Method for maximizing the value of carbonaceous material

Abstract

A method for pyrolyzing coal to produce a raw hydrogen-rich gas and a hot char composed of carbon that is divided into two streams, one gasified to make a second gas and one reacted with steam to produce hot activated carbon that is divided into a first sub-stream and a second sub-stream. The hydrogen rich gas, after cleanup, is converted to methanol which, in turn, is synthesized into gasoline or synthetic natural gas. The second gas, after clean-up, fuels a turbine to generate electricity while exhausting a flue gas (N 2 +CO 2 ) that is reacted with the first sub-stream of hot activated carbon and with hydrogen for synthesis into urea (CO(NH 2 ) 2 ). The urea is mixed with the second sub-stream of activated carbon to produce a fertilizer which is introduced into soil to store plant nutrients. This process produces fuel, electricity, and enhancement of plant growth.

1 . A method for maximizing the value of carbonaceous material in an environmentally acceptable manner comprising the following steps:
 pyrolyzing the carbonaceous material in an atmosphere which is deficient of oxygen to produce a first gas and a hot char which possesses a cellular structure that is essentially made up of carbon;   dividing said char into two streams comprising a first stream of char and a second stream of char;   gasifying said first stream of char to produce a second gas;   utilizing said first stream of gas and said second stream of gas as fuels for the formation of one or more than one subsequent form of energy while emitting a flue gas containing carbon dioxide (CO 2 ) into the atmosphere, said CO 2  being a greenhouse gas and being suspected of causing global warming; and   sequestering said second stream of char in soil in order to compensate for at least a portion of the CO 2  emitted into the atmosphere while increasing the capability of the soil to retain nutrients in the cellular structure of the sequestered char to result in an increase in the yield of plant growth from said soil, said increase of plant growth being a greater consumer of CO 2  than if said second stream of char were not sequestered in the soil.   
   
   
       2 . The method as set forth in  claim 1  wherein said first gas and said second gas are cleaned prior to the step of utilizing said gases as fuels for the formation of one or more subsequent form of energy. 
   
   
       3 . The method as set forth in  claim 1  wherein said second stream of char is activated to convert it to activated carbon by enhancing the capability of its cellular structure to absorb nutrients. 
   
   
       4 . The method as set forth in  claim 1  wherein said first gas is a hydrogen (H 2 ) rich gas which is suitable for making an upgraded chemical. 
   
   
       5 . The method as set forth in  claim 1  wherein the step of utilizing said first gas and second gas as fuels for the formation of one or more than one subsequent form of energy is further characterized by the step of utilizing both gases as fuels for electric power generation. 
   
   
       6 . The method as set forth in  claim 4  wherein said upgraded chemical takes the form of methanol. 
   
   
       7 . The method as set forth in  claim 4  wherein said upgraded chemical takes the form of synthetic natural gas. 
   
   
       8 . The method as set forth in  claim 6  wherein said methanol is converted into a transport fuel. 
   
   
       9 . The method as set forth in  claim 8  wherein said transport fuel comprises gasoline. 
   
   
       10 . The method as set forth in  claim 1  wherein the step of gasifying said first stream of char to produce a second gas is further characterized by the step of injecting an oxidant to implement the step of gasifying said char to produce a hot second gas at an elevated temperature. 
   
   
       11 . The method as set forth in  claim 10  wherein steam is injected in addition to said oxidant. 
   
   
       12 . The method as set forth in  claim 10  wherein said step of injecting an oxidant comprises the injecting of air to give said second gas additional mass and low NO X  formation properties when it is combusted. 
   
   
       13 . The method as set forth in  claim 12  further comprising the use of said second gas with its additional mass to fuel a combustion turbine to efficiently generate electric power. 
   
   
       14 . The method as set forth in  claim 13  being further characterized by said combustion turbine being part of a combined cycle configuration for the generation of electric power while emitting an off-gas as a waste flue gas consisting mainly of N 2 +CO 2 . 
   
   
       15 . The method as set forth in  claim 14  wherein said combined cycle configuration is operated at a full load continuously to generate the maximum amount of electric power despite off-peak period. 
   
   
       16 . The method as set forth in  claim 15  wherein the excess electric power generated during off-peak period is used to electrolyze water to produce economical H 2  and O 2 . 
   
   
       17 . The method as set forth in  claim 16  wherein said water takes the form of steam that is electrolyzed in a high-temperature electrolysis system. 
   
   
       18 . The method as set forth in  claim 17  wherein said high-temperature electrolysis comprises the recycling of H 2  with said steam to provide a more efficient electrolysis system in the production of H 2 . 
   
   
       19 . The method as set forth in  claim 14  wherein said flue gas consisting of N 2 +CO 2  is combined with H 2  generated via electrolysis to form a mixture of flue gas (N 2 +CO 2 ) plus hydrogen (H 2 ). 
   
   
       20 . The method as set forth in  claim 3  wherein the step of activating said second stream of char to convert it to activated carbon is further characterized by the step of sub-dividing said second stream of char into a “first” sub-stream and a “second” sub-stream. 
   
   
       21 . The method as set forth in  claim 20  wherein said “first” sub-stream is heated in order to create a hot “first” sub-stream of hot activated carbon (C). 
   
   
       22 . The method as set forth in  claim 10  wherein said step of injecting an oxidant to implement the step of gasifying said char to produce a hot second gas at an elevated temperature is further characterized by the step of directing said hot second gas to heat said “first” sub-stream of activated carbon referred to in  claim 21  to increase its reactivity. 
   
   
       23 . The method as set forth on  claim 19  wherein said mixture of flue gas (N 2 +CO 2 ) plus hydrogen (H 2 ) is further combined with said “first” sub-stream of hot activated carbon (C) referred to in  claim 21  to form urea. 
   
   
       24 . The method as set forth in  claim 23  wherein said urea is further mixed with said “second” sub-stream of activated carbon (C) referred to in  claim 20  to form an enhanced urea for the vigorous growth of plant life. 
   
   
       25 . The method as set forth in  claim 1  wherein said carbonaceous material is coal. 
   
   
       26 . The method as set forth in  claim 14  wherein the step of emitting an off-gas as a waste flue gas consisting mainly of N 2 +CO 2  is further characterized by the step of separating the N 2  from the CO 2 . 
   
   
       27 . The method as set forth in  claim 26  comprises the reacting of the CO 2  with ammonia 2(NH 3 ) to form urea (NH 2 .NH 2 .CO) plus water (H 2 O). 
   
   
       28 . The method as set forth in  claim 1  wherein said carbonaceous material contains sulfur. 
   
   
       29 . The method as set forth in  claim 1  wherein said first gas and said second gas are combined, cleaned and utilized to generate electric power while emitting a flue gas which is suspected to create a harmful effect to the environment. 
   
   
       30 . The method as set forth in  claim 2  wherein said first gas and said second gas are cleaned comprises the removal of mercury from both gases. 
   
   
       31 . The method as set forth in  claim 1  wherein said first gas and said second gas are utilized for the poly-generation of various products.