United States Patent: 8268896
Just yesterday, September 18, 2012, technical experts employed - - through our United States Government's Patent and Trademark Office - - by all United States citizens, again confirmed some key facts which we have previously documented for you.
As seen, for two examples, in our reports of:
West Virginia Coal Association | Eastman Coal to Methanol and Electric Power | Research & Development; concerning: "United States Patent Application 20060096298 - Method for Satisfying Variable Power Demand; 2006; Assignee: Eastman Chemical Company, TN; Abstract: A process for satisfying variable power demand and a method for maximizing the monetary value of a synthesis gas stream are disclosed. One or more synthesis gas streams are produced by gasification of carbonaceous materials and passed to a power producing zone to produce electrical power during a period of peak power demand or to a chemical producing zone to produce chemicals such as, for example, methanol, during a period of off-peak power demand. The power-producing zone and the chemical-production zone which are operated cyclically and substantially out of phase in which one or more of the combustion turbines are shut down during a period of off-peak power demand and the syngas fuel diverted to the chemical producing zone. This out of phase cyclical operational mode allows for the power producing zone to maximize electricity output with the high thermodynamic efficiency and for the chemical producing zone to maximize chemical production ... . The economic potential of the combined power and chemical producing zones is enhanced. A process for intermittently producing electrical power and chemicals (and) wherein said carbonaceous material is coal"; and:
West Virginia Coal Association | Germany Co-Produces Methanol & Power from Coal | Research & Development; concerning: "United States Patent 4,665,688 - Power Generating Station with Integrated Coal Gasification; 1987; Inventors: Ulrich Schiffers and Rainer Muller, Germany; Abstract: Power generating plant with an integratd coal gasification plant, with a heat exchanger and gas purification plant connected to the coal gasifier, with a gas turbine and steam power generating plant part connected to the heat exchanger and gas purification plant, and with a methanol synthesis plant";
it is perfectly feasible, through somewhat different optional strategies, to design a single, combined and integrated process that indirectly, through partial oxidation, converts Coal, through an initial production of synthesis gas, "syngas", a blend of Carbon Monoxide and Hydrogen, into both electricity and liquid hydrocarbon fuels.
We further remind you that we have many times cited the Coal conversion and Carbon Dioxide utilization technologies that have, over the course of decades, been established by what is known as the Gas Technology Institute, and it's two precedent organizations, the Institute of Gas Technology and the Gas Research Institute, in the state of Illinois.
A few examples would include:
West Virginia Coal Association | Chicago Gasifies Coal, and Recycles CO2 and Carbon for USDOE | Research & Development; concerning, in part: "United States Patent 5,092,984 - Pyrolysis of Coal; 1992; Assignee: Institute of Gas Technology, Chicago; Abstract: A method for mild gasification of crushed coal in a single vertical elongated reaction vessel ... . Government Interests: The U.S. Government has a paid-up license in this invention and rights as provided for by the terms of contract No. DE-AC21-87MC24266 awarded by the U.S. Department of Energy"; and:
West Virginia Coal Association | Chicago Converts CO2 to Methane | Research & Development; concerning: "United States Patent 3,766,027 - Method and Apparatus for CO(2) Conversion to Methane; 1973; Assignee: Institute of Gas Technology, Chicago; Abstract: A process of fixation and conversion of carbon dioxide from the atmosphere or other sources to produce methane and oxygen ... . A process for the conversion of carbon dioxide to methane"; and:
West Virginia Coal Association | Chicago CO2 + Methane = Hydrocarbons | Research & Development; concerning: "United States Patent 5,064,733 - Electrochemical Conversion of CO2 and CH4 to C2 Hydrocarbons; 1991; Assignee: Gas Research Institute, Chicago; Abstract: A solid electrolyte electrochemical cell and process for concurrent gas phase electrocatalytic oxidative dimerization of methane at one side of the solid electrolyte and reduction of carbon dioxide to gaseous hydrocarbon products at the opposite side of the solid electrolyte".
More about the Gas Technology Institute itself can be learned via:
Gas Technology Institute - Wikipedia, the free encyclopedia; "The Gas Technology Institute is an American non-profit research and development organization which develops, demonstrates, and licenses new energy technologies for private and public clients, with a particular focus on the natural gas industry. The Institute of Gas Technology was founded in 1941 at Illinois Institute of Technology. The Gas Research Institute was founded in 1976. In 2000, the Institute of Gas Technology and the Gas Research Institute combined to form the Gas Technology Institute."
