Production of products with favourable GHG emission reductions from cellulosic feedstocks

• US 9,476,066 B2
• Filed: 02/10/2015
• Issued: 10/25/2016
• Est. Priority Date: 03/06/2014
• Status: Active Grant

• Current Assignee: Iogen Corporation
• Original Assignee: Iogen Corporation
• Inventors: Foody, Patrick J
• Primary Examiner(s): YAMASAKI, ROBERT J
• Application Number:
  US14/618,170
• Publication Number:
  US 20150252386A1
• Time in Patent Office: 623 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 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/0415 Purification by absorption in liquids
• CPC Class Codes: C01B 2203/043 Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
• CPC Class Codes: C01B 2203/047 the impurity being carbon monoxide
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/1211 Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 3/00 Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it separation of gases by physical means B01D; Purification of hydrogen production of water gas or synthesis gas from solid carbonaceous material C10J; purifying or modifying the chemical compositions of combustible technical gases containing carbon monoxide C10K
• CPC Class Codes: C01B 3/34 by reaction of hydrocarbons with gasifying agents
• CPC Class Codes: C07C 1/0485 Set-up of reactors or accessories; Multi-step processes
• CPC Class Codes: C10G 2/32 with the use of catalysts
• CPC Class Codes: C10G 45/00 Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
• CPC Class Codes: C10J 2300/0916 Biomass
• CPC Class Codes: C10J 2300/1659 to liquid hydrocarbons Fischer-Tropsch process C10G2/00
• 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 3/82 Gas withdrawal means
• CPC Class Codes: C10L 2290/04 Gasification
• CPC Class Codes: C10L 2290/06 : Heat exchange, direct or indirect
• CPC Class Codes: C10L 2290/26 : Composting, fermenting or anaerobic digestion fuel components or materials from which fuels are prepared
• CPC Class Codes: C10L 2290/42 : Fischer-Tropsch steps
• CPC Class Codes: C10L 3/08 : Production of synthetic natural gas
• CPC Class Codes: C12P 5/023 : Methane
• CPC Class Codes: C12P 7/10 : substrate containing cellulosic material
• CPC Class Codes: C12P 7/14 : Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
• 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: Y02P 30/00 : Technologies relating to oil refining and petrochemical industry

Abstract

The present invention provides a process for producing one or more products for use as a transportation or heating fuel. In various embodiments the process comprises treating a cellulosic feedstock in one or more processing steps that release extractives from the feedstock. A solids-liquid separation is subsequently conducted on the process stream comprising the extractives and solids. An aqueous stream comprising one or more of the extractives may be fed to an anaerobic digester to produce crude biogas from which one or more impurities may optionally be removed. In various embodiments the process further comprises providing a solids stream to a thermal process. A product produced or derived from the thermal process may displace a product made from fossil fuel. One or more products obtained or derived from at least one of the foregoing process steps are provided for use as a transportation or heating fuel. In various embodiments the process enables advantaged fuel credit generation.

Claims

1. A process for producing a transportation fuel comprising the steps of:

(i) pretreating a cellulosic feedstock in one or more processing steps that release extractives comprising at least acetic acid, acetate, or a combination thereof from the feedstock;

(ii) conducting a solids-liquid separation on a process stream comprising the extractives and solids, thereby producing an aqueous stream comprising soluble extractives and a solids stream comprising insoluble components;

(iii) feeding at least a portion of the aqueous stream comprising the soluble extractives to an anaerobic digester to produce crude biogas;

(iv) removing at least 80 weight % of carbon dioxide present in the crude biogas to produce purified biogas;

(v) providing an inorganic salt-containing liquid stream originating from the anaerobic digester and introducing at least a portion of the inorganic salt-containing liquid stream to (a) the anaerobic digester;

(b) a stage upstream of the anaerobic digester and downstream of step (i);

or (c) a combination thereof, wherein the at least a portion of the inorganic salt-containing liquid stream is not subject to water removal to produce a concentrated salt stream prior to the introducing;

(vi) purging a stream comprising inorganic salt from said inorganic salt-containing liquid stream and subjecting the purged stream to a water removal step;

(vii) providing solids from at least one stream selected from the solids stream comprising the insoluble components and a second solids stream comprising insoluble components to a thermal process to produce an energy product;

(viii) introducing the purified biogas produced in step (iv) to a pipeline for transporting methane and causing withdrawal of an amount of methane from at least one of the pipeline and a connected pipeline;

(ix) providing one or more products obtained or derived from step (viii) for use as a transportation fuel; and

(x) generating or causing the generation of a renewable fuel credit

wherein the inorganic salt-containing liquid stream introduced in step (v) comprises a fraction of the inorganic salt-containing liquid stream originating from the anaerobic digester effective to reduce overall GHG emissions relative to a comparative process wherein the complete inorganic salt-containing stream is subject to water removal and biogas yielded by the comparative process is used for generating internal heat and electricity rather than as a transportation fuel.

