US Navy May 7, 2013, CO2 to Liquid Hydrocarbon Fuels

United States Patent: 8435457

Carbon Dioxide, on a practical basis, can be reclaimed from our environment and then be converted, recycled, into liquid hydrocarbon fuels.

If you've followed our posts at all over the years, you will know that fact has been well-established by at least one impeccable source: The United States Navy.

And, if you still don't believe it, we'll resist the urge to say "go tell it to the Marines", and, instead, direct you to the perhaps less bellicose West Virginia Coal Association, and their web site search engine:

West Virginia Coal Association | Research & Development | Table.

Simply go there, type the word "Navy" in the "Title Filter" box, hit "enter", and see what you get.

Among the results will be:

West Virginia Coal Association | US Navy 2008 CO2 to Synfuel | Research & Development; concerning: "United States Patent 7,420,004 - Producing Synthetic Liquid Hydrocarbon Fuels; 2008; Inventors: Dennis Hardy and Timothy Coffey; Assignee: The USA, as represented by the Secretary of the Navy; Abstract: A process for producing synthetic hydrocarbons that reacts carbon dioxide, obtained from seawater or air, and hydrogen obtained from water, with a catalyst in a chemical process such as reverse water gas shift combined with Fischer Tropsch synthesis. The hydrogen is produced by ... (a) source that is fossil fuel-free, such as wind or wave energy. The process can be either land based or sea based. A system for producing synthetic hydrocarbons, comprising: (a) a unit for recovering carbon dioxide from seawater, air, or a combination thereof; (b) a unit for producing hydrogen from water; and (c) a Fischer Tropsch synthesis unit wherein ... methanol production is combined with Fischer Tropsch synthesis to produce said hydrocarbons from said carbon dioxide and said hydrogen"; and:

West Virginia Coal Association | The US Navy Recycles CO2 into Liquid Hydrocarbo?n Fuels | Research & Development; concerning: "United States Patent 8,017,658 - Synthesis of Hydrocarbons via Catalytic Reduction of CO2; 2011; Inventors:Nick Tran, Dennis Hardy, et. al.; Assignee: The United States of America as represented by the Secretary of the Navy; Abstract: A method of: introducing hydrogen and a feed gas containing at least 50 % carbon dioxide into a reactor containing a Fischer-Tropsch catalyst; and heating the hydrogen and carbon dioxide to a temperature of at least about 190 C. to produce hydrocarbons in the reactor. An apparatus having: a reaction vessel for containing a Fischer-Tropsch catalyst, capable of heating gases to at least about 190 C.; a hydrogen delivery system feeding into the reaction vessel; a carbon dioxide delivery system for delivering a feed gas containing at least 50 % carbon dioxide feeding into the reaction vessel; and a trap for collecting hydrocarbons generated in the reaction vessel".

There will be quite a few more that come up, as well; and, there are more on the way.

Make no mistake; and, don't be misled or deceived.

Although other, less-noble. groups and organizations, as seen in:

West Virginia Coal Association | CO2 and The Price fo Willful Ignorance | Research & Development; which centered on the essay: "'Carbon Tax Revenue and the Budget Deficit: A Win-Win-Win Solution?' (There's an unseen "LOSE" in that title, as well. But it, apparently, like us, doesn't count.); 2012; MIT Joint Program on the Science and Policy of Global Change; Abstract: Bush-era tax cuts are scheduled to expire at the end of 2012, leading to interest in raising revenue through a carbon tax. This revenue could be used to either cut other taxes or to avoid cuts in Federal programs";

hope and anticipate that we will remain economically enslaved to OPEC for our supply of liquid hydrocarbon fuels; and, that, extraordinary taxes can be applied to the producers and consumers of economical and abundant Coal-based electrical power, with the money thereby extracted applied to coveted government programs of social re-engineering conceived of in ivory towers with no real connection to the real world,

the United States Navy, thank Heaven, has demonstrated, and continues to demonstrate, the simple fact, to repeat our opening line, that:

Carbon Dioxide, on a practical basis, can be reclaimed from our environment and then be converted, recycled, into liquid hydrocarbon fuels.

