United States Patent Application: 0100285576
We struggled a bit trying to compose a colorful and attention-grabbing way of introducing what we present in this dispatch: a more productive and CO2-free way of converting our abundant Coal into liquid hydrocarbons.
But, if a simple and straightforward statement of the truth isn't enough to gain the notice of the political leaders and the public voices of US Coal Country, then we US Coal Country citizens, as a people, as a community, have far, far deeper problems than constraints on our supply of Oil, or some conjectural "War On Coal" spun up in the public press cotton candy machine to attract shallow attention and sell papers.
We can economically convert our abundant Coal into any sort of liquid hydrocarbon fuel we choose; and, we can do so in a way that isn't just "Carbon-neutral", but, could, depending upon how we chose to configure the process, be both "Carbon-negative" and, for all practical purposes, just about infinitely sustainable.
Moreover, an additional fact that should lend some credence to that statement is this:
We aren't being told, at long last, that truth - - that, apparently inconvenient, or uninteresting, for the Coal Country press, truth - - by a Coal industry scientist or Coal state educational institution research facility.
It is coming to us straight from what one would suppose to be one of the environmentally-conscious, but dark, hearts of our Coal Country press corps' fast-becoming-trite "War On Coal": Southern California.
First, we remind you that we have previously cited the California Carbon conversion scientist who is the focus of this dispatch.
In several of our reports:
West Virginia Coal Association | California Synfuels from Coal and Carbon-Recycling Wastes | Research & Development; concerning: "United States Patent 7,208,530 - Production of Synthetic Transportation Fuels (via) Self-Sustained Hydro-Gasification; 2007; Inventors: Joseph Norbeck, et. al.; Assignee: The Regents of the University of California; Abstract: A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. A slurry of particles of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor under conditions whereby methane rich producer gases are generated and fed into a steam pyrolytic reformer under conditions whereby synthesis gas comprising hydrogen and carbon monoxide are generated. A portion of the hydrogen generated by the steam pyrolytic reformer is fed through a hydrogen purification filter into the hydro-gasification reactor, the hydrogen therefrom constituting the hydrogen from an internal source. The remaining synthesis gas generated by the steam pyrolytic reformer is either used as fuel for a gaseous fueled engine to produce electricity and/or process heat or is fed into a Fischer-Tropsch or similar reactor under conditions whereby a liquid fuel is produced"; and:
West Virginia Coal Association | California Hydrogasifies Coal & Carbon-Recycling Wastes | Research & Development; concerning: "United States Patent 7,500,997 - Steam Pyrolysis ... to Enhance the Hydro-Gasification of Carbonaceous Materials; 2009; Inventors: Joseph Norbeck, et. al.; Assignee: The Regents of the University of California; Abstract: A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. In one embodiment, a slurry of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor to generate methane rich producer gases which are fed into a steam pyrolytic reformer to generate synthesis gas comprising hydrogen and carbon monoxide. A portion of the hydrogen is used as the internal hydrogen source. The remaining synthesis gas is either used as fuel to produce electricity and/or process heat or is fed into a Fischer-Tropsch reactor to produce liquid fuel" and:
West Virginia Coal Association | California Coal, Biomass and Waste Plastic to Hydrocarbons | Research & Development; concerning: "United States Patent 7,897,649 - Steam Methane Reformer (utilizing) Gas from Steam Hydro-Gasification; 2011; Inventors: Joseph Norbeck, et. al.; Assignee: The Regents of the University of California; Abstract: An improved, economical alternative method to supply steam and methane to a steam methane reformer (SMR) is accomplished by a combination of procedures, wherein product gas from a steam hydro-gasification reactor (SHR) is used as the feedstock for the SMR ... . A process for converting carbonaceous material to synthesis gas ... comprising hydrogen and carbon monoxide is generated at a ratio of between 2:1 and 6:1. The process ... wherein the carbonaceous material comprises municipal waste, biomass, wood, coal, or a natural or synthetic polymer";
we saw that University of California system scientist Joe Norbeck, and an eclectic group of colleagues, has been at work for a number of recent years establishing a rather complete and comprehensive technology that would enable us to start converting our abundant Coal, along with a wide variety of renewable organic materials, into a variable Carbon Monoxide-Hydrogen ratio synthesis gas perfectly suited compositionally for "Fischer-Tropsch or similar" catalytic chemical condensation into a full range of liquid hydrocarbon fuels.
