US20090031615A1 - Integrated method for producing a fuel component from biomass and system therefor - Google Patents

Integrated method for producing a fuel component from biomass and system therefor Download PDF

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US20090031615A1
US20090031615A1 US12/183,370 US18337008A US2009031615A1 US 20090031615 A1 US20090031615 A1 US 20090031615A1 US 18337008 A US18337008 A US 18337008A US 2009031615 A1 US2009031615 A1 US 2009031615A1
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Prior art keywords
biomass
fermentate
heat
corn
separation residue
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US12/183,370
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Narendra Digamber Joshi
Srinivasa Range Gowda
Michael Jay Epstein
Timothy James Held
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General Electric Co
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General Electric Co
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Priority to US12/183,370 priority Critical patent/US20090031615A1/en
Priority to EP08782588A priority patent/EP2176384A1/en
Priority to PCT/US2008/071883 priority patent/WO2009018507A1/en
Priority to CA2694932A priority patent/CA2694932A1/en
Priority to JP2010520216A priority patent/JP2010535282A/ja
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EPSTEIN, MICHAEL JAY, HELD, TIMOTHY JAMES, GOWDA, SRINIVASA RANGE, JOSHI, NARENDRA DIGAMBER
Publication of US20090031615A1 publication Critical patent/US20090031615A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C10G2/32—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/58—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels combined with pre-distillation of the fuel
    • C10J3/60—Processes
    • C10J3/64—Processes with decomposition of the distillation products
    • C10J3/66—Processes with decomposition of the distillation products by introducing them into the gasification zone
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/04—Liquid carbonaceous fuels essentially based on blends of hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0916—Biomass
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
    • C10J2300/1656—Conversion of synthesis gas to chemicals
    • C10J2300/1659—Conversion of synthesis gas to chemicals to liquid hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1681—Integration of gasification processes with another plant or parts within the plant with biological plants, e.g. involving bacteria, algae, fungi
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/10—Process efficiency
    • Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y02T50/678—Aviation using fuels of non-fossil origin

Definitions

  • the present disclosure generally relates to integrated methods and systems for converting biomass into fuels.
  • some embodiments herein relate to integrated methods for converting corn-based biomass into aviation jet fuel.
  • Biofuel can be broadly defined as solid, liquid, or gas fuel consisting of, or derived from, biomass.
  • Biomass is any material derived from recently living organisms, including plants, animals and the byproducts thereof, and is a renewable energy source based on the carbon cycle.
  • Some examples of agricultural products that can be specifically grown for biofuel production include corn, soybeans, rapeseed, wheat and sugar cane.
  • Biofuel is considered an important means of reducing greenhouse gas emissions, as well as increasing energy security by providing a viable alternative to currently used fossil fuels.
  • corn or other biomass
  • Ethanol plants can use corn (or other biomass) to produce ethanol, but usually also produce large quantities of biomass fermentate distillation residues, such as distiller's grain, as a byproduct of the fermentation and distillation process.
  • biomass fermentate distillation residues such as distiller's grain
  • the market for biomass fermentate distillation residues becomes increasingly saturated, resulting in a steady decline in prices and threatening an important revenue stream for ethanol plant owners.
  • One embodiment of the present invention is directed to an integrated method for producing fuel from biomass, which method comprises the steps of (a) providing a feed comprising biomass fermentate separation residue; (b) gasifying feed from step (a) in a gasification reactor to produce a mixture comprising CO and H 2 ; (c) contacting the mixture comprising CO and H 2 with a hydrocarbon synthesis catalyst in a synthesis reactor to produce heat and an effluent comprising a liquid transportation fuel component; and (d) supplying at least a portion of the heat to at least one thermal process selected from the group consisting of biomass liquefaction, fermentation, fermentation product distillation, dehydrating agent regeneration, fermentate separation residue concentrating, and fermentate separation residue drying.
  • a further embodiment of the present invention is directed to an integrated method for producing a turbine fuel from corn-based biomass, the method comprising the steps of: (a) providing a feed comprising corn-based biomass fermentate distillation residue; (b) gasifying feed from step (a) in a gasification reactor to produce a mixture comprising CO and H 2 ; (c) contacting the mixture comprising CO and H 2 with a hydrocarbon synthesis catalyst in a synthesis reactor to produce heat and an effluent comprising a liquid turbine fuel component; and (d) supplying at least a portion of the heat to at least three thermal processes selected from the group consisting of corn liquefaction, corn mash fermentation, corn fermentation product distillation, corn-based ethanol dehydrating agent regeneration, corn mash fermentate distillation residue concentrating, and corn mash fermentate distillation residue drying.
