Enhanced methods of synthetic chemical and fuel production through integrated processing and emission recovery

Abstract

The process described in this embodiment relates to the field of synthetic fuel and synthetic chemical production through co-processing methods such as pyrolysis, combustion, gasification, distillation, catalytic synthesis, methanol synthesis, hydro-treatment, and hydrogenation, cavitation, bioreaction, and water treatment. The inventions described herein relates to synthetic hydrocarbons derived from various carbonaceous materials such as biomass, solid municipal waste and coal which can be converted into typical industrial products and various unique synthetic fuels. The byproducts of each process are directed to other processes for additional product yield and to reduce waste and emissions.

What is claimed is: 
     
         1 . A process of producing synthetic fuels and chemical products comprising:
 a. integrating three or more fuel/chemical production processes such that one or more byproducts of one or more production processes are applied to other processes for additional product yield and to reduce waste and emissions;   b. a raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal; and   c. integrating three or more facilities that utilize said chemical product/fuel production processes such that one or more byproducts produced at one or more said facilities are used in the production of fuel/chemical product at other said facilities for additional product yield and to reduce waste and emissions;   d. operating the integrated fuel/chemical production processes to produce synthetic fuel and chemical products such that one or more byproducts of one or more production processes are utilized in an operation of other fuel/chemical production processes.   
     
     
         2 . The process of  claim 1 , wherein said fuel/chemical production processes are selected from the group consisting of feedstock preparation, pyrolysis, combustion, distillation, gasification, water treatment, catalytic synthesis, hydro-treatment/hydrogenation, methanol synthesis, cavitation, bio-reaction, and air separation. 
     
     
         3 . The process of  claim 2 , wherein the raw feedstock is prepared and input to pyrolysis process. 
     
     
         4 . The process of  claim 1 , wherein the integrated process provides various chemical products such as lubricant, dye, char/coke, gas fuel and synthetic liquid fuel. 
     
     
         5 . The process of  claim 1 , wherein heat, steam, water, hydrogen, carbon dioxide, and oxygen generated by the integrated process are recycled and used by the integrated process. 
     
     
         6 . The process of  claim 2 , wherein the pyrolysis process provides char/coke to the carbonaceous feedstock gasification; the pyrolysis facility and the gasification facility are located in proximity to each other to reduce operating costs. 
     
     
         7 . The process of  claim 2 , wherein the pyrolysis process provides organic compounds to the distillation process; the pyrolysis facility and the distillation facility are located in proximity to each other to reduce operating costs. 
     
     
         8 . The process of  claim 2 , wherein the pyrolysis process provides light gas to combustion process; the pyrolysis facility and the combustion facility are located in proximity to each other to reduce operating costs. 
     
     
         9 . The process of  claim 8 , wherein the combustion process is coupled with air separation such that the off gas produced in combustion is separated and carbon dioxide obtained from separation is used in methanol synthesis; the oxygen resulted from air separation is used in gasification or combustion. 
     
     
         10 . The process of  claim 8 , wherein the combustion process is coupled with bioreactor such that the off gas produced in combustion is used by bioreactor. 
     
     
         11 . The process of  claim 7 , wherein the distillation process is coupled with hydrotreatment/hydrogenation such that the medium liquids obtained from distillation is converted to synthetic fuels by hydrotreament/hydrogenation. 
     
     
         12 . The process of  claim 6 , wherein the gasification/gas separation process is coupled with catalytic synthesis and hydrotreatment/hydrogenation such that the syngas produced by gasification is converted to synthetic fuel by catalytic synthesis followed hydrotreatment/hydrogenation. 
     
     
         13 . The process of  claim 6 , wherein the gasification/gas separation process is coupled with cavitation such that the syngas produced by gasification is converted to synthetic fuel by cavitation. 
     
     
         14 . The process of  claim 6 , wherein the gasification/gas separation process is coupled with methanol sysnthesis such that the carbon dioxide and hydrogen obtained from gasification are converted to methanol by methanol synthesis. 
     
     
         15 . The process of  claim 6 , wherein the gasification/gas separation process is coupled with hydrotreatment/hydrogenation such that the hydrogen obtained from gasification is used in hydrotreatment/hydrogenation. 
     
     
         16 . A process of producing synthetic fuels and chemical products comprising:
 a. Integrating multiple processes including feedstock preparation, pyrolysis, distillation, and combustion;   b. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;   c. a set of by-products of pyrolysis includes organic compounds and char/coke, the organic compounds are input to distillation, the char/coke is used for terra preta;   d. a set of by-products of distillation includes light gas, medium liquids, and heavy liquids, the light gas is input to combustion to generate heat, the medium liquids is used/stored as synthetic fuel, the heavy liquids is recycled as feedstock;   e. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and   f. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.   
     