And, that simple fact was demonstrated to us again just yesterday, while we were at work on a report concerning a somewhat different Coal-related topic, when the United States Patent and Trademark Office published, as excerpted from the initial link in this dispatch:

"United States Patent 8,436,457 - Synthesis of Hydrocarbons Via Catalytic Reduction of CO2

Synthesis of hydrocarbons via catalytic reduction of CO2

Date: May 7, 2013

Inventors: Nick Tran, Dennis Hardy, Samuel Lambrakos, John Michopoulos; DC, MD and VA

(We're listing all the inventors, which we don't usually do, since this is the same team who gave us "United States Patent 8,017,658 - Synthesis of Hydrocarbons via Catalytic Reduction of CO2"; and, we assure you, we will be hearing from them all again in coming reports. This isn't over.)

Assignee: The United States of America, as represented by the Secretary of the Navy

Abstract: A method of: introducing hydrogen and a feed gas containing at least 50 vol % carbon dioxide into a reactor containing a Fischer-Tropsch catalyst; and heating the hydrogen and carbon dioxide to a temperature of at least about 190 C to produce hydrocarbons in the reactor. An apparatus having: a reaction vessel for containing a Fischer-Tropsch catalyst, capable of heating gases to at least about 190 C; a hydrogen delivery system feeding into the reaction vessel; a carbon dioxide delivery system for delivering a feed gas containing at least 50 vol % carbon dioxide feeding into the reaction vessel; and a trap for collecting hydrocarbons generated in the reaction vessel.

(The full Disclosure of our subject, "United States Patent 8,436,457" will read very much like that of the earlier "United States Patent 8,017,658 - Synthesis of Hydrocarbons via Catalytic Reduction of CO2". They, and related US Navy technologies for which US Patents have been applied, are closely similar. The differences, as we, with our limitations and our reduced team of advisors read it, lie in the specification of different catalysts and catalyst configurations, and perhaps a few other things. We, simply, aren't qualified to attempt explanation of the distinctions. However, as seen in our report of:

West Virginia Coal Association | US Navy Announces $3/Gallon Jet Fuel from CO2 | Research & Development; concerning the official US Naval Research Laboratory news release, which presumably went out on the wires: "'Fueling the Fleet, Navy Looks to the Seas'; September 24, 2012; Refueling U.S. Navy vessels, at sea and underway, is a costly endeavor in terms of logistics, time, fiscal constraints and threats to national security and sailors at sea. The U.S. Naval Research Laboratory (NRL) is developing the chemistry for producing jet fuel from renewable resources in theater. The process envisioned would catalytically convert CO2 and H2 directly to liquid hydrocarbon fuel ... . Scientists at the U.S. Naval Research Laboratory (NRL) are developing a process to extract carbon dioxide (CO2) and produce hydrogen gas (H2) from seawater, subsequently catalytically converting the CO2 and H2 into jet fuel";

the Navy isn't shy about broadcasting the news. Why a genuine and responsible US Coal Country journalist, who's readership is in large part reliant on the Coal industry for their livelihoods, and which livelihoods are threatened by Cap and Trade Carbon taxation, hasn't recruited a local Coal Country academic expert to assist in translation, and made a visit, with the expert in tow, to the US Naval Research Laboratory to make direct inquiry and seek full explanation, is beyond understanding.

Further, we note, that, at this point in full United States patent disclosure documents, as accessible via the links, a collection of references to prior art, related US, and sometimes foreign, patents, is included. Among the prior United States patents cited by the US Navy herein, as prior art, are those seen in our reports of:

West Virginia Coal Association | Grumman Aerospace Recycles CO2 | Research & Development; concerning: "United States Patent 4,282,187 - Hydrocarbons from Air, Water and Low Cost Electrical Power; 1981; Inventor: Assignee: Grumman Aerospace Corporation; Abstract: A process for manufacturing synthetic hydrocarbons such as gasoline and/or kerosene from the synthesis of carbon dioxide and hydrogen. The carbon dioxide is obtained from the atmosphere while the hydrogen is obtained during the electrolysis of water"; and:

West Virginia Coal Association | Exxon Recycles CO2 to Gas and Liquids | Research & Development; concerning: "US Patent 5,140,049 - Method for Producing Olefins from H2 and CO2; 1992; Assignee: Exxon Research and Engineering Company; Abstract: This invention relates to a process for producing C2 -C20 olefins from a feed stream consisting of H2 and CO2 using an iron-carbide based catalyst".)