  • a yet further embodiment of the present invention is directed to an integrated system for producing fuel from biomass, the system comprising, (a) a unit configured to provide a feed comprising biomass fermentate separation residue; (b) a gasification reactor for gasifying feed from unit (a) to produce a mixture comprising CO and H 2 , (c) catalytic hydrocarbon synthesis zone configured to react the mixture comprising CO and H 2 to produce heat and an effluent comprising a liquid transportation fuel component; and (d) at least one heat supply conduit configured to supply at least a portion of said heat to at least one thermal process selected from the group consisting of biomass liquefaction, fermentation, fermentation product distillation, dehydrating agent regeneration, fermentate separation residue concentrating, and fermentate separation residue drying.
  • FIG. 1 is a block flow diagram schematically setting forth methods in accordance with embodiments of the invention.
  • FIG. 2 is an illustrative and schematic flow-chart of a method for producing corn-based distiller's grains, in accordance with embodiments of the invention.
  • FIG. 3 is a schematic diagram of a mode of removing heat from a hydrocarbon synthesis reactor, in accordance with embodiments of the invention.
  • FIG. 4 is a block flow diagram, schematically setting forth variant methods in accordance with other embodiments of the invention.
  • an embodiment of the present invention is directed to an integrated method and system for producing fuel from biomass.
  • the method and systems described herein enable the efficient and effective utilization of waste heat from hydrocarbon synthesis of liquid transportation fuel components, in various thermal processes.
  • a biomass fermentate separation residue 10 is supplied to a step of providing 100 a feed comprising the biomass fermentate separation residue 10 .
  • the step of “providing” 100 may comprise a pretreatment step such as pyrolysis, catalytic conversion, drying, concentrating, and/or charring (not specifically shown here).
  • Provided feed 11 comprising biomass fermentate separation residue is recovered from providing step 100 .
  • the provided feed 11 is then supplied to a gasifying step 101 in a gasification reactor, to produce a mixture 12 comprising CO and H 2 .
  • This mixture 12 may be supplied (either directly or indirectly) to a contacting step 102 wherein the mixture 12 is contacted with a hydrocarbon synthesis catalyst in a synthesis reactor to produce heat 14 and an effluent 13 comprising a liquid transportation fuel component.
  • Heat 14 may be supplied to any one or more of six thermal processes 109 , shown collectively in a dotted box.
  • the six thermal processes are biomass liquefaction 103 , fermentation 104 , fermentation product distillation 105 , dehydrating agent regeneration 106 , fermentate separation residue concentrating 107 , and fermentate separation residue drying 108 .
  • biomass is broadly defined as generally including materials derived from plants, such as woody materials, forest residues, agricultural residues, or crops; or the like.
  • biomass as used herein includes materials that are formed as a result of photosynthesis. This is significant for the production of liquid transportation fuel components that are to be considered “carbon-neutral” or even “carbon-negative”, in the context of carbon-containing fuels as suspected climate-change agents.
  • the woody materials and forest residues may include wood, woodchips, saw dust, bark or other such products from trees, straw, grass, and the like.
  • Agricultural residue and crops may further include short rotation herbaceous species, husks such as rice husk, coffee husk, etc., maize (i.e., corn), wheat, corn stover, oilseeds, residues of oilseed extraction, other grains, and the like.
  • the oilseeds may be typical oil bearing seeds like soybean, camolina, canola, rapeseed, corn, cottonseed, sunflower, safflower, olive, peanut, and the like.
  • Biomass may also include material obtained from agro-processing industries such as the oil industry, e.g., a deoiled residue after extraction of oil from the oil seeds. Biomass may also include other tree-based products such as shells, e.g., coconut shell, almond shell, walnut shell, sunflower shell, and the like. Cellulosic fibers like coconut, jute, and the like, may also constitute all or part of biomass.
  • the biomass may also include algae, microalgae, and the like. It could also include agro-products after preliminary processing. As an example, this might include feedstocks such as bagasse (obtained after juice removal from sugarcane), cotton gin trash, and the like.