One subtle key to the good work of Norbeck and friends is the employment of "steam pyrolytic" and "steam methane" reformers, wherein, especially Methane, as can be generated as one "product gas from a steam hydro-gasification reactor", as perhaps better described in our reports of:
West Virginia Coal Association | Consol 1970 Coal + Steam = Methane + Syngas | Research & Development; concerning: "United States Patent 3,503,724 - Producing Mixtures of Methane, Carbon Monoxide and Hydrogen; 1970; Assignee: Consolidation Coal Company, Pittsburgh; This application relates to the production of mixtures of methane, carbon monoxide and hydrogen which are particularly suitable for the preparation of high Btu gas from carbonaceous material such as coal"; and:
GE Converts Coal to Methane and Recycles Carbon for USDOE | Research & Development; concerning: "United States Patent 4,558,027 - Catalysts for Carbon and Coal Gasification; 1985; Inventors: Douglas McKee, et. al., NY (All employees of General Electric Company); Assignee: The United States of America; The invention relates to improved catalysts for carbon and coal gasification and improved processes for catalytic, coal gasification. The United States Government has rights in this invention pursuant to Contract No. DE-AC21-80MC14591 between the U.S. Department of Energy and General Electric Co. Abstract: Catalyst for the production of methane from carbon and/or coal by means of catalytic gasification";
can then itself be reacted with Steam to form Hydrogen and a relatively smaller amount of Carbon Monoxide, as described in:
Fossil fuel reforming - Wikipedia, the free encyclopedia; "steam reacts with methane to yield carbon monoxide and hydrogen. CH4 + H2O = CO + 3H2".
The additional, extra amount of Hydrogen generated by the SMR is needed to mix in with the Hydrogen and Carbon Monoxide generated by the Coal/Carbon gasification, so that syngas better suited for the catalytic synthesis of hydrocarbons can be blended.
Both the initial Coal, and renewable waste Carbon resource, gasification, and, to a lesser extent, though not reflected in the above Wikipedia information, Steam Methane Reforming, "SMR", result in the co-production of some, perhaps minimal, amount of Carbon Dioxide; that due especially to the fact that some significant heat energy, typically through, in both processes, oxidation, must be generated to drive the reactions between both Coal, or Carbon, and Methane, with Steam to generate the Carbon Monoxide, CO, and the Hydrogen, H2.
And, herein, we see that Joe Norbeck & Company have that base covered, as well, in a way that provides additional, as in his above "United States Patent 7,897,649 - Steam Methane Reformer (utilizing) Gas from Steam Hydro-Gasification", "biomass" to be initially gasified with the Coal.
Comment and additional links follow and are inserted within excerpts from the initial link in this dispatch to:
"United States Patent Application 20100285576 - Method to Produce Synthesis Gas or Liquid Fuels from Commingled Algae and Coal Feedstock Using a Steam-Hydrogasification Reactor and a Steam Methane Reformer with CO2 Utilization Through an Algae Farm
Date: November, 2010
Inventors: Joseph M. Norbeck, et. al., CA
(Presumed Assignee: The Regents of the University of California)
Government Interests: This invention was made with support from the City of Riverside, Calif. The City of Riverside has certain rights in this invention.
This invention involves the conversion of coal-algae ... commingled slurry feedstock into a high methane content product gas using a steam hydrogasification process. This gas is then reformed into synthesis gas (H2 and CO). Excess H2 from the synthesis gas is separated and recycled back to the gasifier. The synthesis gas is converted into a liquid fuel such as Fischer-Tropsch diesel. The CO2 emissions from the steam hydrogasification process can be captured and used to grow the algae, which can subsequently be commingled with coal ... to form slurry feedstocks for the hydrogasifier. Thus, this process eliminates CO2 emissions from the conversion plant.
