Process and system for converting carbonaceous feedstocks into energy without greenhouse gas emissions

• US 7,220,502 B2
• Filed: 11/21/2003
• Issued: 05/22/2007
• Est. Priority Date: 06/27/2002
• Status: Active Grant

• Current Assignee: Raven SR, LLC
• Original Assignee: Intellergy Corp.
• Inventors: Galloway, Terry R.
• Primary Examiner(s): Ryan; Patrick Joseph
• Assistant Examiner(s): Lewis; Ben
• Application Number:
  US10/719,504
• Publication Number:
  US 20040115492A1
• Time in Patent Office: 1,278 Days
• Field of Search: 429/12
• US Class Current: 429/426
• CPC Class Codes: C10G 2/32 with the use of catalysts
• CPC Class Codes: C10J 2300/0969 Carbon dioxide
• CPC Class Codes: C10J 2300/0973 Water
• CPC Class Codes: C10J 2300/1659 to liquid hydrocarbons
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 2300/1823 for synthesis gas
• CPC Class Codes: C10J 3/005 Rotary drum or kiln gasifiers
• CPC Class Codes: C10J 3/02 Fixed-bed gasification of lump fuel
• CPC Class Codes: H01M 8/04164 by condensers, gas-liquid separators or filters
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: H01M 8/0631 Reactor construction specially adapted for combination reactor/fuel cell hydrogen C01B3/00; reactors for physicochemical processes B01J19/00
• CPC Class Codes: H01M 8/0643 Gasification of solid fuel
• CPC Class Codes: H01M 8/0662 Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• CPC Class Codes: H01M 8/0668 Removal of carbon monoxide or carbon dioxide
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 30/00 Technologies relating to oil refining and petrochemical industry

Abstract

The process and system of the invention converts carbonaceous feedstock such as coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing medical waste, carbonaceous-containing military waste, carbonaceous-containing industrial waste, carbonaceous-containing medical waste, carbonaceous-containing sewage sludge and municipal solid waste, carbonaceous-containing agricultural waste, carbonaceous-containing biomass, biological and biochemical waste, and mixtures thereof into electrical energy without the production of unwanted greenhouse emissions. The process and system uses a combination of a gasifier, e.g., a kiln, operating in the exit range of at least 700° to about 1600° C. (1300-2900° F.) to convert the carbonaceous feedstock and a greenhouse gas stream into a synthesis gas comprising mostly carbon monoxide and hydrogen without the need for expensive catalysts and or high pressure operations. One portion of the synthesis gas from the gasifier becomes electrochemically oxidized in an electricity-producing fuel cell into an exit gas comprising carbon dioxide and water. The latter is recycled back to the gasifier after a portion of water is condensed out. The second portion of the synthesis gas from the gasifier is converted into useful hydrocarbon products.

Claims

1. A process for converting carbonaceous feedstocks into energy without the production of unwanted greenhouse gas emissions comprising:

(a) converting a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing medical waste, carbonaceous-containing military waste, carbonaceous-containing industrial waste, carbonaceous-containing medical waste, carbonaceous-containing sewage sludge and municipal solid waste, carbonaceous-containing agricultural waste, carbonaceous-containing biomass, biological and biochemical waste, and mixtures thereof, and a greenhouse gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen, said gasification unit is a non-catalytic high temperature, gas-phase, indirectly heated kiln having an inlet means, a gas outlet means, and a solids outlet between the inlet means and the gas outlet means operating at a temperature gradient along the length of the kiln of about 200°

to about 1600°

C. (400-2900°

F.) and at conditions to achieve a gas exit temperature of from at least 700°

to about 1600°

C. (1300-2900°

F.);

(b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a fuel cell (anode) to a first half-cell exit gas comprising carbon dioxide and water;

(c) recovering the carbon dioxide from said first half-cell exit gas to serve as at least 20% of said greenhouse gas stream in step (a); and

(d) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell (cathode) completing the circuit and resulting in the production of electrical energy.