  • Methods in accordance with embodiments comprise a step of providing a feed comprising biomass fermentate separation residue.
  • Such residues can be those produced as a by-product of the separation (e.g., distillation) of biomass fermentation into components.
  • Tile biomass which is fermented is typically one or more plant biomass selected from woody materials, forest residues, agricultural residues, crops, and the like.
  • biomass can fermented microbially to produce chemicals such as alcohols and other organic chemicals.
  • Fermentation-derived alcohols can include butanol and ethanol, and other (usually volatile) organic chemicals can include ketones, carboxylic acids, aldehydes, and the like. These chemicals are desirable products of the biomass fermentation process, but must be separated out from tile fermentate.
  • a typical method of separating a desirable volatile product such as ethanol from a biomass fermentate can involve the distillation of the fermentate.
  • other separation methods such as pervaporation or membrane separation can also be employed to recover the desired volatile organic product from the fermentate.
  • the portion which is rejected from the separation process when is the “biomass fermentate separation residue”; it is this latter material which is employed in methods according to embodiments of the invention.
  • Fermentation processes in accordance with embodiments of the present invention usually involve microbial (e.g., yeast-mediated or bacterial) conversion of a biomass-derived feedstock.
  • corn can be fermented to produce a fermentate comprising ethanol.
  • the corn may be firstly ground to produce a milled corn.
  • the milling can be either dry milling or wet milling.
  • the meal can then be mixed with water and an enzyme, such as alpha-amylase, and then passed to cookers to liquefy starch into a mash. Heat may then be applied at this stage to enhance liquefaction.
  • cooking to a temperature as high as 150° C. may be employed.
  • the mash from the cookers may be cooled and a secondary enzyme, such as glucoamylase, can be added to convert the liquefied starch to fermentable sugars.
  • Yeast can then be added to the mash to ferment the sugars to ethanol and carbon dioxide.
  • One or more fermenters can be used.
  • the fermented mash now called beer, generally contains about 10% ethanol but additionally may contain non-fermentable solids from the corn and yeast cells. Fermented mash can then be transferred to a distillation system to remove ethanol from the solids and the water.
  • the alcohol is typically collected from the distillation system at azeotropic (usually about 95%) concentration, and the distillation residue (sometimes called stillage) is also collected.
  • distillation residue is dried and/or concentrated, it is then termed distiller's grain.
  • one exemplary embodiment of a biomass fermentate separation residue is distiller's grain.
  • FIG. 2 here is shown an illustrative and schematic flow-chart of a method for producing one form of biomass fermentate separation residue, namely, corn-based distiller's grains.
  • Corn is supplied through 15 and is fine milled in 200 to expose its starch.
  • Milled corn is supplied though 16 to cooker 201 , to which is added enzymes (not specifically shown) and heat via steam line 17 .
  • Cooker 201 is an example of a thermal process which may employ heat recovered from the hydrocarbon synthesis reactor.
  • Cooked corn is sent through line 18 to fermenter 202 , to which is also supplied yeast through 19 and enzymes through 20 .
  • the fermented corn mash (“fermentate”) is supplied via 21 to distillation apparatus 203 .
  • distillation apparatus 203 From the bottoms of distillation apparatus 203 is collected corn-based stillage, which is sent via line 24 to a processor 204 , wherein the stillage is processed through a centrifuge and heated dryer to remove liquids. Heat is indirectly supplied through line 25 (in the form of hot gas) and dried distiller's grains are collected via line 26 .
  • distiller's grains recovered as corn-based distillation residue including distiller's wet grains (DWG), distiller's dry grains (DDG), dried distiller's grains with solubles (DDGS), and corn-based grain stillage syrup.
  • DWG distiller's wet grains
  • DDG distiller's dry grains
  • DDGS dried distiller's grains with solubles
  • corn-based grain stillage syrup usually has from about 20 to about 40% solids. It has been found that these and other biomass fermentate separation residues offer advantages when forming liquid transportation fuel components according to embodiment of the invention, since such residues have idea H/C ratios, e.g., usually around 2:1.
  • a feed comprising biomass fermentate separation residue is provided to gasification reactor; such gasification reactor (also referred to as a gasifier) will be described in greater detail hereinunder.
