Process for the production of alcohols

• US 9,051,585 B2
• Filed: 06/12/2008
• Issued: 06/09/2015
• Est. Priority Date: 07/19/2007
• Status: Active Grant

• Current Assignee: Jupeng Bio (HK) Limited
• Original Assignee: Ineos Sales (Uk) Limited (Ineos AG)
• Inventors: Bell, Peter
• Primary Examiner(s): UNDERDAHL, THANE E
• Application Number:
  US12/452,208
• Publication Number:
  US 20100105118A1
• Time in Patent Office: 2,553 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0238 the reforming step being a carbon dioxide reforming step
• CPC Class Codes: C01B 2203/0405 Purification by membrane separation
• CPC Class Codes: C01B 2203/06 Integration with other chemical processes
• CPC Class Codes: C01B 2203/1235 Hydrocarbons
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 3/382 Multi-step processes
• CPC Class Codes: C12P 3/00 Preparation of elements or inorganic compounds except carbon dioxide recovery of carbon dioxides as by-products C12F3/02
• CPC Class Codes: C12P 7/02 containing a hydroxy group
• CPC Class Codes: C12P 7/065 with microorganisms other than yeasts
• 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

Abstract

Process for producing C2+ alcohols from a methane-containing feedstock, by passing the methane-containing feedstock and CO₂ to a non-oxidative reforming process to produce a product stream containing CO, H₂ and CO₂, optionally in the presence of steam, provided that where steam is present in the feed to the reforming process, the steam and CO₂ are present in a molar ratio of less than 5:1. The CO, H₂ and CO₂ stream is passed to a bacterial fermentation step where it is converted to a liquid product stream containing one or more C2+ alcohols and a gaseous product stream containing CO, H₂ and CO₂. The fermentation step is operated to provide a conversion of CO of at least 60%. CO, H₂ and CO₂ are recycled from the gaseous product stream to the reforming process such that the H₂ reacts with carbon dioxide in the reforming process.

Claims

1. A process for the production of C2+ alcohols from a methane-containing feedstock, which process comprises:

(a) passing said methane-containing feedstock and carbon dioxide to a non-oxidative reforming process to produce a first product stream comprising CO, H₂ and CO₂, optionally in the presence of steam, but with the proviso that where steam is present in the feed to the reforming process the steam and CO₂ are present in a molar ratio of less than 5;

1,

(b) passing the first product stream comprising CO, H₂ and CO₂ to a bacterial fermentation step wherein it is converted to produce a second product stream comprising one or more C2+ alcohols in the liquid phase and a gaseous third product stream comprising CO, H₂ and CO₂, the fermentation step being operated to provide a conversion of CO of at least 60%,

wherein CO, H₂ and CO₂ are recycled from the gaseous third product stream to the reforming process of step (a) wherein at least 80% of the CO and 80% of the CO₂ in the gaseous third stream are recycled to the reforming process, and wherein the H₂ reacts with carbon dioxide in the reforming process.

2. A process as claimed in claim 1 wherein the reforming process is dry-gas reforming or steam methane reforming.

3. A process as claimed in claim 2 wherein the reforming process is a sulphur passivated reforming.

4. A process as claimed in claim 1 wherein no specific separation of carbon monoxide from carbon dioxide in the product stream is performed prior to recycle.

5. A process as claimed in claim 1 wherein some of the hydrogen in the gaseous third product stream is separated and utilised as a fuel gas.

6. A process as claimed in claim 1 wherein, where steam is present, the steam:

CO₂ molar ratio is <

1;

1.

7. A process as claimed in claim 1 wherein both the reforming and fermentation steps are operated at a pressure is in the range 2 to 12 barg.

8. A process as claimed in claim 1 wherein a purge is taken from the recycled stream to prevent build-up of inerts.

9. A process as claimed in claim 1 wherein the fermentation process uses acetogenic anaerobic bacteria.

10. A process as claimed in claim 9 wherein the bacteria is selected from Acetogenium kivui, Acetobacterium woodii, Acetoanaerobium noterae, Clostridium Aceticum, Butyribacterium methylotrophicum, Clostridium acetobutylicum, Clostridium thermoaceticum, Eubacterium limosum, Peptostreptococcus productus, Clostridium ljungdahlii and Clostridium carboxydivorans.

11. A process as claimed in claim 10 wherein the bacteria is Clostridium ljungdahlii.

12. A process as claimed in claim 11 wherein the Clostridium ljungdahlii strain is selected from Clostridium ljungdahlii PETC, Clostridium ljungdahlii ERI2, Clostridium ljungdahlii C01, Clostridium ljungdahlii 0-52.