Improved biomass-gasification methods and apparatus are described, for cooling hot syngas without relying on recycling cool syngas. In some variations, methods are provided for producing cooled syngas from a carbon-containing feedstock, comprising: gasifying the feedstock; feeding hot gas along with liquid water to a cooling device to accomplish humidification, thereby reducing the temperature (but not the enthalpy) of the hot gas; and then feeding the stream to a waste-heat recovery unit to recover energy and produce cool syngas. The invented methods and apparatus can prevent fouling of waste-heat recovery units. Additionally, these methods allow for effective management of tars produced during biomass gasification as well as improved water management.
The present invention provides a process for producing gasoline components from syngas. Syngas is converted to one or more of methanol, ethanol, mixed alcohols, and dimethyl ether, followed by various combinations of separations and reactions to produce gasoline components with oxygenates, such as alcohols. The syngas is preferably derived from biomass or another renewable carbon-containing feedstock, thereby providing a biorefining process for the production of renewable gasoline.
C10G 2/00 - Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
C10L 1/06 - Liquid carbonaceous fuels essentially based on blends of hydrocarbons for spark ignition
C07C 1/04 - Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon from oxides of carbon from carbon monoxide with hydrogen
3.
METHODS OF MAKING IMPROVED COBALTMOLYBDENUM-SULFIDE CATALYST COMPOSITIONS FOR HIGHER ALCOHOL SYNTHESIS
This invention improves prior methods of making cobalt-molybdenum- sulfide catalysts for alcohol production from syngas. In one aspect, improved methods are provided for making preferred cobalt-molybdenum-sulfϊde compositions. In another aspect, processes utilizing these catalysts for producing at least one C1-C4 alcohol, such as ethanol, from syngas are described.
C07C 29/156 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the catalyst used containing iron group metals, platinum group metals, or compounds thereof
The present invention provides several variations for converting biomass, and other carbon-containing feedstocks, into syngas. Some variations include pyrolyzing or torrefying biomass in a devolatilization unit to form a gas stream and char, and gasifying the char. Other variations include introducing biomass into a fluid-bed gasifϊer to generate a solid stream and a gas stream, followed by a partial-oxidation or reforming reactor to generate additional syngas from either, or both, of the solid or gas stream from the fluid-bed gasifϊer. Hot syngas is preferably subjected to heat recovery. The syngas produced by the disclosed methods may be used in any desired manner, such as conversion to liquid fuels (e.g., ethanol).
C10J 3/00 - Production of gases containing carbon monoxide and hydrogen, e.g. synthesis gas or town gas, from solid carbonaceous materials by partial oxidation processes involving oxygen or steam
F25J 1/00 - Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
The present invention provides several variations for converting biomass, and other carbon-containing feedstocks, into syngas. Some variations include pyrolyzing or torrefying biomass in a devolatilization unit to form a gas stream and char, and gasifying the char. Other variations include introducing biomass into a fluid-bed gasifϊer to generate a solid stream and a gas stream, followed by a partial-oxidation or reforming reactor to generate additional syngas from either, or both, of the solid or gas stream from the fluid-bed gasifϊer. Hot syngas is preferably subjected to heat recovery. The syngas produced by the disclosed methods may be used in any desired manner, such as conversion to liquid fuels (e.g., ethanol).
C10J 3/00 - Production of gases containing carbon monoxide and hydrogen, e.g. synthesis gas or town gas, from solid carbonaceous materials by partial oxidation processes involving oxygen or steam
F25J 1/00 - Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
6.
PROCESS FOR COMBINED BIODIESEL AND ALCOHOL PRODUCTION, AND FUEL COMPOSITIONS PRODUCED THEREFROM
Improvements to biodiesel compositions, and methods for making those compositions more efficiently, are provided. Some variations of this invention provide processes for producing biodiesel and at least one C1-C4 alcohol, such as ethanol. Other variations provide certain biodiesel compositions containing C2+ alkyl esters. In some embodiments, biodiesel compositions are produced entirely from renewable resources.
The present invention provides methods to increase yields and selectivities to particular alcohols, such as ethanol, during alcohol synthesis from syngas. In some embodiments, a starting catalyst can be activated by contacting with a gas stream under certain preferred activation temperatures, pressures, and compositions.
C07C 29/153 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the catalyst used
8.