As confirmed by our US Department of Energy, and their National Energy Technology Laboratories, via:
NETL: Gasification; "High Temperature Syngas Cooling and Heat Recovery; Synthesis gas (syngas) leaving the reactor is at high temperature; typically 2,500°F to 2,800°F for an entrained-flow gasifier. It is desirable to recover some of the sensible heat from the syngas. Heat recovery systems can reclaim 5-25% of the energy in the feed, depending on the technology employed. The actual design of a syngas cooling and heat recovery system has to consider the characteristics of the coal feed, syngas produced, and the overall gasification process application";
the generation of hydrocarbon synthesis gas, via partial oxidation, from Coal, does generate a lot of heat; and, that heat not only represents a lot of energy that might otherwise be wasted, but, the catalytic chemical condensation of that Coal-derived synthesis gas, as via the Fischer-Tropsch process or related Methanol synthesis processes, is exothermic; that is, such chemical condensation of synthesis gas into hydrocarbons can, in some cases, generate heat in addition to the heat generated by the gasification.
And, to avoid damage to the catalytic reactors and for the sake of efficiency, it is desirable to extract at least some of the heat from the Coal-derived synthesis gas; and, as in especially the above-cited "United States Patent 4,665,688 - Power Generating Station with Integrated Coal Gasification", do something productive with that extracted heat.
Herein, we learn that the Gas Technology Institute, as just confirmed by the US Government, has further refined the principles embodied in our above-cited references to both: "United States Patent Application 20060096298 - Method for Satisfying Variable Power Demand" and "United States Patent 4,665,688 - Power Generating Station with Integrated Coal Gasification"; albeit through a somewhat different approach.
As seen, with one - we think pertinent - comment and reference inserted, in excerpts from the initial link in this dispatch to:
"United States Patent 8,268,896 - Co-production of Fuels, Chemicals and Electric Power
(Co-production of fuels, chemicals and electric power using gas turbines - Gas Technology Institute)
Date: September 18, 2012
Inventors: Arunabha Basu, et. al., Illinois
Assignee: Gas Technology Institute, Des Plaines, IL
Abstract: A method and system for co-production of electric power, fuel, and chemicals in which a synthesis gas at a first pressure is expanded using a stand-alone mechanical expander or a partial oxidation gas turbine, simultaneously producing electric power and an expanded synthesis gas at a second pressure after which the expanded synthesis gas is converted to a fuel and/or a chemical.
Claims: A method for co-production of fuels, chemicals, and electric power comprising the steps of: generating a pressurized synthesis gas having a first pressure and having a first temperature in a range of about 2200 F to about 2500 F; expanding said pressurized synthesis gas at said first temperature using a stand-alone mechanical expander or a partial oxidation gas turbine, simultaneously producing electric power and an expanded synthesis gas at a second pressure and a second temperature; and (then) converting said expanded synthesis gas to at least one of a fuel and a chemical.
The method ... wherein said pressurized synthesis gas is produced from a fuel and an oxidant introduced into a reactor vessel (and) wherein said oxidant is mixed with CO2.
(Please note, concerning the above and as per our introductory comments, and, as seen for just one example in:
Shell Oil Coal + CO2 + H2O = Hydrocarbon Syngas | Research & Development; concerning: "United States Patent 7,829,601 - Partial Oxidation Process of a Solid Carbonaceous Feed; 2010; Assignee: Shell Oil Company, Texas; Abstract: The invention is directed to a process for preparing a mixture comprising CO and H2 by operating a partial oxidation process of a solid carbonaceous feed (and) , which process comprises the steps of: (Supplying) the solid carbonaceous feed and an oxygen-containing stream to a burner, wherein a CO2 containing transport gas is used to transport the solid carbonaceous feed to the burner";
Carbon Dioxide, as recovered from whatever source, can be used, and consumed, along with Oxygen, as one of the agents of Coal gasification.)
The method ... wherein a CO2/O2 molar ratio is in the range of about 0.1 to about 2.0 (and, further) wherein said CO2/O2 molar ratio is in the range of about 0.9 to about 1.1.
(In other words, we can use and consume just as much CO2 as Oxygen in the initial gasification.)
The method ... wherein said oxidant is selected from the group consisting of air, oxygen, oxygen-enriched air, steam, and mixtures thereof.