  • the step of “providing” a feed may comprise a treatment step performed upon the biomass fermentate separation residue, prior to its being fed to a gasification reactor.
  • a treatment step may be selected from one or more of pyrolysis, catalytic conversion, drying, concentrating, and charring; and the like.
  • Each of these treatment steps may be capable of rendering biomass fermentate separation residue into a state more suitable for gasification.
  • a biomass fermentate separation residue such as DWG should be dried and/or concentrated prior to being fed to a gasifier, so as to enhance the efficiency of the reactor and avoid agglomeration or other deleterious effects of the moisture.
  • a catalytic conversion of biomass fermentate separation residue may be performed, to convert the residue to a form more suitable for gasification (e.g., more solids and/or higher carbon content and/or less tarry character).
  • the step of “providing” a feed comprising a biomass fermentate separation residue may simply comprise conveying or feeding a biomass fermentate separation residue to a gasifier, without any of the treatment steps noted above.
  • the present disclosure also encompasses embodiments where the biomass fermentate separation residue is combined with a supplemental feed member, such as another biomass-based material (e.g., corn stover) and/or carbonaceous fuel.
  • biomass fermentate separation residue is combined or mixed with at least one supplemental feed member selected from low rank coal, liquid hydrocarbonaceous fuel, coke, oil shale, tar sands, asphalt, pitch, another biomass-based material, and mixtures thereof, and the like.
  • the combining or mixing may occur within a gasifier, or more usually, prior to being fed to a gasifier.
  • low rank coals are generally understood by persons skilled in the art to typically be those coals having a lower grade than bituminous, e.g., sub-bituminous or lignitic coal.
  • such low rank coals may have a relatively high oxygen content, such as from about 16% to 25% by weight.
  • Other characteristics of low rank coals may include a relatively high moisture content, such as in the range of about 10% to 40%, and a relatively high dry ash content, such as in the range of about 12% to 40%.
  • Low rank coals are present in abundance in tie mid-continenit region of the United States (as Powder River Basin coal), and in China (as brown coal).
  • the biomass fermentate separation residue may be directly combined therewith, or one or more of the aforementioned treatment steps (e.g., pyrolysis, catalytic conversion, drying, concentrating, charring) is performed upon a biomass fermentate separation residue prior to mixing with the supplemental feed member.
  • treatment steps e.g., pyrolysis, catalytic conversion, drying, concentrating, charring
  • the feed is gasified in a gasification reactor to produce a mixture comprising at least carbon monoxide and hydrogen.
  • gasification refers to a process which converts carbonaceous and/or hydrocarbon feedstocks into a synthesis gas (also known as syngas) comprising hydrogen and carbon monoxide.
  • a carbonaceous feedstock arid (2) air, oxygen, steam, water and/or CO 2 ; are contacted within a gasification reactor, where partial oxidation of the feedstock occurs.
  • Non-gasifiable ash material and unconverted and/or incompletely converted feedstock are by-products of the process.
  • a quench process is used to cool and saturate the syngas.
  • a gasification reactor may suitably be one or more type, such as fixed bed, bubbling bed, fluidized bed, entrained flow gasifier; or the like.
  • the gasification reactor may have at least one characteristic selected from slurry-fed, pressurized, slagging; or the like.
  • gasifying agents such as oxygen, air, steam, or combination of these, are used to fluidize the feedstock and carry it at least some distance through the gasification reactor.
  • the gasification reactor can be operated in a pressurized mode (which can be any pressure above atmospheric but is typically between about 10 bar and about 40 bar); which may in certain cases afford good overall efficiencies.
  • the gasification reactor may instead be operated at substantially atmospheric pressure.
  • one may operate the gasification reactors at temperatures higher than about 1000° C., e.g., from about 1000° C. to about 1400° C., to more effectively gasify tarry components of the feed.
  • operation at such high temperatures could require use of expensive refractory materials in the gasification reactor.
  • the gasification reactor is operated at moderate temperatures, typically from about 700° C. to about 1000° C.
  • step (a) through (d) are noted as process steps for the present integrated method for producing fuel from biomass, this is not to be taken to exclude the presence or use of other steps, to be described hereinunder.
  • the mixture of CO and hydrogen generated in the gasification reactor in step (b) may also undergo further treatment steps such as scrubbing to remove acidic gases; or water-gas shifting to adjust the CO/hydrogen ratio.
