Liquid fuel production system having parallel product gas generation
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IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01J-019/24
B01J-004/00
C10J-003/72
C10G-002/00
출원번호
US-0791994
(2017-10-24)
등록번호
US-10099200
(2018-10-16)
발명자
/ 주소
Chandran, Ravi
Newport, Dave G.
Burciaga, Daniel A.
Leo, Daniel Michael
Miller, Justin Kevin
Harrington, Kaitlin Emily
Attwood, Brian Christopher
출원인 / 주소
ThermoChem Recovery International, Inc.
대리인 / 주소
Womble Bond Dickinson (US) LLP
인용정보
피인용 횟수 :
0인용 특허 :
124
초록▼
A liquid fuel product system is configured to produce liquid fuels from carbonaceous materials. The liquid fuel product system includes a plurality of feedstock delivery systems, a plurality of first stage product gas generation systems, a plurality of second stage product gas generation systems, a
A liquid fuel product system is configured to produce liquid fuels from carbonaceous materials. The liquid fuel product system includes a plurality of feedstock delivery systems, a plurality of first stage product gas generation systems, a plurality of second stage product gas generation systems, a plurality of third stage product gas generation systems, a primary gas clean-up system, a compression system, a secondary gas clean-up system, and a synthesis system that includes one or more from the group consisting of ethanol, mixed alcohols, methanol, dimethyl ether, and Fischer-Tropsch products.
대표청구항▼
1. A liquid fuel production system, comprising: (a) a plurality of feedstock delivery systems (2000, 2000′), each comprising a feedstock input (2-IN1, 2-IN1′) configured to accept carbonaceous material, a feedstock gas input (2-IN2, 2-IN2′) configured to accept carbon dioxide, and a mixture output (
1. A liquid fuel production system, comprising: (a) a plurality of feedstock delivery systems (2000, 2000′), each comprising a feedstock input (2-IN1, 2-IN1′) configured to accept carbonaceous material, a feedstock gas input (2-IN2, 2-IN2′) configured to accept carbon dioxide, and a mixture output (2-OUT1, 2-OUT1′); wherein each feedstock delivery system (2000, 2000′) is configured to blend the carbonaceous material with carbon dioxide to generate a carbonaceous material and gas mixture which is discharged via the mixture output (2-OUT1, 2-OUT1′);(b) a plurality of first stage product gas generation systems (3A, 3A′), each comprising a first reactor mixture input (3A-IN1, 3A-IN1′) configured to accept at least a portion of said carbonaceous material and gas mixture, and a first reactor gas output (3A-OUT1, 3A-OUT1′), wherein each first stage product gas generation system is configured to react the carbonaceous material with steam and optionally also with an oxygen-containing gas and/or carbon dioxide to generate first reactor product gas which is discharged via said first reactor gas output (3A-OUT1, 3A-OUT1′);(c) a plurality of second stage product gas generation systems (3B, 3B′), each comprising a second reactor gas input (3B-IN1, 3B-IN1′) configured to accept at least a portion of said first reactor product gas, and a second reactor gas output (3B-OUT1, 3B-OUT1′), wherein each second stage product gas generation system (3B, 3B′) is configured to react the first reactor product gas with an oxygen-containing gas and optionally also with steam and/or carbon dioxide to generate heat and a second reactor product gas which is discharged via said second reactor gas output (3B-OUT1, 3B-OUT1′);(d) a plurality of third stage product gas generation systems (3C, 3C′), each comprising a third reactor gas input (3C-IN1, 3C-IN1′) configured to accept at least a portion of said second reactor product gas, and a third reactor output (3C-OUT1, 3C-OUT1′), wherein each third stage product gas generation system (3C, 3C′) is configured to exothermically react a portion of the second reactor product gas with an oxygen-containing gas and optionally also with a hydrocarbon to generate heat and a third reactor product gas which is discharged via the third reactor output (3C-OUT1, 3C-OUT1′);(e) a primary gas clean-up system (4000) comprising a primary gas clean-up input (4-IN1) configured to accept third reactor product gas from the plurality of the third reactor outputs (3C-OUT1, 3C-OUT1′), and a primary gas clean-up output (4-OUT1); wherein the primary gas clean-up system (4000) is configured to reduce the temperature, and remove solids and water from the third reactor product gas and discharge primary product gas via the primary gas clean-up output (4-OUT1);(f) a compression system (5000) comprising a compression system input (5-IN1) configured to accept the primary