Energy efficient system and process for the continuous production of fuels and energy from syngas

Abstract

A system and apparatus is provided that maximizes mass and energy conversion efficiencies in an integrated thermochemical process for the conversion of fossil fuel or renewable biomass to synthesis gas. The system combines gasification, catalytic conversion of gas to liquid, electricity generation, steam and chilled water generation with a system controller to maximize the conversion efficiency from syngas to merchantable products over the efficiency of syngas alone burned as a fuel. A clean synthesis gas stream is introduced into a catalytic reactor that utilizes specially formulated catalysts to generate liquid fuel from CO and H 2 while concentrating CH 4 and other combustible, but non-reactive gases in the syngas product stream. The methane rich stream is introduced into an engine for the production of electricity and heat while the unreacted CO and H 2 can be recycled to produce additional liquid fuel. Excess heat can be used for other co-located processes and facilities.

1 . A process for the continuous production of electricity, heat and syngas derived products, comprising:
 converting biomass or fossil fuels to a stream of synthesis gases;   analyzing characteristics of said stream of synthesis gases;   supplementing said stream of synthesis gases with hydrogen gas from a source of hydrogen gas to produce a supplemented stream of synthesis gas with a regulated composition;   reacting the supplemented synthesis gas stream with catalysts selected to convert carbon monoxide and hydrogen to reaction products to produce a stream of reaction products and unreacted synthesis gases;   separating reaction products from the unreacted synthesis gases; and   combusting the unreacted synthesis gases to produce electricity and heat.   
   
   
       2 . A process as recited in  claim 1 , further comprising:
 mixing a portion of the unreacted synthesis gases with said supplemented stream of synthesis gases; and   recycling said mixed gas stream through the catalyst for at least one cycle,   wherein the conversion efficiency of reactive gases to products is maximized.   
   
   
       3 . A process as recited in  claim 1 , further comprising:
 monitoring of the characteristics of the pre- and post-catalyst gas stream;   optimizing a ratio of recycle gas with synthesis gas to provide a synthesis gas stream that has approximately the highest reaction efficiency with the catalysts; and   concentrating said recycled unreacted gas stream gases prior to combustion.   
   
   
       4 . A process as recited in  claim 3 , further comprising:
 using software models to analyze said monitored gas characteristics to establish optimum operating conditions; and   controlling temperature, pressure, space velocity, chemical composition and recycle rates of said pre- and post catalyst synthesis gas streams.   
   
   
       5 . A process as recited in  claim 1 , further comprising:
 converting carbon dioxide gas in said synthesis gas stream to carbon monoxide gas.   
   
   
       6 . A process as recited in  claim 1 , wherein said hydrogen source is generated by electrolysis of water with electricity generated by the system. 
   
   
       7 . A process as recited in  claim 1 , further comprising:
 producing steam from excess heat from combustion, catalytic reactor and synthesis gas production to produce steam; and   generating electricity from the steam, thereby increasing the energy efficiency of the entire system.   
   
   
       8 . A process as recited in  claim 1 , further comprising:
 using a portion of the excess heat from combustion of said unreacted synthesis gases for gasification of carbonaceous feedstock.   
   
   
       9 . A process as recited in  claim 1 , further comprising:
 using a portion of the excess heat from combustion of said unreacted synthesis gases for an absorptive chiller used to provide chilled fluids for a condenser to separate reaction products from a post catalyst gas stream.   
   
   
       10 . A process as recited in  claim 1 , further comprising:
 controlling compressors, valves and flow rates of gas with a process controller and sensors.   
   
   
       11 . A process for the continuous production of electricity, heat and syngas derived products, comprising:
 generating synthesis gas stream from a carbonaceous feedstock;   reacting the synthesis gas stream with catalysts selected to convert carbon monoxide and hydrogen to reaction products to produce a stream of reaction products and unreacted synthesis gases;   separating reaction products from the unreacted synthesis gases;   splitting said unreacted synthesis gases into two streams;   recycling a portion of unreacted synthesis gases through said catalysts for at least one cycle;   combusting a portion of the unreacted synthesis gases;   monitoring pressure, temperature, gas composition and flow rates of the synthesis gas flow and recycled synthesis gas flow with sensors;   controlling the pressure, temperature, gas composition and flow rates of the synthesis gas flow and recycled synthesis gas flow and output of reaction products and electricity with a process controller; and   producing steam with excess heat from a gas combustion chamber.   
   
   
       12 . A process as recited in  claim 11 , further comprising:
 analyzing continuously said stream of synthesis gases and recycled gases; and   supplementing said stream of gases with hydrogen gas from a source of hydrogen gas to produce a supplemented stream of synthesis gas with a regulated ratio of hydrogen to carbon monoxide.   
   
   
       13 . A catalytic reactor, comprising:
 a reaction vessel with at least one reaction chamber and an intake duct and an output duct;   a first hydrogenation catalyst;   a carbonylation catalyst; and   a second hydrogenation catalyst,   wherein gas containing carbon monoxide and hydrogen entering through said intake duct can pass sequentially through each catalyst and through the output duct.   
   
   
       14 . A catalytic reactor as recited in  claim 13 , further comprising:
 means for heating gasses within said reaction vessel.   
   
   
       15 . A catalytic reactor as recited in  claim 13 , further comprising:
 a catalyst support carrier.   
   
   
       16 . A catalytic reactor as recited in  claim 15 , wherein said support carrier is a carrier selected from the group of carriers consisting essentially of aluminum oxide, silica, a zeolite, titanium oxide, metal and clay. 
   
   
       17 . A catalytic reactor as recited in  claim 13 , wherein said first hydrogenation catalyst is a catalyst selected from the group of catalysts consisting essentially of Cu, Zn, Mo, Ni, or Fe. 
   
   
       18 . A catalytic reactor as recited in  claim 13 , wherein said hydrogenation catalyst further comprises an alkali metal promoter, selected from the group of promoters consisting essentially of Ti, Zr, Pd, and Mn. 
   
   
       19 . A catalytic reactor as recited in  claim 13 , wherein said carbonylation catalyst comprises at least one Group VIII metal and at least one co-catalyst. 
   
   
       20 . A catalytic reactor as recited in  claim 13 , wherein said co-catalyst comprises yttrium metal, a lanthanide series metal or an actinide series metal.