Claims: An apparatus comprising: a reaction vessel containing a kieselguhr supported catalyst comprising cobalt, potassium, thorium, and magnesium, capable of heating gases contained therein to at least about 190 C; a hydrogen delivery system feeding into the reaction vessel; a carbon dioxide delivery system feeding into the reaction vessel that delivers a feed gas containing at least 50 vol % carbon dioxide; and a trap that collects hydrocarbons generated in the reaction vessel; wherein the hydrogen delivery system extracts hydrogen from water or the carbon dioxide delivery system extracts carbon dioxide from seawater.

(Diatomaceous earth - Wikipedia, the free encyclopedia; "Diatomaceous earth ...also known as ... kieselgur/kieselguhr, is a naturally occurring, soft, siliceous sedimentary rock that is easily crumbled into a fine white to off-white powder. It is used as (among other things, a) porous support for chemical catalysts".)

The ... carbon dioxide delivery system extracts carbon dioxide from seawater; and wherein the hydrogen delivery system produces hydrogen as a product of a process.

(For some examples of the above, see:

West Virginia Coal Association | US Navy Recovers Environmental CO2 for Hydrocarbon Synthesis | Research & Development; "United States Patent 8,313,557 - Recovery of CO2 from Seawater/Aqueous Bicarbonate Systems; 2012; Assignee: The United States of America as Represented by the Secretary of the Navy; Abstract: The present invention is generally directed to a system for recovering CO2 from seawater or aqueous bicarbonate solutions using a gas permeable membrane with multiple layers. At elevated pressures, gaseous CO2 and bound CO2 in the ionic form of bicarbonate and carbonate diffuse from the seawater or bicarbonate solution through the multiple layers of the membrane. Also disclosed is the related method of recovering CO2 from seawater or aqueous bicarbonate solutions"; and:

West Virginia Coal Association | USDOE Efficient Hydrogen for Liquid Fuel Synthesis | Research & Development; concerning: "United States Patent Application 20120149789 - Apparatus and Methods for the Electrolysis of Water; 2012; Assignee: UT-Battelle, LLC; Oak Ridge, TN (Oak Ridge National Laboratory; the USDOE); An apparatus for the electrolytic splitting of water into hydrogen and/or oxygen".)

The apparatus ... wherein the hydrogen delivery system extracts hydrogen from water; and wherein the carbon dioxide delivery system produces carbon dioxide as a product of a process.

(See, for one example:

West Virginia Coal Association | 2011 Efficient Extraction of Flue Gas CO2 | Research & Development; concerning: "United States Patent 7,927, 572 - Purifying Carbon Dioxide and Producing Acid; 2011; Assignee: Praxair Technology, Inc.; Abstract: Carbon dioxide is purified by processes employing NOx-rich sulfuric acid that can be formed by removal of SO2 from the carbon dioxide. Claims: A process for treating gaseous carbon dioxide ... wherein said gaseous feed stream of carbon dioxide is formed by combustion (and) recovering product sulfuric acid. The invention is useful in treatment of gaseous carbon dioxide streams which may be obtained in many ways. In particular, gaseous carbon dioxide streams with which the invention is useful include those produced by combustion, especially flue gas streams produced by combustion of hydrocarbonaceous fuels such as coal ... which upgrades the purity of the carbon dioxide and produces a product stream having a desired high carbon dioxide level (95 to 99.9%)".)

The apparatus ... wherein the carbon dioxide delivery system extracts carbon dioxide from air.

(See, for just one example:

West Virginia Coal Association | US Navy and Columbia University Recycle Atmospheric CO2 | Research & Development; concerning, in part: "United States Patent 7,833,328 - Scrubber for Capturing Carbon Dioxide from Air; 2010; Assignee: Columbia University; Abstract: The present invention is ... adapted to remove carbon dioxide from open air under ambient conditions".)

Description and Field: The invention is generally related to hydrocarbon synthesis. 

There are several well-established processes for direct hydrogenation of gases such as CO or CO2 to produce hydrocarbon fuels. One of the most successful was developed in Germany in the 1920's by Franz Fischer and Hans Tropsch.

In 1938, early German plants produced 591,000 metric tons per year ... of oil and gasoline using the Fischer-Tropsch process, which reacts carbon monoxide and hydrogen with a catalyst to produce liquid hydrocarbons and water.

(Fischer–Tropsch process - Wikipedia, the free encyclopedia; The Fischer–Tropsch process ... converts a mixture of carbon monoxide and hydrogen into liquid hydrocarbons (and) produces a synthetic lubrication oil and synthetic fuel, typically from coal.)