  • a step of adjusting the CO/H 2 ratio in a mixture can be accomplished by an adjusting step selected from one or more of: selective removal of CO, selective removal of hydrogen, water-gas shift, reverse-water-gas-shift; or the like. In cases where selective removal of CO or selective removal of hydrogen is desired, it may be performed by selective oxidation or by membrane processing. Adjusting the CO/H 2 ratio in the mixture may promote the formation of desired products in the effluent of the hydrocarbon synthesis reactor, as explained in further detail below.
  • raw product syngas from gasification reactors further comprises other gaseous components as impurities in addition to CO and hydrogen.
  • These impurities may include CO 2 , NH 3 , H 2 S, HCN, HCl, COS, nitrogen, mercury, and the like.
  • Such other gaseous components may be deleterious to downstream processing steps (e.g., hydrocarbon synthesis) performed upon the mixture, or may lessen the efficiency of these downstream processing steps.
  • methods of the present disclosure further comprise an additional step of scrubbing or otherwise at least partially removing at least one impurity selected from ammonia, carbon dioxide, hydrogen sulfide, HCl, hydrogen cyanide, mercury, nitrogen and carbonyl sulfide from the mixture comprising CO and H 2 prior to contacting the mixture with the hydrocarbon synthesis catalyst.
  • Scrubbers may be suitably employed for the acidic gaseous impurities (e.g., CO 2 and H 2 S), while guard beds may be used for mercury removal.
  • carbon dioxide may in certain cases be sequestered so as to limit emission of climate-change suspect compounds.
  • a gaseous mixture comprising CO and H 2 (suitably scrubbed of impurities and adjusted in CO/H 2 ratio, as appropriate), is passed to a synthesis reactor in which contact is made with a hydrocarbon synthesis catalyst, to produce heat and an effluent comprising a liquid transportation fuel component.
  • a hydrocarbon synthesis catalyst may comprise any of the catalytic materials heretofore known for hydrocarbon synthesis by the Fischer-Tropsch (F-T) reaction, such as at least one selected from Fe, Co, Ni, Re, Ru; and the like. These catalytic materials may be provided in elemental and/or compound form.
  • these catalytic materials may be provided and used in dispersed form and supported upon an inorganic support material, such as a refractory inorganic support material, e.g., zirconia, titania, or alumina.
  • an inorganic support material such as a refractory inorganic support material, e.g., zirconia, titania, or alumina.
  • the catalytic materials of the hydrocarbon synthesis catalyst of the present embodiments further comprises one or more promoter material.
  • the hydrocarbon synthesis catalyst comprises one or more of Fe, Co, Ni, Re, Ru present in an amount of from about 1% to about 50% by weight of total hydrocarbon synthesis catalyst.
  • hydrocarbon synthesis catalyst comprises at least one selected from Fe, Co, Ni, Re, Ru
  • any one or more of the following may be employed as co-catalysts or promoters: Re, Ru, Pt, Fe, Ni, Th, Zr, Hf, U, Mg and La; and the like.
  • use of Co as catalyst material promotes the formation of paraffins.
  • a gaseous mixture comprising CO and H 2 is contacted with a hydrocarbon synthesis catalyst under conditions of temperature such as between about 140° C. to about 400° C. (or more narrowly, between about 200° C. to about 250° C.); and at conditions of pressure such as between about 0.5 to about 50 bars (or more narrowly, between about 2 to about 25 bars). Note that here (as elsewhere in this disclosure), all ranges disclosed are inclusive of the recited endpoint and are independently combinable.
  • the hydrocarbon synthesis reactor may be one or more of a variety of reactor types; for example, fixed bed reactors containing one or more catalyst beds, slurry reactors, fluidized bed reactors, or a combination of different type reactors.
  • the hydrocarbon synthesis process is a slurry Fischer-Tropsch process, in which a syngas comprising a mixture of H 2 and CO is bubbled up through a slurry in a reactor which comprises a particulate hydrocarbon synthesis catalyst dispersed and suspended in a slurry liquid comprising hydrocarbon products of the synthesis reaction which are liquid at the reaction conditions.
  • the contact of syngas with the hydrocarbon synthesis catalyst in the synthesis reactor results in an effluent comprising one or more liquid transportation fuel component.