product gas at a first pressure from the primary gas clean-up output (4-OUT1), and a compression system output (5-OUT1), wherein the compression system (5000) is configured to increase a pressure of the primary product gas and discharge compressed product gas via the compression system output (5-OUT1) at a second pressure greater than the first pressure at which the primary product gas entered via the compression system input (5-IN1), and wherein the compressed product gas comprising carbon dioxide;(g) a secondary gas clean-up system (6000) comprising a secondary gas clean-up input (6-IN1) configured to accept the compressed product gas, a secondary gas clean-up system output (6-OUT1), and a carbon dioxide output (6-OUT2), wherein the secondary gas clean-up system (6000) is configured to remove carbon dioxide from the compressed product gas to thereby generate a carbon dioxide depleted secondary product gas that is discharged via the secondary gas clean-up system output (6-OUT1), and discharge carbon dioxide via the carbon dioxide output (6-OUT2); and(h) a synthesis system (7000) comprising a synthesis system input (7-IN1) configured to accept the carbon dioxide depleted secondary product gas, and a synthesis system output (7-OUT1), wherein the synthesis system is configured to catalytically synthesize a synthesis product that is discharged via the synthesis system output (7-OUT1), and wherein the synthesis product includes one or more from the group consisting of ethanol, mixed alcohols, methanol, dimethyl ether, and Fischer-Tropsch products. 2. The liquid fuel production system according to claim 1, wherein: the feedstock gas input (2-IN2, 2-IN2′) of each feedstock delivery system (2000, 2000′) is configured to accept carbon dioxide from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000). 3. The liquid fuel production system according to claim 2, further comprising: a feedstock delivery system CO2 heat exchanger (HX-2000) positioned between the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000) and the feedstock gas input (2-IN2, 2-IN2′) of the feedstock delivery system (2000, 2000′), wherein the feedstock delivery system CO2 heat exchanger (HX-2000) is configured to reduce a temperature of the carbon dioxide transferred from the secondary gas clean-up system (6000) and realize a reduced temperature gas (580). 4. The liquid fuel production system according to claim 3, wherein: the feedstock delivery system CO2 heat exchanger (HX-2000) has a heat transfer medium inlet (525) and a heat transfer medium outlet (550);a heat transfer medium (575) passes through the heat exchanger (HX-2000) from the heat transfer medium inlet (525) to the heat transfer medium outlet (550), to remove heat from the carbon dioxide and realize the reduced temperature gas (580). 5. The liquid fuel production system according to claim 4, further comprising: a water removal system (585) positioned between the feedstock delivery system CO2 heat exchanger (HX-2000) and the feedstock gas input (2-IN2, 2-IN2′) of each feedstock delivery system (2000, 2000′), wherein:the water removal system (585) is configured to remove water or moisture within the carbon dioxide transferred from the secondary gas clean-up system (6000) and realize a water-depleted gas (590). 6. The liquid fuel production system according to claim 1, wherein: each first stage product gas generation system (3A, 3A′) is equipped with a first stage gas input (3A-IN5, 3A-IN5′) that is configured to accept carbon dioxide from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000). 7. The liquid fuel production system according to claim 1, wherein: each second stage product gas generation system (3B, 3B′) is equipped with a second stage gas input (3B-IN4, 3B-IN4′) that is configured to accept carbon dioxide from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000). 8. The liquid fuel production system according to claim 1, wherein: each feedstock delivery system (2000, 2000′) has a feedstock gas input (2-IN2, 2-IN2′) that is configured to accept carbon dioxide transferred from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000);each first stage product gas generation system (3A, 3A′) is equipped with a first stage gas input (3A-IN5, 3A-IN5′) that is configured to accept carbon dioxide from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000); andeach second stage product gas generation system (3B, 3B′) is equipped with a second stage gas input (3B-IN4, 3B-IN4′) that is configured to accept carbon dioxide from the carbon dioxide output (6-OUT2) of the secondary gas clean-up system (6000). 