System for making renewable fuels including gasoline, diesel, and jet fuel

Abstract

Multiple catalytic processing stations coupled with a system which produces volatile gas streams from biomass decomposition at discrete increasing temperatures or constant temperature. These catalytic processing stations can be programmed to maximize conversion of biomass to jet fuel components. The system may also include a processing station for subjecting biomass within the stations to at least one programmable starting temperature (T start ) and for incrementing an individual processing station temperature by programmable increments (ΔT) to produce a volatile and a non-volatile component. Further, methods for converting biomass and char to renewable jet fuel, diesel, and kerosene are disclosed.

1 . A system for the conversion of biomass to diesel or jet fuel, comprising:
 a device containing a number of processing stations (N) and a series of catalysts;   each processing station capable of subjecting biomass within the station to at least one starting temperature (T start ) to produce a volatile and a non-volatile component;   at least one catalyst reactor for receiving volatile components generated in each processing station; and   wherein, the at least one catalyst reactor contains a catalyst selected from the group consisting of: dehydration catalysts, olefin oligomerization catalysts and hydrotreating catalysts.   
     
     
         2 . The system of  claim 1 , further comprising additional catalyst reactors. 
     
     
         3 . The system of  claim 2 , wherein the additional catalyst reactors are used in series. 
     
     
         4 . The system of  claim 2 , wherein the additional catalyst reactors are used in parallel. 
     
     
         5 . The system of  claim 1 , further comprising a temperature controller for incrementing an individual processing station temperature by increments (ΔT). 
     
     
         6 . The system of  claim 1 , wherein the non-volatile component is a carbonaceous material. 
     
     
         7 . The system of  claim 1 , further comprising a gasifier for converting the carbonaceous material to syngas. 
     
     
         8 . The system of  claim 7 , further comprising a conduit from the gasifier to a catalyst reactor for the introduction of syngas. 
     
     
         9 . The system of  claim 1 , wherein N ranges from 2 to 1000, and wherein T start  ranges from 100° C. to 1000° C. 
     
     
         10 . The system of  claim 5 , wherein the temperature increment (ΔT) ranges from 0° C. to 200° C. 
     
     
         11 . The system of  claim 1 , further comprising a reservoir for housing a co-feed, and a conduit for introduction of the co-feed to the volatile components or to at least one of the processing stations, wherein the co-feed is selected from the group consisting of alcohols, aldehydes, ketones, ethers, carboxylic acids, and hydrocarbons. 
     
     
         12 . The system of  claim 11 , further comprising a conduit from the gasifier to a catalyst reactor containing a syngas conversion catalyst wherein the co-feed is generated via the syngas conversion catalyst. 
     
     
         13 . The system of  claim 1 , wherein biomass is selected from the group consisting of lipids, hemicellulose, cellulose and lignins. 
     
     
         14 . The system of  claim 13 , wherein the biomass is a mixture of two or more types of biomass selected from the group consisting of lipids, hemicellulose, cellulose and lignins. 
     
     
         15 . The system of  claim 13 , wherein T start  is selected according to the type of biomass with the highest concentration in the mixture of two or more types of biomass. 
     
     
         16 . The system of  claim 1 , wherein at least two processing stations are set at the same T start . 
     
     
         17 . The system of  claim 1 , wherein all of the processing stations are set at the same T start . 
     
     
         18 . The system of  claim 1 , wherein the T start  is a substantially constant temperature. 
     
     
         19 . The system of  claim 1 , wherein the non-volatile component is thermally conductive. 
     
     
         20 . The system of  claim 1 , wherein the non-volatile component at the Nth processing station comprises char. 
     
     
         21 . The system of  claim 1 , wherein the Nth processing station comprise an input capable of receiving an external source of water, carbon dioxide or methane, or internally provided recycled water or combustible gases arising from the catalyst treatment. 
     
     
         22 . The system of  claim 1 , wherein the dehydration catalyst comprises any acid catalyst or combination of acid catalysts. 
     
     
         23 . The system of  claim 1 , wherein the olefin oligomerization catalyst is a dehydration catalyst. 
     
     
         24 . The system of  claim 1 , further comprising conduits to direct water, carbon dioxide, and methanol generated in the system to the gasifier for use in the conversion of the non-volatile components to syngas. 
     
     
         25 . The system of  claim 24 , wherein the non-volatile component from a station comprises feedstock for the next station. 
     
     
         26 . The system of  claim 1 , wherein the diesel or jet fuel produced comprises one or more kerosene components. 
     
     
         27 . The system of  claim 1 , wherein the diesel or jet fuel produced comprises one or more jet fuel components. 
     
     
         28 . The system of  claim 1 , wherein the diesel or jet fuel produced comprises one or more diesel fuel components. 
     
     
         29 . The system of  claim 6 , wherein internally generated water, carbon dioxide, methanol are used as reactants in the conversion of the carbonaceous material to syngas. 
     
     
         30 . The system of  claim 1 , wherein the processing station is selected from the group consisting of a pyrolysis reactor, a fixed bed reactor, a fluidized bed reactor, a circulating bed reactor, a bubbling fluid bed reactor, a vacuum moving bed reactor, an entrained flow reactor, a cyclonic reactor, a vortex reactor, a rotating cone reactor, an auger reactor, an ablative reactor, a microwave assisted pyrolysis reactor, a plasma assisted pyrolysis reactor, a chamber in a biomass fractionating system, gasifier, and a vacuum moving bed reactors. 
     