METHODS AND APPARATUS FOR SELECTIVELY PRODUCING ETHANOL FROM SYNTHESIS GAS
The invention provides methods and apparatus for selectively producing ethanol from syngas. As disclosed herein, syngas derived from cellulosic biomass (or other sources) can be catalytically converted into methanol, which in turn can be catalytically converted into acetic acid or acetates. Finally, the acetic acid or acetates can be reduced to ethanol according to several variations. In some embodiments, yields of ethanol from biomass can exceed 100 gallons per dry ton of biomass.
C10K 3/02 - Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
Improved methods of introducing promoters to catalysts are described. The present invention provides a convenient method of uniformly distributing a catalyst promoter, to provide for intimate contact between the promoter and the active catalyst sites. This intimate contact can enhance the activity and/or product selectivity of the promoted catalyst. In some embodiments, the method includes reacting an alkali metal with an alcohol in a non-aqueous medium, contacting the resulting solution with a starting catalyst, and depositing the alkali metal onto the starting catalyst to form an alkali-promoted catalyst.
C07C 29/153 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the catalyst used
10.
MULTI-ZONE REFORMING METHODS AND APPARATUS FOR CONVERSION OF DEVOLATILIZED BIOMASS TO SYNGAS
The present invention provides improved methods and apparatus for producing syngas from any carbon-containing feed material. In one aspect, a multi-zone reformer system is provided. A first reaction zone can reduce the presence of refractory tars, while a second reaction zone in communication with the first reaction zone can steam- reform methane and other components from the first reaction zone, to generate high- quality syngas suitable for conversion to liquid fuels, such as ethanol. Other embodiments employ a plurality of reaction zones for added system functionality.
C10J 3/00 - Production of gases containing carbon monoxide and hydrogen, e.g. synthesis gas or town gas, from solid carbonaceous materials by partial oxidation processes involving oxygen or steam
C10L 3/00 - Gaseous fuelsNatural gasSynthetic natural gas obtained by processes not covered by subclasses , Liquefied petroleum gas
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
11.
METHODS AND APPARATUS FOR SYNTHESIS OF ALCOHOLS FROM SYNGAS
This invention provides a method for producing ethanol and 2-propanol from syngas, the method comprising: (a) converting syngas into methanol using a methanol- synthesis catalyst; (b) converting methanol into ethylene and propylene using a methanol-to-olefms catalyst; and (c) hydrating ethylene into ethanol and propylene into 2-propanol. As taught herein, the combined yield of the ethanol and the 2- propanol from biomass can be at least 100 gallons per dry ton biomass. In certain embodiments, the yield of ethanol is at least 100 gallons per dry ton biomass. In some embodiments, the yield of 2-propanol is at least 50 gallons per dry ton biomass.
C07C 29/16 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by oxo-reaction combined with reduction
The present invention provides methods of intercalating a catalyst promoter to form a catalyst composition suitable for converting syngas into alcohols, such as ethanol. Effective conditions for promoter intercalation are provided herein. This invention also provides novel compositions that can be characterized by interplanar spacings of the promoter within the catalyst composition.
The invention herein provides methods of activating a catalyst composition. These methods include annealing a catalyst with an inert gas, under effective conditions, and then contacting the annealed catalyst with syngas to produce an activated catalyst. These steps can also be reversed. The activated catalysts can be employed to convert syngas into products, such as alcohols, with improved selectivities and yields.
The present invention features methods and apparatus for the pyrolysis or torrefaction of a carbon-containing feedstock before it is converted to syngas. In some embodiments, biomass is first pretreated by torrefaction and/or pyrolysis, followed by devolatilization and/or steam reforming to produce syngas. Various mixtures of such pretreated biomass, combined with fresh biomass, can be employed to produce syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.
In one aspect of this invention, catalytic compositions produced by calcining intermediates of the formula [NR4]X[M1M2S8] are provided, wherein M1 is Mo or W; M2 is Co, Ni, or Pd; x is 2 or 3; and R is a C3-C8 alkyl group. Another aspect provides catalytic compositions produced by calcining intermediates of the formula Ax[M1M2S8], wherein A is selected from K, Rb, Cs, Sr, and Ba. Also provided are methods for making the compositions, and methods of using the compositions for the catalytic conversion of syngas into C1-C4 alcohols such as ethanol.