(We are compelled to interrupt here at some unfortunately tedious length. First, this CO2-recycling Coal conversion process is quite similar in concept to another about which we recently reported, as in:
West Virginia Coal Association | Coal + Biomass to Liquids, with Algae CO2 Recycling | Research & Development; concerning: "United States Patent Application 20120144887 - Integrated Coal to Liquids Process and System with CO2 Mitigation Using Algal Biomass; 2012; Assignee: Accelergy Corporation, Houston; Abstract: An ICBTL (Integrated Coal and Biomass To Liquids) system having a low GHG footprint for converting coal or coal and biomass to liquid fuels in which a carbon-based feed is converted to liquids by direct liquefaction and optionally by indirect liquefaction and the liquids are upgraded to produce premium fuels. CO2 produced by the process is used to produce algal biomass and photosynthetic microorganisms in a photobioreactor. Optionally, lipids extracted from the some or all of the algal biomass is hydroprocessed to produce fuel components and biomass residues and the carbon-based feed (are) gasified to produce hydrogen and syngas for the direct and indirect liquefaction processes. CO2 may also be produced by a steam methane reformer for supplying CO2 to produce the algal biomass";
and, we note that the link we included in that report to the US Patent and Trademark Office, USPTO, record of Application 20120144887 has, as with other links to USPTO records in other of our reports, not proven durable; and, now leads to another, unrelated US Patent Application. Following are two additional links to records of that US Patent Application on independent sites which, at the time of this transmission, functioned properly:
Integrated Coal To Liquids Process And System With Co2 Mitigation Using Algal Biomass - ACCELERGY CORPORATION
Integrated Coal To Liquids Process And System With Co2 Mitigation Using Algal Biomass - US Patent Application 20120144887 Clai.
And, while we're at it, just in case, here are two additional independent site links to records of our subject:
Method to produce synthesis gas or liquid fuels from commingled algae and coal feedstock using a steam-hydrogasification react
Method to produce synthesis gas or liquid fuels from commingled algae and coal feedstock using a steam-hydrogasification react.
They look identical, we know; but, they are links to records of our subject at two separate sites.)
Claims: A process of using algae from an algae farm as slurry feedstock for hydrogasfication and to capture carbon dioxide emissions during liquid fuel production comprising: providing a slurry feedstock to a hydrogasification reactor; heating the slurry feedstock with hydrogen, at a temperature and pressure sufficient to generate a stream of methane and carbon monoxide rich gas product; subjecting the resultant producer gas to steam methane reforming under conditions whereby synthesis gas comprising hydrogen, carbon monoxide and carbon dioxide is generated; providing an algae farm, and feeding the algae farm with the carbon dioxide generated from said steam reforming.
The process ... further comprising feeding the hydrogasfication reactor with the algae from the algae farm.
The process ... wherein the feedstock comprises of carbonaceous material and algae.
The process ... wherein the process is able to run solely/only on the H2, CO2, and water actually generated from the process itself.
The process ... wherein the carbonaceous material is selected from the group consisting of municipal waste, biomass, wood, coal, or natural or synthetic polymer.
The process ... further comprising feeding the synthesis gas into a Fischer-Tropsch reactor whereby liquid fuel, carbon dioxide, and water is generated.
The process further comprising recycling the water generated by the Fischer-Tropsch reactor into the hydrogasification reactor.
(The "carbon dioxide" "generated by the Fischer-Tropsch reactor" could, of course, be recycled to the "algae farm".)
The process ... further comprising a direct coal liquefaction process whereby liquid fuel and resid are generated.
The process ... further comprising feeding said resid into the hydrogasfication reactor.
(See, for example, our report of:
Consol Hydrogasifies CoalTL Residues | Research & Development; concerning: "United States Patent 4,248,605 - Gasification of Coal Liquefaction Residues; 1981; Assignee: Conoco, Inc., CT; Abstract: A method for gasifying the bottoms fraction from a coal liquefaction process".)
The process ... wherein the hydrogen generated from the steam reforming is recycled back into the steam hydrogasfication reactor.
The process ... wherein the hydrogen generated from the steam reforming is recycled back into the steam hydrogasfication reactor and direct coal liquefaction process.
(Note that this invention can, as well, be used in conjunction with and coupled to a "Direct", "DCL", as well as an "Indirect", "ICL", Coal liquefaction process, as for one example, seen in:
Exxon 1982 CoalTL Uses WVU CoalTL Hydrogen Donor Solvent | Research & Development; concerning: "United States Patent 4,345,989 - Catalytic Hydrogen-donor Liquefaction Process; 1982; Assignee: Exxon Research and Engineering Company; Abstract: Coal or a similar solid carbonaceous feed material is converted into lower molecular weight liquid hydrocarbons by contacting the feed material with a hydrogen-donor solvent containing above about 0.6 weight percent donatable hydrogen and molecular hydrogen in a liquefaction zone".)