9. The liquid fuel production system according to claim 1, wherein: each feedstock delivery system (2000, 2000′) includes: a bulk transfer (2A) subsystem that is configured to accept carbonaceous material as an input (2-IN1) to the feedstock delivery system (2000) and discharge a carbonaceous material via an output (2A-OUT1);a flow splitting (2B) subsystem that is configured to accept a carbonaceous material as an input (2B-IN1) and discharge carbonaceous material via a plurality of outputs (2B-OUT1A, 2B-OUT1B);a plurality of mass flow regulation (2C, 2C′) subsystems that are configured to accept carbonaceous material as an input (2C-IN1A, 2C-IN1B) from said plurality of flow splitting (2B) outputs (2B-OUT1A, 2B-OUT1B) and in turn each discharge carbonaceous material via an output (2C-OUT1A, 2C-OUT1B);a plurality of densification (2D, 2D′) subsystems that are each configured to accept carbonaceous material as an input (2D-IN1A, 2D-IN1B) from each mass flow regulation (2C, 2C′) output (2C-OUT1A, 2C-OUT1B) and in turn each discharge carbonaceous material via an output (2D-OUT1A, 2D-OUT1B);a plurality of plug control (2E, 2E′) subsystems are each configured to accept carbonaceous material as an input (2E-IN1A, 2E-IN1B) from each densification (2D, 2D′) output (2D-OUT1A, 2D-OUT1B) and in turn each discharge carbonaceous material via an output (2E-OUT1A, 2E-OUT1B);a plurality of density reduction (2F, 2F′) subsystems that are each configured to accept carbonaceous material as an input (2F-IN1A, 2F-IN1B) from each plug control (2E, 2E′) output (2E-OUT1A, 2E-OUT1B) and in turn each discharge carbonaceous material via an output (2F-OUT1A, 2F-OUT1B);a plurality of gas mixing (2G, 2G′) subsystems that are each configured to accept carbonaceous material as an input (2G-IN1A, 2G-IN1B) from each density reduction (2F, 2F′) output (2F-OUT1A, 2F-OUT1B) and are configured to accept a gas via an input (2G-IN2A, 2G-IN2B) and mix the gas with the carbonaceous material to discharge a mixture of gas and carbonaceous material via an output (2G-OUT1A, 2G-OUT1B); anda plurality of transport (2H, 2H′) subsystems that are each configured to accept the mixture of gas and carbonaceous material as an input (2H-IN1A, 2H-IN1B) from each gas mixing (2G, 2G′) output (2G-OUT1A, 2G-OUT1B) and in turn each discharge a first carbonaceous material and gas mixture (510A) via an output (2H-OUT1A) and a second carbonaceous material and gas mixture (510B) via an output (2H-OUT1B). 10. The liquid fuel production system according to claim 9, wherein the feedstock delivery system (2000) further includes: a first splitter (2B1) having a splitter input (2B-03) through which bulk carbonaceous material (2B-01) is received, the first splitter (2B1) configured to split the received bulk carbonaceous material (2B-01) into a first plurality of carbonaceous material streams (2B-02A, 2B-02B, 2B-02C), each stream exiting the first splitter via a splitter output (2B-07, 2B-09, 2B-11);a first plurality of gas and carbonaceous material mixing systems (2G1, 2G1A, 2G1B, 2G1C), each configured to receive a carbonaceous material stream from a corresponding splitter output and output a carbonaceous material and gas mixture (2G-02, 2G-02A, 2G-02B, 2G-02C); wherein each gas and carbonaceous material mixing system comprises: a mixing chamber (G00);a first isolation valve (VG1) and a second isolation (VG2) spaced apart from one another along a length of the mixing chamber and thereby partitioning the mixing chamber into an entry section (G21), a middle section (G20) and an exit section (G19), the first isolation valve positioned between the entry section (G21) and the middle section (G20), the second isolation valve position between the middle section and that exit section (G19);a mixing chamber carbonaceous material stream input (G03, G03A, G03B, G03C) to the entry section, configured to receive said carbonaceous material stream from said corresponding splitter output;a mixing chamber gas input (G08, G08A, G08B, G08C) connected to a source of mixing gas (2G-03, 2G-03A, 2G-03B, 2G-03C) via a gas input valve (VG3, VG3A, VG3B, VG3C); anda mixing chamber output (G05, G05A, G05B, G05C) connected to said exit section;a first plurality of transport assemblies (2H1, 2H1A, 2H1B, 2H1C), each configured to receive said carbonaceous material and gas mixture from a corresponding mixing chamber output, and transfer said mixture toward a corresponding feedstock input belonging to a first reactor (100) to which the feedstock delivery system is connected; anda computer (COMP) configured to control at least the gas and carbonaceous material mixing systems. 