Additionally, well-known methods have been developed to produce methanol from carbon dioxide and hydrogen.

(Concerning the above statement, see, for just two examples, our reports of:

West Virginia Coal Association | USDOE Converts 100% of Power Plant CO2 to Methanol | Research & Development; concerning: "Brookhaven National Laboratory Report Number 63316; The Carnol Process System for CO2 Mitigation and Methanol Production; Meyer Steinberg, Department of Advanced Technology, Brookhaven National Laboratory; Abstract - The feasibility of an alternative CO2 mitigation system and a methanol production process is investigated. The Carnol system has three components: (i) a coal-fired power plant supplying flue gas CO2, (ii) the Carnol process which converts the CO2 with H2...to methanol, (iii) use of methanol as a fuel component in the automotive sector. The Carnol system is technically feasible and economically competitive with alternative CO2-disposal systems for coal-fired power plants (and) is estimated to be economically attractive compared to the current market price of methanol"; and:

West Virginia Coal Association | Even More California 2009 CO2 to Methanol | Research & Development; concerning: "United States Patent 7,605,293 - Efficient and Selective Chemical Recycling of Carbon Dioxide to Methanol, Dimethyl Ether and Derived Products; 2009; Inventors: George Olah and G.K. Surya Prakash; 
Assignee: University of Southern California; Abstract: An environmentally beneficial method of producing methanol from varied sources of carbon dioxide including flue gases of fossil fuel burning powerplants".)

Summary: The invention comprises a method comprising: introducing hydrogen and a feed gas containing at least 50 vol % carbon dioxide into a reactor containing a Fischer-Tropsch catalyst; and heating the hydrogen and carbon dioxide to a temperature of at least about 190 C to produce hydrocarbons in the reactor. 

The invention further comprises an apparatus comprising: a reaction vessel for containing a Fischer-Tropsch catalyst, capable of heating gases contained therein to at least about 190 C; a hydrogen delivery system feeding into the reaction vessel; a carbon dioxide delivery system for delivering a feed gas containing at least 50 vol % carbon dioxide feeding into the reaction vessel; and a trap for collecting hydrocarbons generated in the reaction vessel.

The method involves the reaction of hydrogen and carbon dioxide using a Fischer-Tropsch catalyst to produce hydrocarbons. One possible reaction equation is shown below. The reaction is exothermic ... .

Fischer-Tropsch catalysts are known in the art ... . Such catalyst include, but are not limited to, platinum group metals, ruthenium, rhodium, cobalt, nickel, iron, molybdenum, tungsten, palladium, platinum, iridium, rhenium, osmium, and any such metals on a support such as alumina, kieselguhr, zeolite, silica, and titanium dioxide. One example catalyst is a kieselguhr supported cobalt-based catalyst (KCBC) containing kieselguhr, cobalt, magnesium, thorium, and optionally potassium. KCEC may also be doped with palladium and ruthenium. 

The hydrogen and carbon dioxide can be introduced into the reactor in gaseous form.

The carbon dioxide feed gas contains at least 50, 75, 90, or 99 vol % carbon dioxide.

Any means of delivering the gas may be used, including but not limited to, from a gas cylinder or as the product of another process. For example, the hydrogen may be extracted from water or seawater by electrolysis. The carbon dioxide may be extracted from the ambient air or from sea water.

Hydrogen and carbon dioxide that are not directly derived from fossil fuels may be used.

The reaction may take place with little to no carbon monoxide or methanol in the feed gas (and) may occur in a single vessel in one step. 

The hydrocarbons can be collected in a trap and cooled to liquid or solid form. The product may be a waxy substance containing high molecular weight hydrocarbons. The hydrocarbons may contain hydroxyl, carbonyl, and carboxyl groups. The waxy material can be refined to produce hydrocarbon fuels."

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In sum, and to extrapolate only a little:

We the People, through our US Government, as our Government is embodied in the US Navy, now have the tools in hand to free our vital Coal and Coal-use industries, and their customers, from the venal, duplicitous threat of Cap and Trade CO2 taxation; and, to free our entire nation, all of our people, from the chains of economic, diplomatic and military enslavement to the often less than admirable foreign nations of OPEC.

That fact was confirmed, as herein, just the day before yesterday by an independent technical assessment branch of our US Government, through their issuance of "United States Patent 8,436,457 - Synthesis of Hydrocarbons Via Catalytic Reduction of CO2".