2. The process of claim 1, further comprising removing additional liquid from the solids stream of step (ii) to produce a concentrated solids stream.

3. The process of claim 1, wherein the renewable fuel credit is an Advanced Biofuel RIN.

4. The process of claim 1, wherein the inorganic salt-containing liquid stream of step (v) or a portion thereof is introduced to the solids-liquid separation.

5. The process of claim 1, wherein the inorganic salt-containing stream of step (v) is introduced to the anaerobic digester.

6. The process of claim 1, further comprising conducting a second solids-liquid separation on a solids stream comprising the insoluble components or a stream derived therefrom to produce a second aqueous stream and introducing the second aqueous stream or a portion thereof to the digester or to a stage upstream of the digester.

7. The process of claim 1, further comprising obtaining a slurry comprising microorganisms from the digester, conducting a solids-liquid separation on said slurry to obtain a concentrated slurry of microorganisms and introducing the concentrated slurry of microorganisms to the digester or to a stage upstream of the digester.

8. The process of claim 1, wherein the solids stream of step (vii) is gasified in the thermal process to produce syngas and the syngas is reacted to form a fuel or fuel intermediate.

9. The process of claim 1, wherein the aqueous stream of step (ii) comprises sulfur and said process further comprises:

(a) converting the sulfur or a portion thereof to gaseous hydrogen sulfide in said digester;

(b) treating the gaseous hydrogen sulfide to produce elemental sulfur or an oxide of sulfur;

(c) recovering an acid comprising sulfuric acid, sulfurous acid, sulfur dioxide or a combination thereof from the elemental sulfur or oxides of sulfur; and

(d) using the recovered acid in the process as a catalyst or for neutralizing alkali.

10. The process of claim 1, wherein the step of pretreating uses steam, pretreatment chemical, or a combination thereof, to produce a pretreated feedstock.

11. The process of claim 10, wherein the process comprises a step in which cellulose in said pretreated feedstock is hydrolyzed to produce glucose with cellulase enzymes.

12. The process of claim 11, wherein at least a portion of the inorganic salt-containing stream of step (v) is introduced to the step in which cellulose in said pretreated feedstock is hydrolyzed.

13. The process of claim 11, wherein the glucose is fermented to produce a fermentation product.

14. The process of claim 13, wherein the fermentation product is an alcohol.

15. The process of claim 14, wherein the alcohol is concentrated in an alcohol concentration step, and a still bottoms stream results from said concentration step.

16. The process of claim 15, wherein the solids-liquid separation of step (ii) is conducted on the still bottoms stream.

17. The process of claim 1, further comprising causing (a) methane to be converted to hydrogen in a process comprising reforming;

and (b) the hydrogen to be used in a process comprising hydrogenating a crude oil derived liquid hydrocarbon to produce a liquid transportation or heating fuel.

18. The process of claim 1, further comprising providing one or more products obtained or derived from step (vii) for use as a transportation fuel.

19. The process of claim 1, wherein step (x) comprises generating numerical information relating to the one or more products of step (ix), said information comprising at least 1 parameter selected from:

(a) the type of transportation fuel;

(b) the year in which the product was produced;

(c) a registration number associated with the producer or importer;

(d) a serial number associated with a batch; and

(e) an amount of fuel used as a fossil fuel replacement.

20. The process of claim 1, wherein the portion of the inorganic salt-containing liquid stream is greater than about 50%.

21. The process of claim 1, wherein the portion of the inorganic salt-containing liquid stream is greater than about 75%.

22. The process of claim 1, comprising recovering salt from the purge stream.

23. The process of claim 1, wherein generating or causing the generation of a renewable fuel credit comprises obtaining a renewable fuel credit associated with the purified biogas.

24. The process of claim 1, wherein generating or causing the generation of a renewable fuel credit comprises obtaining a renewable fuel credit for transportation fuel use of hydrogen gas obtained from the biogas.

25. The process of claim 1, wherein subjecting the purge stream to water removal comprises an evaporation, concentration with a membrane, freeze crystallization, or a combination thereof.

26. The process of claim 1, wherein the reductions in GHG emissions resulting from subjecting the purge stream produced in step (vi) to water removal rather than subjecting the complete inorganic salt-containing liquid stream to water removal offsets increased GHG emissions associated with step (iv) and step (viii) relative to the comparative process.

27. The process of claim 26, wherein the purge stream has a higher concentration of inorganic salt than organics.

28. The process of claim 1, wherein the stream comprising inorganic salt purged in step (vi) has a higher concentration of inorganic salt than organics.