11. The liquid fuel production system according to claim 10, wherein said each gas and carbonaceous material mixing system (2G1) further comprises: a mixing chamber middle section gas input (G12) connected to said source of mixing gas (2G-03) via a middle section gas input valve (VG4);a mixing chamber exit section gas input (G16) to said source of mixing gas (2G-03) via an exit section gas input valve (VG5); anda differential pressure sensor (DPG) configured to gauge a pressure differential between the mixing chamber entry section (G21) and the mixing chamber exit section (G19), and output a differential pressure sensor signal (XDPG) in response thereto. 12. The liquid fuel production system according to claim 11, further comprising: an evacuation gas line (G22) connected to at least one of the entry section and the middle section of the mixing chamber;a gas evacuation valve (VG6) connected to the evacuation gas line to selectively allow gas to be evacuated from the mixing chamber;a particulate filter (G26) connected to the evacuation gas line, between the mixing chamber and the gas evacuation valve; anda gas evacuation pressure sensor (P-G) connected to the evacuation gas line, between the particulate filter and the gas evacuation valve. 13. The liquid fuel production system according to claim 11, further comprising: an evacuation gas line (G22) connected to at least one of the entry section and the middle section of the mixing chamber; anda gas evacuation valve (VG6) connected to the evacuation gas line to selectively allow gas to be evacuated from the mixing chamber;wherein the computer (COMP) is programmed to cause the system to selectively occupy one of a plurality of valve states, including:a start-up valve state (2G(1)) in which: the first and second isolation valves (VG1, VG2) are closed,the gas evacuation valve (VG6) is closed, andthe entry section gas input valve (VG3), the middle section gas input valve (VG4), and the exit section gas input valve (VG5) are open,so that mixing gas entering the mixing chamber at a pressure sufficient to isolate the entry and/or middle sections from a first reactor (100) to which the feedstock delivery system is connected;a normal operation valve state (2G(2)) in which: the first and second isolation valves (VG1, VG2) are open, the gas evacuation valve (VG6) is closed, andat least one of the entry section gas input valve (VG3), the middle section gas input valve (VG4), and the exit section gas input valve (VG5) is open,so that mixing gas entering the mixing chamber mixes with carbonaceous material to form a carbonaceous material and gas mixture which then leaves the mixing chamber via the mixing chamber output, anda shut down valve state (2G(3)) in which: the first and second isolation valves (VG1, VG2) are closed,the gas evacuation valve (VG6) is open, andthe entry section gas input valve (VG3), the middle section gas input valve (VG4), and the exit section gas input valve (VG5) are open,so that mixing gas entering the mixing chamber is at a pressure sufficient to isolate the entry and/or middle sections from a first reactor (100) to which the feedstock delivery system is connected, and purge residual particulate matter within the mixing chamber through the evacuation gas line. 14. The liquid fuel production system according to claim 11, wherein, when the first isolation valve (VG1) and second isolation valve (VG2) are closed, the computer (COMP) is programmed to: cause mixing gas to be introduced into the entry section (G21) of the mixing chamber (G00) via the entry section gas input (G08);receive the differential pressure sensor signal (XDPG) from the differential pressure sensor (DPG), the differential pressure sensor signal being reflective of a differential pressure between the entry section (G21) and the exit section (G19);compare the differential pressure sensor signal (XDPG) to a pre-determined differential pressure threshold; andbased on the result of comparing, output a signal to open the first and second isolation valves. 15. The feedstock delivery system according to claim 10, wherein: the gas and carbonaceous material mixing system (2G1) further comprises a restriction (RO-G) positioned between the source of mixing gas (2G-03) and the mixing chamber gas input (G08, G08A, G08B, G08C);the source of mixing gas is carbon dioxide produced by a secondary gas clean-up system (6000);the carbon dioxide passes through the restriction (RO-G) before entering the mixing chamber (G00) via a mixing chamber gas input; anda pressure drop of the carbon dioxide across the restriction (RO-G) ranges from about 50 psig to about 2000 psig.
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