  • a “liquid transportation fuel component” (which usually comprises at least paraffins) may itself be used as a liquid transportation fuel, or may be suitably blended with another fuel and/or additive to be useful as a liquid transportation fuel. Therefore, the term “component” is employed to signify that the effluent from the synthesis reactor may be used as part of a liquid transportation fuel, or as a fuel itself (after any appropriate separation and/or hydroprocessing, as explained more fully below).
  • liquid transportation fuel components that has sufficient lubricity and other parameters such that it can be used as a jet turbine fuel.
  • liquid transportation fuel components require admixture with other fuels and/or additives in order to be useful as a jet turbine fuel.
  • a “liquid transportation fuel” and a “liquid transportation fuel component” generally refers to hydrocarbonaceous fuels boiling within the range of gasoline, jet fuel, kerosene, or diesel.
  • the liquid transportation fuel component may be used as a turbine fuel.
  • the formation of a desired type of liquid transportation fuel component may be promoted by: (1) choosing the proper chemical composition for the feed comprising biomass fermentate separation residue; (2) adjusting the CO/H 2 ratio of the syngas formed in the gasification reactor; (3) adjusting conditions including temperature, pressure, and/or catalyst in the hydrocarbon synthesis reactor; and (4) combinations of the foregoing.
  • the H/C ratio in dried distiller's grains may be ideal for conversion into (e.g., paraffinic) liquid transportation fuel components.
  • a “turbine fuel” refers to a fuel composition which may be burned in a turbine to provide power. Turbines may be stationary, such as those used to generate electricity, or they may be used to power mobile platforms, such as providing power for ships or airplanes. Turbine fuels meeting certain specifications may be used as jet fuel for airplanes. Specifications for turbine fuel intended for use in jet engines are more stringent than those for fuels intended for use in turbines used to produce electricity.
  • jet fuel is a material suitable for use in aviation turbines and typically meets the current version of at least one of the following specifications: ASTM D1655; DEF STAN 91-91/3 (DERD 2494); International Air Transportation Association (IATA) “Guidance Material for Aviation Turbine Fuels Specifications”, 4th edition, March 2000; United States military jet fuel specifications MIL-DTL-5624; and MIL-DTL-83133, and variants thereof.
  • jet fuel is an aviation fuel with various specified grades such as Jet-A, JP-A, JP-B, JP-4, JP-5, JP-7, JP-8, JP8+100, and the like. Jet fuel is a special grade of kerosene; the specifications of various grades are specified by various standards. As an example, JP-8 is defined by standard MIL-T-83133C.
  • liquid transportation fuel component where the liquid transportation fuel component according to embodiments of the invention is to be used for aviation turbine or jet fuel purposes, it generally meets one or more of the following parameters: an H/C ratio of greater than about 1.85, more narrowly, between about 1.85 and about 2.20; a flash point of at least about 38° C., more narrowly, from about 38° C. to about 60° C., and even more narrowly from about 40° C. to about 60° C.; and a freeze point of less than about ⁇ 40° C., more narrowly less than about ⁇ 47° C., often having an average freeze point of from about ⁇ 50° C. to about ⁇ 60° C. (freeze point as defined by ASTM-D-2386).
  • the liquid transportation fuel component additionally meets one or more of the jet fuel standard specifications noted previously.
  • various additives such as antioxidants, antistatic agents, corrosion inhibitors, icing inhibitors, etc., may be added to the liquid transportation fuel component, before it is used in transportation, e.g., before it is used as jet fuel or aviation turbine fuel.
  • the amount and type of additives may be different for different grades of transportation fuel.
  • the contact of syngas with the hydrocarbon synthesis catalyst in the synthesis reactor results in an effluent comprising one or more liquid transportation fuel component, where the liquid transportation fuel component is thereafter upgraded by hydroprocessing.
  • This additional hydroprocessing, step is generally selected from one or more of hydrocracking, hydrotreating, and isomerization; and the like.
  • Such hydroprocessing steps per se are generally known to persons of skill in the art of hydrocarbon processing.
  • Hydroprocessing may usually be carried out in the presence of free hydrogen, for removal of alcohols and hydrogenation of olefins present in the effluent.
  • upgrading by hydroprocessing may be performed upon some or all of the liquid transportation fuel component, in order to impart desired properties.