The disclosed invention provides methods and apparatus for producing one or more C1-C4 alcohols (such as ethanol) from syngas, while simultaneously removing CO2, thereby providing low CO2 yields. The present invention provides reactors for producing one or more C1-C4 alcohols from syngas, the reactors containing a first composition capable of catalyzing the conversion of syngas to C1-C4 alcohols under reaction conditions and a second composition capable of (a) adsorbing CO2 under the reaction conditions and then (b) releasing at least some of the CO2 under different regeneration conditions.
B01D 53/00 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols
B01D 53/34 - Chemical or biological purification of waste gases
17.
METHODS AND APPARATUS FOR PRODUCING ETHANOL FROM SYNGAS WITH HIGH CARBON EFFICIENCY
The present invention discloses and teaches new methods of converting syngas into ethanol and/or other higher alcohols. Preferred embodiments recycle methanol, partially convert it to syngas, and then convert this additional syngas also to C2+ alcohols. Generally, the invention provides reactors comprising catalysts capable of converting syngas to alcohols with low selectivities to carbon dioxide and methane, and further provides process strategies to separate and recycle unreacted syngas as well as methanol produced by the catalyst. The invention is capable of turning modest per-pass reaction selectivities to a particular alcohol, such as ethanol, into economically significant net selectivities and yields.
C07C 27/06 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds by reduction of oxygen-containing compounds by hydrogenation of oxides of carbon
C07C 27/00 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds
18.
COBALT-MOLYBDENUM SULFIDE CATALYST MATERIALS AND METHODS FOR ETHANOL PRODUCTION FROM SYNGAS
The present invention provides methods and compositions for the chemical conversion of syngas to alcohols. The invention includes catalyst compositions, methods of making the catalyst compositions, and methods of using the catalyst compositions. Certain embodiments teach compositions for catalyzing the conversion of syngas into products comprising at least one C1-C4 alcohol, such as ethanol. These compositions generally include cobalt, molybdenum, and sulfur. Preferred catalyst compositions for converting syngas into alcohols include cobalt associated with sulfide in certain preferred stoichiometries as described and taught herein.
B01J 23/78 - Catalysts comprising metals or metal oxides or hydroxides, not provided for in group of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups with alkali- or alkaline earth metals or beryllium
C07C 27/06 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds by reduction of oxygen-containing compounds by hydrogenation of oxides of carbon
C07C 29/15 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
This invention features methods and apparatus for producing syngas from any carbon-containing feed material. In some embodiments, a substoichiometric amount of oxygen is used to enhance the formation of syngas. In various embodiments, both oxygen and steam are added during the conversion of the feed material into syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.
C01B 3/38 - Production of hydrogen or of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
C07C 27/06 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds by reduction of oxygen-containing compounds by hydrogenation of oxides of carbon
Methods and apparatus for producing alcohols from syngas are disclosed herein. In some variations, syngas is catalytically converted to methanol in a first reaction zone, and residual syngas from the first reaction zone is then catalytically converted to ethanol in a second reaction zone. Also, in some variations, syngas is catalytically converted to methanol in high yield in a first reaction zone, and the methanol is then converted (optionally, with additional syngas) to ethanol in a second reaction zone.
C07C 27/06 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds by reduction of oxygen-containing compounds by hydrogenation of oxides of carbon
C07C 29/00 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
The present invention provides modular and distributed methods and systems to convert biomass feedstocks into synthesis gas (syngas). The syngas can then be turned into liquid chemicals and fuels such as ethanol. The modular units of the invention bring the conversion process to the biomass source, thereby minimizing feedstock transportation costs. The modules are capable of being connected to, and/or disconnected from, each other to easily adjust the overall feedstock capacity. The present invention also provides methods and systems to determine an optimal number and distribution of modular conversion units spatially located within a region of land. The disclosed methods and systems are flexible, efficient, scalable, and are capable of being cost-effective at any commercial scale of operation.
C07C 27/00 - Processes involving the simultaneous production of more than one class of oxygen-containing compounds
C07C 29/141 - Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen-containing functional group of C=O containing groups, e.g. —COOH of a —CHO group with hydrogen or hydrogen-containing gases
B01J 8/00 - Chemical or physical processes in general, conducted in the presence of fluids and solid particlesApparatus for such processes
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