SYSTEMS, METHODS, AND COMPOSITIONS FOR PRODUCTION OF SYNTHETIC HYDROCARBON COMPOUNDS

• US 20100111783A1
• Filed: 12/24/2009
• Published: 05/06/2010
• Est. Priority Date: 03/16/2005
• Status: Abandoned Application

• Current Assignee: Fuelcor, LLC
• Original Assignee: Fuelcor, LLC
• Inventors: SEVERINSKY, Alexander J.
• Application Number:
  US12/647,178
• Publication Number:
  US 20100111783A1
• Time in Patent Office: Days
• US Class Current: 422/188
• CPC Class Codes: C01B 2203/0294 containing three or more CO-shift steps
• CPC Class Codes: C01B 3/16 using catalysts
• CPC Class Codes: C10G 2/30 from carbon monoxide with hydrogen
• CPC Class Codes: C10G 2/32 with the use of catalysts
• CPC Class Codes: C10G 2300/1022 Fischer-Tropsch products
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/1238 by plasma
• CPC Class Codes: C10J 2300/1659 to liquid hydrocarbons Fischer-Tropsch process C10G2/00
• CPC Class Codes: C10J 3/18 using electricity
• CPC Class Codes: C10K 3/026 Increasing the carbon monoxide content, e.g. reverse water-gas shift [RWGS]
• CPC Class Codes: C25B 1/04 by electrolysis of water
• CPC Class Codes: C25B 15/08 Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• CPC Class Codes: Y02E 20/18 Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
• CPC Class Codes: Y02E 60/36 Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
• CPC Class Codes: Y02P 20/00 Technologies relating to chemical industry
• CPC Class Codes: Y02P 20/10 Process efficiency
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y02P 20/133 Renewable energy sources, e.g. sunlight

Abstract

A process and system for producing hydrocarbon compounds or fuels that recycle products of hydrocarbon compound combustion—carbon dioxide or carbon monoxide, or both, and water. The energy for recycling is electricity derived from preferably not fossil based fuels, like from nuclear fuels or from renewable energy. The process comprises electrolysing water, and then using hydrogen to reduce externally supplied carbon dioxide to carbon monoxide, then using so produced carbon monoxide together with any externally supplied carbon monoxide and hydrogen in Fischer-Tropsch reactors, with upstream upgrading to desired specification fuels—for example, gasoline, jet fuel, kerosene, diesel fuel, and others. Energy released in some of these processes is used by other processes. Using adiabatic temperature changes and isothermal pressure changes for gas processing and separation, large amounts of required energy are internally recycled using electric and heat distribution lines. Phase conversion of working fluid is used in heat distribution lines for increased energy efficiency. The resulting use of electric energy is less than 1.4 times the amount of the high heating value of combustion of so produced hydrocarbon compounds when carbon dioxide is converted to carbon monoxide in the invention, and less than 0.84 when carbon monoxide is the source.

Claims

1-80. -80. (canceled)

81. A system for producing hydrocarbon compounds comprising at least the following units:

a) a reverse water gas shift reactor assembly supplied with hydrogen gas and carbon dioxide gas to generate a syngas, that is a mixture of at least carbon monoxide gas and hydrogen gas, water steam, and residual carbon dioxide gas;

b) a unit for generating a mixture of at least hydrocarbon compounds from at least carbon monoxide gas and hydrogen gas;

characterized in that the reverse water gas shift reactor assembly comprises;

a) a first reverse water gas shift reactor supplied with hydrogen gas and carbon dioxide gas, wherein the molar ratio of hydrogen to carbon dioxide is more than one, to generate a first syngas stream comprising a mixture of at least carbon monoxide gas and hydrogen gas, water steam, and residual carbon dioxide gas;

b) a unit for condensing at least some water steam from the first syngas stream to generate a second syngas stream;

c) a second reverse water gas shift reactor supplied with the second syngas stream to generate a third syngas stream;

d) a unit for condensing at least some water steam from the third syngas stream to generate a fourth syngas stream, which is supplied to the unit for generating a mixture of at least hydrocarbon compounds.

82. The system of claim 81, wherein the operating temperatures of the reverse water gas shift reactors is between 350°

C. and 500°

C.