  • a liquid transportation fuel component in accordance with some embodiments of the present invention can be upgraded by hydroprocessing to be suitable for use as aviation turbine fuel.
  • the effluent from the hydrocarbon synthesis reactor comprising one or more liquid transportation fuel component may be separated by one or more distillation or other separation process.
  • distillation or separation will be on the basis of boiling point.
  • the effluent comprising one or more liquid transportation fuel component may be distilled into one or more lower boiling fractions and one or more higher boiling fractions. It may be advantageous to perform such distillation to separate liquid fuel components from waxy fuel components.
  • both distillation and hydroprocessing, in any order, may be performed upon effluent from the hydrocarbon synthesis reactor.
  • integrated methods comprise supplying at least a portion of heat produced by the hydrocarbon synthesis step to at least one thermal process which requires heat, selected from biomass liquefaction, fermentation, fermentation product distillation, dehydrating agent regeneration, fermentate separation residue concentrating, and fermentate separation residue drying. More particularly, the heat produced by the hydrocarbon synthesis step is supplied to at least two, or at least three, or at least four, or at least five, of said thermal processes. Although each of these processes which require heat is denoted as a “thermal process”, this is not to indicate that only thermal or physical processes occur; each of these processes may also additionally comprise chemical and/or biochemical process.
  • a biomass liquefaction process can be a ground corn cooking process whereby corn meal is heated in the presence of moisture and an enzyme.
  • the term “integrated,” as used herein, means that certain steps of the method are interrelated or dependent upon either earlier or later steps of the total method.
  • the heat which emanates from the synthesis reactor may be recovered in many suitable ways, including heat recovery by indirect heat exchange with the synthesis reactor, either internal to the reactor or externally, or by heat recovery from the hot effluent gases removed as product from the reactor.
  • a stream can be removed (e.g., the overhead stream) that comprises water, among other components.
  • Heat may be obtained from the hydrocarbon synthesis reactors by cooling the water-containing stream from the reactor, or by cooling the reactor itself, or by cooling other effluent streams from the reactor. More specifically, one or more hot effluent stream from the hydrocarbon synthesis reactor may be passed through a heat exchanger.
  • a usable heat exchanger can be a shell and tube heat exchanger or a welded plate and frame heat exchanger.
  • the synthesis reactor may contain cooling coils, which serve to remove heat generated during the highly exothermic Fischer-Tropsch reaction. Both cooling coils internal to the hydrocarbon synthesis reactor, and heat exchangers for heat removal from hot effluent streams, can be used simultaneously.
  • heat transfer fluids such as steam or heated air or other heated gas are well known and effective means for supplying recovered heat to where it is required.
  • FIG. 3 here is shown a schematic diagram of an exemplary (but non-limiting) mode of removing heat from a hydrocarbon synthesis reactor and supplying it to one or more thermal processes.
  • Fischer-Tropsch reactor 300 is fed with a syngas through line 30 , and an effluent comprising a liquid transportation fuel component is recovered through 31 .
  • Cooling water in line 32 is fed through cooling coils within reactor 300 to make indirect heat contact with the hot reactor, and the steam raised by this process is supplied to drive the one or more thermal processes 109 .
  • Thermal processes which requires heat are selected from one or more of biomass liquefaction, fermentation, fermentation product distillation, dehydrating agent regeneration, fermentate separation residue concentrating, and fermentate separation residue drying.
  • the integrated systems and methods disclosed herein may obviate or reduce the necessity to import energy to drive these thermal processes.
  • fermentate separation residue drying e.g., drying distiller's grains
  • This can increase costs for producing ethanol from corn.
  • the present methods and systems may offer the advantage of cost savings by recycling a form of waste heat.
  • a biomass liquefaction process may comprise enzymatic and/or bacterial decomposition of any of the biomass materials noted previously.
  • An exemplary but non-limiting type of biomass liquefaction may be the previously-described process where milled corn is mixed with water and an enzyme, and then passed to cookers to liquefy starch into a mash. Heat is usually required to enhance liquefaction.
  • a fermentation process may comprise enzymatic, bacterial, and/or yeast-mediated production of an alcohol from a biomass material.
  • An exemplary but non-limiting type of fermentation process can include the previously-described process for recovery of ethanol from corn mash fermentation. Fermentation processes benefit from heat input.