     
         17 . A process of producing synthetic fuels and chemical products comprising:
 a. Integrating multiple processes including feedstock preparation, pyrolysis, distillation, combustion and gasification/gas separation, air separation, methanol synthesis, catalytic synthesis, hydrogreatment/hydrogenation;   b. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;   c. a set of by-products of pyrolysis includes LP light gas, organic compounds, and char/coke, the LP light gas is input to combustion, the organic compounds are input to distillation, the char/coke is input to gasification;   d. a set of by-products of combustion includes off gas, steam, and heat, the offgas is input to air separation, the steam and heat is input to gasification;   e. a set of by-products of distillation includes LP light gas, heavy liquids, and medium liquids, the LP light gas is input to combustion, the medium liquids is input to hydrotreatment/hydrogenation, the heavy liquids is input for various uses;   f. a set of by-products of gasification/gas separation includes carbon dioxide, hydrogen, syngas, and heat/stream, the carbon dioxide and hydrogen are input to methanol synthesis, the syngas is input to catalytic synthesis, the heat and steam is input to catalytic synthesis and hydrotreatement/hydrogenation, the hydrogen is also input to hydrotreatment/hydrogenation;   g. a set of by-products of air separation includes oxygen, carbon dioxide, and various gases, oxygen is input to gasification and combustion, carbon dioxide is input to methanol synthesis, the various gases is input for other processes or can be used/stored as synthetic fuel;   h. a set of by-products of methanol synthesis includes light fuel and steam, the light fuel can be used/stored as synthetic fuel, the steam is input to gasification;   i. a set of by-products of catalytic synthesis includes HP light gas, heavy liquids, and medium liquids, HP light gas is input to gas separation and can produce carbon dioxide, the heavy liquids are for various uses, the medium liquids is input to hydrotreatment/hydrogenation and can produce various fuels of different density;   j. a set of by-products of hydrotreatment/hydrogenation includes light fuels, medium fuels, and heavy fuels, all these fuels can be used/stored as synthetic fuel;   k. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and   l. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.   
     
     
         18 . The process of producing synthetic fuels and chemical products in  claim 8  further comprising a water treatment process and a bio-reaction process, wherein
 a. a waste water is treated by the water treatment process to yield a set of product which includes LP light gas, water, and solid material, LP light gas and water are input to combustion, solid material is further treated by the feedstock preparation so as to input to pyrolysis; 
 b. a set of by-products of bio-reaction includes carbon dioxide and oxygen which are separated to oxygen and other gases by air separation, oxygen can be further used in gasification; 
 c. the off-gas produced in the process of combustion is input to bio-reactor instead of air separation; 
 d. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and 
 e. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions. 
 
     
     
         19 . A process of producing synthetic fuels and chemical products comprising:
 a. Integrating multiple processes including feedstock preparation, water treatment, pyrolysis, combustion, gasification/gas separation, cavitation, air separation, and methanol synthesis;   b. a waste water is treated by the water treatment process to yield a set of products which includes LP light gas, water, and solid material, LP light gas and water are input to combustion, solid material is further treated by the feedstock preparation so as to input to pyrolysis;   c. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;   d. a set of by-products of pyrolysis includes LP light gas, organic compounds, and char/coke, the LP light gas is input to combustion, the organic compounds are input to cavitation, the char/coke is input to gasification;   e. a set of by-products of combustion includes off gas, steam, and heat, the offgas is input to the bio-reactor, the steam and heat is input to gasification;   f. a set of by-products of gasification/gas separation includes carbon dioxide, hydrogen, syngas, and heat/stream, the carbon dioxide and hydrogen are input to methanol synthesis, the syngas is input to cavitation, the heat and steam is input to catalytic synthesis and hydrotreatement/hydrogenation, the hydrogen is also input to hydrotreatment/hydrogenation;   g. a set of by-products of cavitation/distillation includes LP light gas, light fuels, medium fuels, and heavy fuels, the LP light gas is input to combustion, the light fuels, medium fuels, and heavy fuels are used/stored as synthetic fuels;   h. a set of by-products of bio-reaction includes carbon dioxide and oxygen which are separated to oxygen and other gases by air separation, oxygen can be further used in gasification;   i. a set of by-products of air separation includes oxygen, carbon dioxide, and various gases, oxygen is input to gasification and combustion, carbon dioxide is input to methanol synthesis, the various gases is input for other processes or can be used/stored as synthetic fuel;   j. a set of by-products of methanol synthesis includes light fuel and steam, the light fuel can be used/stored as synthetic fuel, the steam is input to gasification;   k. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and   l. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.