(Oxygen is preferable, as we've separately documented, relative to "air", so that co-generation of undesirable oxides of Nitrogen is avoided - which wastes Oxygen, in any case. Note, however, the inclusion of "steam", H2O, which, as in:
Texaco 1951 Coal + CO2 + H2O + O2 = Syngas | Research & Development; concerning: "United States Patent 2,558,746 - Carbon Monoxide and Other Gases from Carbonaceous Materials; 1951; Assignee: The Texas Company; Abstract: This invention relates to a process and apparatus for the generation of gases comprising carbon monoxide from carbonaceous materials. In one of its more specific aspects it relates to a process and apparatus for the generation of a mixture of carbon monoxide and hydrogen, suitable as a feed for the synthesis of hydrocarbons, from powdered coal. The present invention is concerned with the generation of a mixture of carbon monoxide and hydrogen (and) is particularly suited to the production of a feed gas for the synthesis of hydrocarbons (and) the method and apparatus is especially useful when powdered coal is used as the feed material. In the gasification of carbonaceous material with oxygen, particularly solid fuels, the ... oxidation reaction, being highly exothermic, releases large quantities of heat (and) carbon dioxide ... in contact with hot carbon ... reacts with the carbon to produce carbon monoxide. Steam also reacts with heated carbon to produce carbon monoxide and hydrogen";
contributes to the production of needed Hydrogen.)
The method ... wherein said first pressure is greater than about 60 psig (and/or) wherein said first pressure is greater than about 1500 psig.
The method ... wherein said fuel (produced) is a Fischer-Tropsch liquid fuel (and) wherein a portion of said liquid fuel is introduced into a second partial oxidation reactor and converted to additional syngas, which additional syngas is recycled to a Fisher-Tropsch reactor used to produce said liquid fuel.
(We have seen similar recycling of the produced Fischer-Tropsch fuel specified in other, related disclosures of Coal conversion technology, but remain uncertain as to what advantage is gained.)
The method ... wherein said synthesis gas is introduced into a combustor and heated to an inlet temperature of said stand-alone mechanical expander or said partial oxidation gas turbine.
A method for co-production of fuels, chemicals, and electric power comprising the steps of:
- introducing a fuel, an oxidant, and CO2 into a reactor vessel, producing pressurized synthesis gas at a first pressure having a temperature in a range of about 2200 F to about 2500 F;
- expanding said pressurized synthesis gas at said temperature, simultaneously producing electric power and an expanded synthesis gas at a second pressure less than said first pressure and greater than one atmosphere;
- and converting said expanded synthesis gas to at least one of a fuel and a chemical.
Background and Field: This invention relates to a method and system for co-producing fuels, chemicals, and electric power. In one aspect, this invention relates to the use of mechanical expanders and gas turbines for co-producing fuels, chemicals, and electric power. In one aspect, this invention relates to the use of gas turbines for the production of synthetic gas, also referred to as syngas, and electric power, and the subsequent conversion of the syngas to various liquid fuels and/or chemicals.
Summary: (The) objects of this invention are addressed by a method for co-producing fuels, chemicals, and electric power in which a synthesis gas is generated in a reactor vessel, producing pressurized synthesis gas at a first pressure which is expanded using a stand-alone mechanical expander or partial oxidation gas turbine, simultaneously producing electric power and an expanded synthesis gas at a second pressure, and the expanded synthesis gas is converted to a fuel and/or a chemical. In contrast to a conventional gas turbine having a closed-coupled air compressor and expander system, the use of a stand-alone mechanical expander facilitates the generation of syngas at pressures substantially higher than about one atmosphere by employing significantly high back-pressures at the exit to the expander.
(An included illustration, not accessible via USPTO online records, diagrams the) co-production of fuels and electric power in accordance with (one) embodiment of this invention employing a stand-alone mechanical expander and coal or biomass gasification for syngas generation ... .
(Concerning the above, we remind you that, as seen, for one example, in:
West Virginia Coal Association | Exxon Co-Gasifies Coal and Carbon-Recycling Biomass | Research & Development; concerning: "United States Patent Application 20100083575 - Co-gasification Process for Hydrocarbon Solids and Biomass; 2010; Assignee: ExxonMobil Research and Engineering Company; Abstract: A process for the co-gasification of carbonaceous solids (coal) and biomass in which the ... heat required for pyrolyzing the biomass can conveniently be obtained from the heat exchanger used to cool the hot synthesis gas product emerging from the gasifier (and) wherein the solid carbonaceous particles comprise coal (and) wherein the biomass comprises biological matter selected from wood, plant matter, municipal waste, green waste, byproducts of farming or food processing waste, sewage sludge, black liquor from wood pulp, and algae";
it is perfectly feasible to co-gasify CO2-recycling botanical and other renewable organic wastes along with Coal, and to use the "heat ... obtained from the heat exchanger used to cool the hot synthesis gas product emerging from the gasifier", as specified by our subject, "United States Patent 8,268,896 - Co-production of Fuels, Chemicals and Electric Power", to be used in the generation of electricity, for other productive and synergistic purposes, as well.)
