Renewable engine fuel and method of producing same

• US 8,556,999 B2
• Filed: 03/04/2010
• Issued: 10/15/2013
• Est. Priority Date: 07/27/2007
• Status: Active Grant

• Current Assignee: Swift Enterprises Ltd
• Original Assignee: Swift Fuels, LLC
• Inventors: Rusek, John J, Rusek, Mary-Louise, Ziulkowski, Jonathon D, Zink, Justin D
• Primary Examiner(s): Toomer, Cephia D
• Application Number:
  US12/717,480
• Publication Number:
  US 20100268005A1
• Time in Patent Office: 1,321 Days
• Field of Search: 443/07, 446/05, 435/148, 435/160, 585/240, 585/319, 585/331, 585/357, 585/409
• US Class Current: 44/307
• CPC Class Codes: C07C 1/2074 of only one compound
• CPC Class Codes: C07C 15/02 Monocyclic hydrocarbons
• CPC Class Codes: C07C 2521/04 Alumina
• CPC Class Codes: C07C 2521/08 Silica
• CPC Class Codes: C07C 2523/20 Vanadium, niobium or tantalum
• CPC Class Codes: C07C 2527/25 Nitrates
• CPC Class Codes: C07C 9/18 with five carbon atoms
• CPC Class Codes: C10L 1/02 essentially based on components consisting of carbon, hydrogen, and oxygen only
• CPC Class Codes: C10L 1/023 for spark ignition
• CPC Class Codes: C10L 1/04 essentially based on blends of hydrocarbons
• CPC Class Codes: C10L 1/06 for spark ignition
• CPC Class Codes: C10L 1/1824 mono-hydroxy
• CPC Class Codes: C12P 5/005 aromatic naphthacene C12P29/00
• CPC Class Codes: C12P 5/02 acyclic C12P5/007 takes precedence
• CPC Class Codes: C12P 7/16 Butanols
• CPC Class Codes: C12P 7/36 produced from substrate containing grain or cereal material
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02T 50/678 Aviation using fuels of non-fossil origin

Abstract

The present invention provides non-petroleum high-octane fuel derived from biomass sources, and a method of producing same. The method of production involves reducing the biomass feedstocks to sugars, fermenting the sugars using microorganisms or mutagens thereof to produce ethanol or acetic acid, converting the acetic acid or ethanol to acetone, and converting the acetone to mesitylene and isopentane, the major components of the renewable engine fuel. Trimerization of acetone can be carried out in the presence of a catalyst containing at least one metal selected from the group consisting of niobium, iron and manganese. The ethanol can be converted to mesitylene in a dehydration reaction in the presence of a catalyst of zinc oxide/calcium oxide, and unreacted ethanol and water separated from mesitylene by distillation. These ethanol-based, biomass-derived fuels are fully renewable, may be formulated to have a wide range of octane values and energy, and may effectively be used to replace 100 LL aviation fuel (known as AvGas), as well as high-octane, rocket, diesel, turbine engine fuels, as well as two-cycle, spark-ignited engine fuels.

Claims

1. A method of producing bio-mass derived high-octane fuel, comprising the steps of:

(a) fermenting a biomass with a microorganism or a mutagen thereof to produce a mixture of metabolites comprising acetone and butanol;

(b) separating the acetone from butanol and any ethanol or other solvents in the mixture by fractional distillation;

(c) dimerizing a portion of resultant acetone from step (b) to form isopentane;

(d) trimerizing another portion of the acetone from step (b) using a catalyst containing at least one metal selected from the group consisting of niobium, iron, and manganese to form mesitylene, and

(e) mixing the mesitylene with the isopentane from steps (c) and (d), whereby to form the biomass-derived high-octane fuel.

2. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the microorganisms are one or more chosen from among thermoanaerobacter kivui, moorella thermoacetica, moorella thermoautotrophica, thermoanaerobacter thermosaccharolyticum, and saccharophagus degradans, strain 2-40.

3. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the biomass is selected from the group consisting of sugars, celluloses, lignins, starches, and lignocelluloses.

4. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the biomass is selected from the group consisting of hard woods, grasses, corn stover, sorghum, corn fiber, and oat hulls, which are pretreated with enzymes or strong acids to break any hemicellulose chains into their sugar monomers.

5. The method of producing bio-mass derived high-octane fuel according to claim 1, wherein the fermentation in step (a) is conducted in an anaerobic reactor in the absence of oxygen.

6. The method of producing bio-mass derived high-octane fuel of claim 1, wherein metabolites of acetone, butanol and any ethanol from step (a) are stripped from the fermentation when concentrations thereof over 2 to 3 wt % are obtained, whereby to avoid any poisoning of the microorganism.

7. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the trimerizing of acetone in step (d) is carried out in the gas phase by passing acetone in contact with a catalyst containing niobium oxide at elevated temperatures.

8. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the dimerization of acetone in step (c) is carried out in a catalytic reaction to yield isopentane.

9. The method of producing bio-mass derived high-octane fuel of claim 1, wherein the dimerization of acetone in step (c) is carried out in a gas phase catalytic reaction.

10. The method of producing bio-mass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of niobium oxide on a base of alumina washcoat on calcined aluminized stainless steel corrugated film.

11. The method of producing biomass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of niobium oxide on a base of alumina beads.

12. The method of producing biomass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of niobium oxide on silica gel.

13. The method of producing biomass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of manganese nitrate on alumina beads.

14. The method of producing biomass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of manganese nitrate on silica gel.

15. The method of producing biomass derived high-octane fuel of claim 7, wherein the trimerization of acetone in step (d) is carried out with a catalyst of manganese nitrate on a base of alumina washcoat on calcined aluminized stainless steel corrugated film.

16. The method of producing biomass derived high-octane fuel according to claim 1, wherein the microorganism is clostridium or variants thereof.