Methods for gasification of carbonaceous materials

• US 8,585,789 B2
• Filed: 04/13/2010
• Issued: 11/19/2013
• Est. Priority Date: 04/13/2010
• Status: Expired due to Fees

• Current Assignee: Jupeng Bio (HK) Limited
• Original Assignee: Ineos USA LLC (Ineos AG)
• Inventors: Sutradhar, Bhagya Chandra, Ko, Ching-Whan
• Primary Examiner(s): Akram, Imran
• Application Number:
  US12/798,871
• Publication Number:
  US 20110250662A1
• Time in Patent Office: 1,316 Days
• Field of Search: None
• US Class Current: 48/197.R
• CPC Class Codes: C01B 2203/025 containing a partial oxidation step
• CPC Class Codes: C01B 3/36 using oxygen or mixtures containing oxygen as gasifying agents
• CPC Class Codes: C10J 2300/0956 Air or oxygen enriched air
• CPC Class Codes: C10J 2300/0959 Oxygen
• CPC Class Codes: C10J 2300/0969 Carbon dioxide
• CPC Class Codes: C10J 2300/1665 to alcohols, e.g. methanol or ethanol preparation of alcohols in general C07C29/00
• CPC Class Codes: C10J 2300/1681 with biological plants, e.g. involving bacteria, algae, fungi
• CPC Class Codes: C10J 3/00 Production of combustible gases containing carbon monoxide from solid carbonaceous fuels destructive distillation processes C10B
• CPC Class Codes: C10J 3/20 Apparatus; Plants
• CPC Class Codes: C10J 3/721 Multistage gasification, e.g. plural parallel or serial gasification stages
• CPC Class Codes: C10K 3/005 by partial oxidation
• CPC Class Codes: C10K 3/008 by cracking
• CPC Class Codes: C12P 7/065 with microorganisms other than yeasts
• CPC Class Codes: C12P 7/08 produced as by-product or from waste or cellulosic material substrate
• 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: Y10T 29/53 Means to assemble or disassemble

Abstract

The present disclosure is generally directed to process of gasification of carbonaceous materials to produce synthesis gas or syngas. The present disclosure provides improved methods of gasification comprising: adding one or more carbonaceous materials, adding a molecular oxygen-containing gas, adding carbon dioxide gas and optionally adding water into said gasifier. This disclosure is also directed to process of production of one or more alcohols from said syngas via fermentation or digestion in the presence of at least one microorganism.

Claims

1. A method of gasification of carbonaceous materials in a gasifier to produce a product gas comprising carbon monoxide, hydrogen, and tar;

comprising;

adding one or more carbonaceous materials, adding a molecular oxygen containing gas, adding carbon dioxide gas and optionally adding water into said gasifier;

wherein

amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises greater than about 2.0 and less than about 3.0;

wherein

the gasifier produces ash comprising ash-carbon and wherein said ash comprises less than about 10% of ash-carbon;

wherein said product gas is treated at a temperature of about 1750°

F. to about 3500°

F. in the presence of molecular oxygen to produce a raw syngas comprising carbon monoxide, hydrogen, and syngas-carbon;

wherein

said raw-syngas comprises less than about 0.5 pound syngas-carbon per 1000 SCF raw-syngas produced, wherein

said gasifier comprises non-catalytic gasification.

2. The method of claim 1 wherein one or more said carbonaceous materials comprises selection from carbonaceous material, carbonaceous liquid product, industrial carbonaceous liquid recycle, carbonaceous municipal solid waste (MSW), carbonaceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood waste, carbonaceous construction material, carbonaceous vegetative material, carbonaceous petrochemical coproducts, carbonaceous coal, plastic, waste plastic, coke oven tar, fibersoft, tires, lignin, black liquor, polymers, waste polymers, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, energy crops, forest processing residues, wood processing residues, livestock wastes, poultry wastes, food processing residues, fermentative process wastes, carbonaceous industrial waste, alcohol production wastes, ethanol coproducts, spent grains, spent microorganisms or their combinations.

3. The method of claim 1 wherein carbon content of one or more said carbonaceous materials comprises about 0.25 to about 1.0 pound per pound of one or more said carbonaceous materials on a water free basis.

4. The method of claim 1 wherein hydrogen content of one or more said carbonaceous materials comprises about 0.0 to about 0.25 pound per pound of one or more said carbonaceous materials on a water free basis.

5. The method of claim 1 wherein oxygen content of one or more said carbonaceous materials comprises about 0.0 to about 0.5 pound per pound of one or more said carbonaceous materials on a water free basis.

6. The method of claim 1, wherein the carbon to hydrogen mass ratio in one or more of said carbonaceous material comprises 1 to 20.

7. The method of claim 1, wherein the carbon to oxygen mass ratio in one or more of said carbonaceous material comprises 1 to 200.

8. The method of claim 1, wherein the CO to CO2 ratio greater than 1.4.

9. The method of claim 1, wherein the raw syngas volume ranges from 50387 to 86109 KSCF/DT.

10. A method of gasification of carbonaceous materials in a gasifier to produce syngas;

said gasifier comprising a first reaction zone and a second reaction zone;

said method comprising;

adding one or more carbonaceous materials into said first reaction zone of gasifier;

adding a molecular oxygen containing gas, carbon dioxide gas and optionally adding water or steam into one or both of said first reaction zone and second reaction zone of said gasifier;

wherein

amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises greater than about 2.0 and less than about 3.0;

wherein

said raw-syngas comprises less than about 0.5 pound syngas-carbon per 1000 SCF raw-syngas produced;

wherein

said gasifier comprises non-catalytic gasification.

11. The method of claim 10 wherein said first reaction zone temperature comprises 650-1450.degree. F.

12. The method of claim 10 wherein said second reaction zone temperature comprises 1750-3500.degree. F.

13. The method of claim 10 comprising adding carbon dioxide gas into the first reaction zone of said gasifier.

14. The method of claim 10 further comprising:

subjecting said raw syngas to cooling and cleaning up to produce a clean syngas;

contacting said clean syngas with a biocatalyst in a fermentation container to produce an alcohol product mixture.

15. The method of claim 10 further comprising:

subjecting said raw syngas to cooling and cleaning up to produce a clean syngas;

contacting said clean syngas with a biocatalyst in a fermentation container to produce an alcohol product mixture.