The process ... wherein the hydrogasification process can occur in the absence of catalysts.
The process ... wherein the hydrogasification process can occur in the absence of oxygen.
A process for using algae in an algae farm comprising growing the algae using CO2 released from a syngas producing process, and feeding the algae as part of a slurry feedstock into the syngas producing process.
An apparatus for hydrogasification of carbonaceous material comprising: a hydrogasification reactor; a gas clean up unit; a steam methane reformer; and an algae farm.
The apparatus ... further comprising apparatuses used in a DCL process.
Background and Field: The invention relates to a steam hydrogasification process and apparatus utilizing commingled algae-carbonaceous material to generate synthesis gas or liquid fuels.
Summary: A method of using algae in an algae farm as slurry feedstock for steam hydrogasfication and to capture carbon dioxide emissions during liquid fuel production is provided that involves providing a slurry feedstock to a hydrogasification reactor; heating the slurry feedstock with hydrogen, at a temperature and pressure sufficient to generate a stream of methane and carbon monoxide rich gas product; subjecting the resultant producer gas to steam methane reforming under conditions whereby synthesis gas comprising hydrogen, carbon monoxide and carbon dioxide is generated; providing an algae farm, and feeding the algae farm with carbon dioxide generated from said steam reforming.
In another embodiment, a steam hydrogasification process is provided that combines the use of an algae farm and a direct coal liquefaction process, where resid generated by the liquefaction process can be commingled with algae to feed the steam hydrogasifier.
In yet another embodiment, a steam hydrogasification process is provided that combines the use of an algae farm and a direct coal liquefaction process, where resid generated by the liquefaction process can be commingled with algae to feed the steam hydrogasifier, and hydrogen generated by a steam methane reformer is fed into the liquefaction process.
The present invention is advantageous because it provides a flexible steam hydrogasification process that can:
1) utilize algae farms to form coal or resid-algae slurries as feedstock for steam hydrogasification;
2) utilize algae farms to capture carbon dioxide generated by the steam hydrogasification process; and:
3) generate hydrogen that can be fed to a direct coal liquefaction process."
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Again, note that Coal; carbonaceous residues from the separate direct Coal liquefaction, i.e., "resid"; and, Algae biomass can be combined in the initial "steam hydrogasification".
And, consider that could well be Algae biomass after, as in:
Illinois Algae Convert Flue Gas CO2 into $60 Oil for USDOE | Research & Development; concerning: "Removal of Carbon Dioxide from Flue Gases by Algae; 1993; Contract FC22-92PC92521; Institute of Gas Technology, Chicago; Sponsors: Illinois Dept. of Energy and Natural Resources, Springfield, IL (and) USDOE, Washington, DC; The objective of this research program is to determine the feasibility of the alga Botryococcus braunii as a biocatalyst for the photosynthetic conversion of flue gas CO2 to hydrocarbons. The feasibility and economic evaluation estimated the cost of oil produced from flue gas CO2 by algae to range between $45 and $75 per barrel"
their bio-lipids, synthesized from "flue gas CO2", had been extracted to make "oil (for) "between $45 and $75 per barrel".
Further, those Illinois Algae, above, were grown on regular old flue gas CO2, as we might get from one of our economically essential Coal-fired power plants; and, there seems no set ratio or limit in the process of our subject, "United States Patent Application 20100285576 - Method to Produce Synthesis Gas or Liquid Fuels from Commingled Algae and Coal Feedstock", on the relative amounts of Coal and Algae that can be blended into the initial gasification "Feedstock".
So, it seems perfectly feasible to us that a plant operating the process of "United States Patent Application 20100285576", and making liquid hydrocarbon fuels out of Coal and Algae, a Coal conversion plant that had recycled it's own Carbon Dioxide with Algae, could also take in and convert Algae biomass from a Coal-fired power plant right next door, or just down the river, where they had been capturing their CO2 and feeding it to Algae of their own, as per the Institute of Gas Technology's above scenario developed under contract to the USDOE and the government of President Obama's home state of Illinois, after they had extracted "$45" to "$75 per barrel" Oil from that Algae.
Of course, the only way we would know any of that for certain is if one of our Coal Country news hounds got off their cans and got on the phone to California, and asked Joe the Carbon Conversion Chemist all about it.