  • a fermentation product distillation process typically comprises distillation of a fermentate to separate an alcohol.
  • a fermentation product distillation process is the distillation of fermented corn mash to recover ethanol as a fermentation product.
  • a fermentation product distillation process usually requires heat to drive the production of the desired alcohol, e.g., azeotropic ethanol.
  • a dehydrating agent regeneration process generally comprises regeneration of a spent solid dehydrating agent.
  • a spent solid dehydrating agent has been used to dehydrate a biomass fermentation product (e.g., ethanol from corn fermentation).
  • a biomass fermentation product e.g., ethanol from corn fermentation.
  • the most accepted approach to dehydration of ethanol now used industrially is to use adsorption by molecular sieves as solid dehydrating agent, such as zeolite 3A.
  • zeolite 3A zeolite 3A
  • zeolite 3A zeolite 3A
  • zeolite 3A zeolite 3A
  • a fermentate separation residue concentrating process generally comprises reducing the volume of a fermentate separation residue.
  • a “fermentate separation residue” can be the rejected residue after separation (e.g., distillation) of a desired product (e.g., an alcohol or other volatile organic compound) from a biomass (e.g., corn) fermentate.
  • a desired product e.g., an alcohol or other volatile organic compound
  • Such fermentate separation residue may include corn-based distiller's grains or distiller's syrup. Reduction in volume may be performed in a centrifuge. Heat may sometimes be employed to aid in volume reduction.
  • a fermentate separation residue drying process may include removing at least some moisture from a fermentate separation residue, such as drying corn-based distiller's grains in a dryer (e.g., a steam tube rotary or ring dryer). Often, for particular purposes, such residues require drying to a given moisture level prior to further utilization, e.g., prior to gasification or use as feed. In such cases, drying can be accomplished using conventional means, such as steam dryer, gas dryer, spray dryer, pneumatic conveying dryer, fluidized bed dryers, rotary kilns, or the like.
  • the thermal process is used to generate, separate and/or treat the biomass fermentate separation residue; or the thermal process is used to treat another product of the same process which generates, separates and/or treats the biomass fermentate separation residue.
  • the thermal process to which heat is supplied may be a process that concentrates or dries the biomass fermentate separation residue that is sent to the “providing” step (a). For example, this would be the case where dried distiller's grains are converted into liquid transportation fuels, and the heat from hydrocarbon synthesis is used to dry these distiller's grains.
  • the thermal process may be a process that liquefies, ferments, or distills the biomass from which the biomass fermentate separation residue is derived.
  • this would be the case where heat from hydrocarbon synthesis from syngas is used to ferment, liquefy, or distill corn to make the distiller's grains which are gasified to make the syngas.
  • the thermal process may be one which treats another product of the same process which generates, separates and/or treats the biomass fermentate separation residue. For example, this would occur when heat from hydrocarbon synthesis is used to regenerate a drying agent that has been used to dry ethanol, made in the same process that also makes distiller's grains.
  • Both a supplemental feed member 34 comprising Powder River Basin coal, and a biomass fermentate separation residue 35 are supplied to a step of providing 400 a feed.
  • the step of “providing” 400 may comprise a pretreatment step such as pyrolysis, catalytic conversion, drying, concentrating, and/or charring (not specifically shown here).
  • the step of providing 400 generates a provided feed 36 .
  • the provided feed 36 is then supplied to a gasifying step 401 in a gasification reactor, to produce a mixture 37 comprising, CO and H 2 .
  • This mixture 37 is supplied (either directly or indirectly) to a contacting step 402 wherein the mixture 37 is contacted with a hydrocarbon synthesis catalyst in a synthesis reactor to produce heat 40 and an effluent 38 comprising at least paraffins.
  • the effluent 38 is then upgraded in a hydroprocessing step 403 to produce a liquid transportation fuel component 39 .
  • Heat 40 may be supplied to any one or more of six thermal processes 410 , shown collectively in a dotted box.
  • Each of the six thermal processes are biomass liquefaction 404 , fermentation 405 , fermentation product distillation 406 , dehydrating agent regeneration 407 , fermentate separation residue concentrating 408 , and fermentate separation residue drying 409 .
  • approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise value specified, in some cases.
  • the modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, includes the degree of error associated with the measurement of the particular quantity).

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