2. The process of claim 1 wherein said greenhouse gas stream is carbon dioxide.

3. The process of claim 1 is used as in a waste-to-energy fossil fuel plant.

4. The process of claim 1 is used in a petroleum refinery.

5. The process of claim 1 is used in a petrochemical plant.

6. The process of claim 1 wherein said kiln is indirectly heated over its entire length.

7. The process of claim 1 wherein a portion of said synthesis gas from said gasification unit is converted in a chemical reactor into useful hydrocarbon products.

8. The process of claim 7 wherein said chemical reactor is a Fischer-Tropsch reactor.

9. The process of claim 1 wherein a major portion of the water is condensed from said first half-cell exit gas using a condenser.

10. The process of claim 9 wherein CO2 and at least a portion of the condensed water is passed to said gasification unit in an amount to adjust the hydrogen to carbon ratio of the combined carbonaceous feedstock and greenhouse gas stream is sufficient to result in a synthesis gas having an optimum ratio for the Fischer-Tropsch reactor.

11. The process of claim 10 wherein said synthesis gas has a hydrogen to carbon ratio in the range of about 1.75 to about 2.5.

12. The process of claim 1 wherein the amount of greenhouse gas stream is adjusted in step (a) so that the combined carbonaceous feedstock and greenhouse gas stream to said gasification unit has a hydrogen to carbon monoxide ratio in the range of about 1.2 to about 2.5.

13. The process of claim 1 wherein the oxygen-containing gas in step (d) is air and the nitrogen portion as a result of the electrical reduction is exited into the atmosphere.

14. The process of claim 1 wherein said first half-cell of said fuel cell contains an electrolyte surrounding a porous catalytic anode electrode.

15. The process of claim 14 wherein said second half-cell of said fuel cell contains an electronically conducting electrolyte surrounding a catalytic cathode electrode.

16. The process of claim 15 wherein said first and second half-cells of said fuel cell are separated by an ionically conducting membrane that will not allow passage of components from the respective half-cells.

17. A process for converting carbonaceous feedstocks into energy without the production of unwanted greenhouse gas emissions comprising:

(a) converting a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing medical waste, carbonaceous-containing military waste, carbonaceous-containing industrial waste, carbonaceous-containing medical waste, carbonaceous-containing sewage sludge and municipal solid waste, carbonaceous-containing agricultural waste, carbonaceous-containing biomass, biological and biochemical waste, and mixtures thereof and a greenhouse gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen, said gasification unit is a non-catalytic high temperature, gas-phase, indirectly heated kiln having an inlet means, a gas outlet means, and a solids outlet between the inlet means and the gas outlet means operating at a temperature gradient along the length of the kiln of about 200°

C. to about 1600°

C. (400-2900°

F.) and at conditions to achieve a gas exit temperature of from at least 700°

to about 1600°

C. (1300-2900°

F.);

(b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a fuel cell (anode) to a first half-cell exit gas comprising carbon dioxide and water; and

(c) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell (cathode) completing the circuit and resulting in the production of electrical energy.

18. The process of claim 17 wherein said greenhouse gas stream is carbon dioxide.

19. The process of claim 17 wherein said greenhouse gas stream is methane.

20. The process of claim 17 wherein a portion of said synthesis gas from said gasification unit is converted in a chemical reactor into useful hydrocarbon products.

21. The process of claim 20 wherein said chemical reactor is a Fischer-Tropsch reactor.

22. The process of claim 17 wherein a major portion of the water is condensed from said first half-cell exit gas using a condenser.

23. The process of claim 22 wherein CO₂ and at least a portion of the condensed water is passed to said gasification unit in an amount to adjust the hydrogen to carbon ratio of the combined carbonaceous feedstock and greenhouse gas stream is sufficient to result in a synthesis gas having an optimum ratio for the Fischer-Tropsch reactor.

24. The process of claim 17 wherein the amount of greenhouse gas stream is adjusted in step (a) so that the combined carbonaceous feedstock and greenhouse gas stream to said gasification unit has a hydrogen to carbon monoxide ratio in the range of about 1.2 to about 2.5.

25. The process of claim 17 wherein the oxygen-containing gas in step (c) is air and the nitrogen portion as a result of the electrical reduction is exited into the atmosphere.