The invention claimed herein is a method and system for co-producing fuels, chemicals, and electric power in which pressurized synthesis gas at a first pressure is expanded using a stand-alone mechanical expander or partial oxidation gas turbine, simultaneously producing electric power and an expanded synthesis gas at a second pressure which is converted to a fuel and/or a chemical.
The synthesis gas, typically comprising substantial amounts of H2 and CO, may be produced by any means known to those skilled in the art including gasification of carbonaceous materials such as coal and biomass.
Various oxidants and oxygen carriers including oxygen-enriched air, oxygen, air, CO2, steam, and mixtures thereof may be employed.
The use of CO2 is particularly advantageous due to its higher molecular weight. Because gas turbines are "mass machines" with a specific volumetric throughput, using a higher molecular weight gas increases the machine's output. In addition, due to the higher molecular weight, CO2 has better heat transfer properties.
In accordance with one embodiment of this invention, the syngas is produced in a coal or biomass gasifier.
The hot syngas ... is introduced ... into a conventional stand-alone mechanical expander in which the syngas is expanded to co-produce electric power and a relatively cooled syngas (and, with some additional, specified conditioning) the syngas is converted to a liquid fuel, such as diesel, gasoline, ethanol or LPG, or the conditioned syngas may be provided to a syngas-to-chemical processing step in which the syngas is converted to a chemical, such as hydrogen, ammonia, methanol, etc.
(Another illustration diagrams) a method for co-producing fuels, chemicals, and electric power in accordance with one embodiment of this invention employing a partial oxidation reactor for generation of the hot syngas. Example calculations for this process are shown in (a table attached to the full document) and (an enclosed figure shows) a mixture of CO2 and O2, the components of which may be provided by any suitable source, such as: (1) CO2 recovered, for example, from power plants, and (2) a vacuum pressure swing adsorption (VPSA) unit or a cryogenic air separation unit (ASU) for supplying O2 ... (and, the) mixture is compressed in a CO2 - O2 compressor (as shown), producing a compressed mixture which is provided together with a fuel to a partial oxidation reactor ... in which the fuel is partially oxidized, producing a hot syngas."
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We do, of course, need a source of Oxygen to make this happen, and to enable the synthesis and production, via an initial partial oxidation of Coal and Biomass, with some added and included Carbon Dioxide, of a "hot syngas".
We suggest that, in addition to an "air separation unit (ASU) for supplying O2", some of the Oxygen could be made, as in:
USDOE Algae Recycle CO2 into Liquid Fuels | Research & Development; concerning: "Liquid Fuels from Microalgae; 1987; National Renewable Energy Laboratory (NREL), Golden, CO; USDOE; Abstract: The goal of the DOE/SERI Aquatic Species Program is to develop the technology to produce gasoline and diesel fuels from microalgae. A technical and economic analysis, "Fuels from Microalgae," demonstrates that liquid fuels can be produced from mass-cultured microalgae at prices that will be competitive with those of conventional fuels by the year 2010. The algae can be grown in large outdoor ponds, using the resources of sunlight, saline water, nitrogen, phosphorus, and carbon dioxide (and) can convert these raw materials into proteins, carbohydrates, and lipids. Analysis of fuel conversion options for microalgae biomass has demonstrated that the promise of microalgae for fuel production is best realized through using conversion processes based on cellular lipids. The two most promising fuel conversion options are transesterification to produce fuels similar to diesel fuels and catalytic conversion to produce gasoline. Although microalgae lipids represent the premium energy product, the energy trapped in the other biomass constituents can also be used; e.g., the cell residue after lipid extraction";
by Algae, during the normal course of their photosynthetic metabolism, while they were consuming "carbon dioxide", and, in addition to the needed Oxygen, were also making "cellular lipids" which can be processed via "transesterification to produce fuels similar to diesel fuels and" via "catalytic conversion to produce gasoline", and, at the same time, "other biomass constituents ... the cell residue", which could, via the processes of the above-cited "US Patent Application 20100083575 - Co-gasification Process for Hydrocarbon Solids and Biomass" and "US Patent 7,829,601 - Partial Oxidation Process of a Solid Carbonaceous Feed", in combination with the process of our subject, "United States Patent 8,268,896", be converted, along with some of our abundant Coal and a little of our some-say too abundant Carbon Dioxide, into "Fuels, Chemicals and Electric Power".
