a) A step of converting C1-C5 alcohols into a mixture of C2-C7 olefins to produce flow A, b) Depending on the case, a step to separate the fraction mainly of C2 olefins from flow A for recirculation to the alcohol conversion step, to create or separate the oligomerization conversion, and to generate flow B mainly of C4+, c) Depending on the circumstances, the steps include purifying stream A and / or stream B and combining them with renewable isobutane or petrochemical isobutane to create stream C suitable for alkylation, d) The step of subjecting stream C to an alkylation process in order to produce stream D of unpurified, renewable alkylate, e) Depending on the circumstances, a step of refining flow D to make it suitable for direct use as renewable gasoline and A process that includes this. 85. The process according to embodiment 84, comprising the step of separating a fraction mainly of C2 olefins from stream A for recirculation to an alcohol conversion step to create or separate an oligomerization conversion and generate a stream B mainly of C4+. 86. The process according to embodiment 84, optionally comprising the step of purifying stream A and / or stream B and combining them with regenerative isobutane or petrochemical isobutane to create a stream C suitable for alkylation. 87. The process according to embodiment 84, comprising the step of refining flow D to make it suitable for direct use as renewable gasoline. 88. A process for converting bio-based ethanol into high-octane gasoline fraction and jet fuel fraction, a) A step of converting ethanol to ethylene, followed by a one-step conversion to a mixture of C3-C8 olefins, b) A step of co-oligomerizing C3-C8 olefins, linear butenes and / or fractions thereof with isobutylene, thereby increasing branching, to provide octane gasoline fractions and jet fuel fractions. A process that includes this. 89. The process according to embodiment 88, wherein isobutylene is co-oligomerized with linear butene. 90. The process according to embodiment 88, wherein a mixture of isobutylene and a linear olefin is co-oligomerized with one or more suitable acidic catalysts at a temperature of 80°C to 260°C and a pressure of 250 to 500 psig. 91. The process according to embodiment 90, wherein the mixture of isobutylene and linear butene is derived from isobutanol and ethanol, respectively. 92. The process according to embodiment 90, wherein the catalyst is selected from the group consisting of zirconium tungstate catalyst, nickel and / or cobalt-doped zirconium tungstate catalyst, zeolite, or metal (IB-VIIB group)-doped zeolite and / or any combination thereof. 93. The process according to embodiment 90, wherein the catalyst is a mixture of catalysts containing zirconia tungstate + ZSM5 zeolite (Si / Al=55). 94. The process according to embodiment 88, wherein oligomerization is carried out using a mixture of 14% isobutylene, 55% linear butene (n-butene, cis / trans-2-butene), and 31% pentene, under conditions of T=175°C and WHSV=1.7 in a reactor at a pressure of approximately 250 psig. 95. The process according to any one of claims 80, 84, or 88, wherein the alcohol comprises a minimum ethanol content of about 85% to 90% by weight and a maximum water content of 10% to 15% by weight. 96. The process according to claim 95, wherein the alcohol comprises an ethanol content of at least about 85% by weight, 86% by weight, 87% by weight, 88% by weight, 89% by weight, or 90% by weight. 97. The process according to claim 95 or 96, wherein the alcohol contains up to about 10% by weight, 11% by weight, 12% by weight, 13% by weight, 14% by weight, or 15% by weight of water. 98. The process according to any one of claims 80, 84, or 88, wherein the alcohol comprises a minimum of about 88% by weight of ethanol and a maximum of 12% by weight of water.

Claims

1. Reusable C １ ~C ５ A process for producing renewable transport fuel from alcohol, a. C １ ~C ５ Alcohol C ２ ~C ７ The steps include converting to an olefin mixture to generate flow A, b. In some cases, mainly C for recirculation to the alcohol conversion step. ２ The olefin fraction is separated from flow A to create or separate oligomerization conversion, mainly C ４＋ The steps to generate flow B, c. Depending on the circumstances, the steps include purifying flow A and / or flow B, and combining the purified flow A and / or flow B to create flow C suitable for oligomerization to fuel range olefins, d. The step of oligomerizing flow C to create fuel-range olefin and creating flow D, e. Depending on the circumstances, the step of hydrogenating flow D to create a flow E mainly consisting of paraffin, f. A step of separating flow E into a fraction suitable for use as transport fuel. A process that includes this.

2. For recirculation to the alcohol conversion step, mainly C ２ separate the fraction of olefins from stream A to create or separate the oligomerization conversion and generate stream B mainly of C ４＋ The process according to claim 1, comprising the step of

3. The process according to claim 1, comprising the step of purifying and combining flow A and / or flow B to create flow C suitable for oligomerization to fuel range olefins.

4. The process according to claim 1, comprising the step of hydrogenating flow D to create a flow E mainly of paraffin.

5. Reusable C １ ~C ５ A process for producing renewable alkylates from alcohol, a. C １ ~C ５ Alcohol C ２ ~C ７ The steps include converting to an olefin mixture to generate flow A, b. In some cases, mainly C for recirculation to the alcohol conversion step. ２ The olefin fraction is separated from flow A to create or separate oligomerization conversion, mainly C ４＋ The steps to generate flow B, c. Depending on the circumstances, the steps include purifying stream A and / or stream B and combining them with regenerative isobutane or petrochemical isobutane to create stream C suitable for alkylation, d. The step of subjecting flow C to an alkylation process in order to produce an unpurified, renewable alkylate flow D, e. Depending on the circumstances, a step of refining flow D to make it suitable for direct use as renewable gasoline. A process that includes this.

6. For the recirculation to the aforementioned alcohol conversion step, mainly C ２ The olefin fraction is separated from flow A to create or separate oligomerization conversion, mainly C ４＋ The process according to claim 5, comprising the step of generating flow B.

7. The process according to claim 5, optionally comprising the step of purifying stream A and / or stream B and combining them with regenerative isobutane or petrochemical isobutane to create a stream C suitable for alkylation.

8. The process according to claim 5, comprising the step of refining flow D to make it suitable for direct use as renewable gasoline.

9. A process for converting bio-based ethanol into high-octane gasoline fractions and jet fuel fractions, a. Ethanol is converted to ethylene, followed by C ３ ~C ８ A step of converting to an olefin mixture in one step, b. The above C ３ ~C ８ The steps of co-oligomerizing olefins, linear butenes and / or fractions thereof with isobutylene, thereby increasing branching, to provide octane gasoline fractions and jet fuel fractions. A process that includes this.

10. The process according to claim 9, wherein the oligomerization is carried out using a mixture of 14% isobutylene, 55% linear butene (n-butene, cis / trans-2-butene), and 31% pentene, under pressure of about 250 psig, in a reactor at T = 175°C and WHSV = 1.

7.

11. The process according to claim 1, 5, or 9, wherein the alcohol comprises a minimum ethanol content of about 85% to 90% by weight and a maximum water content of 10% to 15% by weight.

12. The process according to claim 11, wherein the alcohol contains an ethanol content of at least about 85% by weight, 86% by weight, 87% by weight, 88% by weight, 89% by weight, or 90% by weight.

13. The process according to claim 11 or 12, wherein the alcohol contains up to about 10% by weight, 11% by weight, 12% by weight, 13% by weight, 14% by weight, or 15% by weight of water.

14. The process according to claim 1, 5, or 9, wherein the alcohol comprises a minimum of about 88% by weight of ethanol and a maximum of 12% by weight of water.

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