Process and system for producing liquid fuel from carbon dioxide and water

• US 8,506,910 B2
• Filed: 04/20/2012
• Issued: 08/13/2013
• Est. Priority Date: 03/20/2006
• Status: Active Grant

• Current Assignee: Ehf Cri
• Original Assignee: Cri Ehf
• Inventors: Singh, Shwetank, Sigurbjornsson, Omar Freyr, Tran, Kim-Chinh
• Primary Examiner(s): Griffin, Walter D
• Assistant Examiner(s): YOUNG, NATASHA E
• Application Number:
  US13/452,073
• Publication Number:
  US 20120201717A1
• Time in Patent Office: 480 Days
• Field of Search: 422/129, 422/162, 422/187, 422/600, 422/630, 423/414, 518700-704, 518706-708, 518711-721
• US Class Current: 422/630
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0255 containing a non-catalytic partial oxidation step
• CPC Class Codes: C01B 2203/0261 containing a catalytic partial oxidation step [CPO]
• CPC Class Codes: C01B 2203/062 Hydrocarbon production, e.g. Fischer-Tropsch process
• CPC Class Codes: C01B 2203/1247 Higher hydrocarbons
• CPC Class Codes: C01B 2203/84 Energy production
• CPC Class Codes: C01B 3/34 by reaction of hydrocarbons with gasifying agents
• CPC Class Codes: C07C 29/1516 Multisteps
• CPC Class Codes: C07C 31/04 Methanol
• CPC Class Codes: C10G 2/32 with the use of catalysts
• CPC Class Codes: C10G 2300/4043 Limiting CO2 emissions
• CPC Class Codes: C10G 2300/4081 Recycling aspects
• CPC Class Codes: C10G 2300/42 Hydrogen of special source or of special composition
• CPC Class Codes: C10G 2400/02 Gasoline
• CPC Class Codes: C10G 2400/04 Diesel oil
• CPC Class Codes: C10G 2400/20 C2-C4 olefins
• CPC Class Codes: C10K 3/026 Increasing the carbon monoxide content, e.g. reverse water-gas shift [RWGS]
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials
• CPC Class Codes: Y02P 30/00 Technologies relating to oil refining and petrochemical industry
• CPC Class Codes: Y02P 30/40 : Ethylene production

Abstract

A process and system for producing high octane fuel from carbon dioxide and water is disclosed. The feedstock for the production line is industrial carbon dioxide and water, which may be of lower quality. The end product can be high octane gasoline, high cetane diesel or other liquid hydrocarbon mixtures suitable for driving conventional combustion engines or hydrocarbons suitable for further industrial processing or commercial use. Products, such as dimethyl ether or methanol may also be withdrawn from the production line. The process is nearly emission free and reprocesses all hydrocarbons not suitable for liquid fuel to form high octane products. The heat generated by exothermic reactions in the process is fully utilized as is the heat produced in the reprocessing of hydrocarbons not suitable for liquid fuel.

Claims

1. A system for production of liquid fuel from carbon dioxide and water using electricity, the system comprising:

(a) a purification unit in fluid communication with stack gas units of industrial plants and/or power plants, said purification unit arranged and designed to separate the carbon dioxide from stack gases;

(b) an electrolysis unit arranged to convert water into hydrogen and oxygen;

(c) a first mixing unit disposed downstream of and in fluid communication with said purification unit and said electrolysis unit to mix said carbon dioxide and said hydrogen;

(d) a catalytic reactor disposed downstream of and in fluid communication with the said first mixing unit to receive the mixture of said carbon dioxide and said hydrogen and to produce methanol and carbon monoxide and said water;

(e) a second mixing unit disposed downstream of and in fluid communication with the said catalytic reactor, said second mixing unit arranged and designed to accept a portion of said carbon monoxide;

(f) a liquid fuel generation unit disposed downstream of and in fluid communication with said second mixing unit, said liquid fuel generation unit arranged and designed to receive and convert a portion of said carbon monoxide in the presence of a substantially pure hydrogen gas to produce said liquid fuel; and

(g) an oxidation unit disposed downstream of and in fluid communication with said liquid fuel generation unit, said oxidation unit arranged and designed to oxidize any unaccepted portion of separated hydrocarbon product under conditions producing a combustion product comprising said hydrogen, said carbon monoxide, said carbon dioxide and said water.

2. The system of claim 1, wherein said catalytic reactor further comprises a reverse water gas shift reactor for the formation of said carbon monoxide.

3. The system of claim 1, wherein said second mixing unit is disposed downstream of said purification unit to receive a direct supply of said carbon dioxide.

4. The system of claim 1, wherein said second mixing unit directly supplies a mixture of said carbon dioxide and said hydrogen to said liquid fuel generation unit for the production of said liquid fuel.

5. The system of claim 1, wherein said liquid fuel generation unit further comprises of series of reactors used for the production of said liquid fuel.

6. The system of claim 1, wherein said liquid fuel generation unit comprises at least one of a methanol reactor, a methanol-to-gasoline reactor, and a Fischer-Tropsch reactor.

7. The system of claim 1, wherein said second mixing unit further comprises at least one control valve to feed various amounts of mixture of said carbon monoxide and said hydrogen to said liquid fuel generation unit to produce desired proportions of said liquid fuel.

8. The system of claim 1, wherein said second mixing unit is disposed downstream of and in fluid communication with said electrolysis unit to receive said hydrogen gas.

9. The system of claim 1, wherein said oxidation unit is in fluid communication with said second mixing unit to provide said carbon dioxide.

10. The system of claim 1, wherein said oxidation unit is at least one of a complete oxidation chamber, a partial oxidation chamber, a steam reformer and an auto reformer.