83. The system of claim 81, wherein the reverse water gas shift reactor assembly comprises more than two sequentially arranged reverse water gas shift reactors with units for condensing at least some water steam from the exiting syngas stream therebetween.

84. The system of claim 83, wherein the operating temperatures of the reverse water gas shift reactors is between 350°

C. and 500°

C.

85. The system of claim 81, further comprising one or more separating units, which may be provided after a reverse water gas shift reactor, and before a following reverse water gas shift reactor or a unit for generating a mixture of at least hydrocarbon compounds, to separate at least some carbon dioxide from the stream of syngas exiting from at least one of the reverse water gas shift reactors and entering into a following reverse water gas shift reactor or unit for generating a mixture of at least hydrocarbon compounds.

86. The system of claim 83, further comprising one or more separating units, which may be provided after a reverse water gas shift reactor, and before a following reverse water gas shift reactor or a unit for generating a mixture of at least hydrocarbon compounds, to separate at least some carbon dioxide from the stream of syngas exiting from at least one of the reverse water gas shift reactors and entering into a following reverse water gas shift reactor or unit for generating a mixture of at least hydrocarbon compounds.

87. The system of claim 85, further comprising a unit for supplying removed carbon dioxide gas to at least one of the preceding reverse water gas shift reactors.

88. The system of claim 86, further comprising a unit for supplying removed carbon dioxide gas to at least one of the preceding reverse water gas shift reactors.

89. The system of claim 87, wherein at least a portion of the removed carbon dioxide is supplied to the first reverse water gas shift reactor.

90. The system of claim 88, wherein at least a portion of the removed carbon dioxide is supplied to the first reverse water gas shift reactor.

91. The system of claim 81, further comprising a separating unit to separate carbon dioxide from a stream exiting the unit for generating a mixture of at least hydrocarbon compounds, wherein the stream comprises a mixture of at least hydrocarbon compounds and carbon dioxide, and wherein the separated carbon dioxide is supplied to the first reverse water gas shift reactor.

92. The system of claim 83, further comprising a separating unit to separate carbon dioxide from a stream exiting the unit for generating a mixture of at least hydrocarbon compounds, wherein the stream comprises a mixture of at least hydrocarbon compounds and carbon dioxide, and wherein the separated carbon dioxide is supplied to the first reverse water gas shift reactor.

93. The system of claim 85, further comprising a separating unit to separate carbon dioxide from a stream exiting the unit for generating a mixture of at least hydrocarbon compounds, wherein the stream comprises a mixture of at least hydrocarbon compounds and carbon dioxide, and wherein the separated carbon dioxide is supplied to the first reverse water gas shift reactor.

94. The system of claim 86, further comprising a separating unit to separate carbon dioxide from a stream exiting the unit for generating a mixture of at least hydrocarbon compounds, wherein the stream comprises a mixture of at least hydrocarbon compounds and carbon dioxide, and wherein the separated carbon dioxide is supplied to the first reverse water gas shift reactor.

95. The system of claim 81, further comprising:

a) a unit for generating carbon monoxide made by an optional reaction process that converts carbon dioxide to carbon monoxide; and

b) a unit for providing a portion of the stream exiting a reverse water gas shift reactor to a unit for generating a mixture of hydrocarbon compounds from at least carbon monoxide gas and hydrogen gas.

96. The system of claim 83, further comprising:

a) a unit for generating carbon monoxide made by an optional reaction process that converts carbon dioxide to carbon monoxide; and

b) a unit for providing a portion of the stream exiting a reverse water gas shift reactor to a unit for generating a mixture of hydrocarbon compounds from at least carbon monoxide gas and hydrogen gas.

97. The system of claim 85, further comprising:

a) a unit for generating carbon monoxide made by an optional reaction process that converts carbon dioxide to carbon monoxide; and

b) a unit for providing a portion of the stream exiting a reverse water gas shift reactor to a unit for generating a mixture of hydrocarbon compounds from at least carbon monoxide gas and hydrogen gas.

98. The system of claim 86, further comprising:

a) a unit for generating carbon monoxide made by an optional reaction process that converts carbon dioxide to carbon monoxide; and

b) a unit for providing a portion of the stream exiting a reverse water gas shift reactor to a unit for generating a mixture of hydrocarbon compounds from at least carbon monoxide gas and hydrogen gas.