     
         31 . A system for converting char to a renewable fuel, comprising:
 a device containing a plurality of processing stations (N) and a series of catalysts;   each processing station capable of subjecting char within the station to at least one starting temperature (T start ) to produce syngas;   
       at least one catalyst reactor for receiving syngas generated in each processing station; and 
       wherein, the at least one catalyst reactor contains a catalyst selected from the group consisting of: syngas conversion catalysts, methanol synthesis catalyst, DME synthesis catalysts, dehydration catalysts, olefin oligomerization catalysts and hydrotreating catalysts. 
     
     
         32 . The system of  claim 31 , further comprising additional catalyst reactors. 
     
     
         33 . The system of  claim 32 , wherein the additional catalyst reactors are used in series. 
     
     
         34 . The system of  claim 32 , wherein the additional catalyst reactors are used in parallel. 
     
     
         35 . The system of  claim 31 , wherein the processing station is selected from the group consisting of a pyrolysis reactor, a fixed bed reactor, a fluidized bed reactor, a circulating bed reactor, a bubbling fluid bed reactor, a vacuum moving bed reactor, an entrained flow reactor, a cyclonic reactor, a vortex reactor, a rotating cone reactor, an auger reactor, an ablative reactor, a microwave assisted pyrolysis reactor, a plasma assisted pyrolysis reactor, a chamber in a biomass fractionating system, gasifier, and a vacuum moving bed reactors. 
     
     
         36 . The system of  claim 31 , further comprising a temperature controller for incrementing an individual processing station temperature by increments (ΔT). 
     
     
         37 . The system of  claim 31 , wherein N ranges from 2 to 1000, and wherein T start  ranges from 100° C. to 1000° C. 
     
     
         38 . The system of  claim 36 , wherein the temperature increment (ΔT) ranges from 0° C. to 200° C. 
     
     
         39 . The system of  claim 31 , further comprising a reservoir for housing a co-feed, and a conduit for introduction of the co-feed to the volatile components or to at least one of the processing stations, wherein the co-feed is selected from the group consisting of alcohols, aldehydes, ketones, ethers, carboxylic acids, and hydrocarbons. 
     
     
         40 . The system of  claim 31 , wherein the Nth processing station comprises an input capable of receiving an external source of water, carbon dioxide or methane, or internally provided recycled water or combustible gases arising from the catalyst treatment. 
     
     
         41 . The system of  claim 31 , wherein the dehydration catalyst comprises any acid catalyst or combination of acid catalysts. 
     
     
         42 . The system of  claim 31 , wherein the olefin oligomerization catalyst is a dehydration catalyst. 
     
     
         43 . The system of  claim 31 , wherein the renewable fuel comprises one or more kerosene components, or one or more jet fuel components. 
     
     
         44 . A method for converting biomass to diesel or jet fuel, comprising:
 dispensing biomass into a plurality of processing stations (N);   subjecting biomass within the station to at least one starting temperature (T start ) to produce a volatile and a non-volatile component;   directing the volatile component to at least one catalyst reactor designed to perform one or more of the processes selected from the group consisting of dehydration, olefin oligomerization and hydrotreating;   collecting the diesel or jet fuel produced in the at least one catalyst reactor.   
     
     
         45 . The method of  claim 44 , further comprising additional catalyst reactors. 
     
     
         46 . The method of  claim 45 , wherein the additional catalyst reactors are used in series. 
     
     
         47 . The method of  claim 45 , wherein the additional catalyst reactors are used in parallel. 
     
     
         48 . The method of  claim 44 , further comprising using a temperature controller for incrementing an individual processing station temperature by increments (ΔT). 
     
     
         49 . The method of  claim 44 , wherein the non-volatile component is a carbonaceous material. 
     
     
         50 . The method of  claim 44 , further comprising converting the carbonaceous material to syngas. 
     
     
         51 . The method of  claim 44 , wherein N ranges from 2 to 1000, and wherein T start  ranges from 100° C. to 1000° C. 
     
     
         52 . The method of  claim 44 , wherein the temperature increment (ΔT) ranges from 0° C. to 200° C. 
     
     
         53 . The method of  claim 1 , further comprising introducing co-feed to the volatile components or to at least one of the processing stations, wherein the co-feed is selected from the group consisting of alcohols, aldehydes, ketones, ethers, carboxylic acids, and hydrocarbons. 
     
     
         54 . The method of  claim 53 , further comprising a catalyst reactor containing a syngas conversion catalyst wherein the co-feed is generated via the syngas conversion catalyst. 
     
     
         55 . The method of  claim 44 , wherein biomass is selected from the group consisting of lipids, hemicellulose, cellulose and lignins. 
     
     
         56 . The method of  claim 55 , wherein the biomass is a mixture of two or more types of biomass selected from the group consisting of lipids, hemicellulose, cellulose and lignins. 
     
     
         57 . The method of  claim 56 , wherein T start  is selected according to the type of biomass with the highest concentration in the mixture of two or more types of biomass. 
     
     
         58 . The method of  claim 44 , wherein at least two processing stations are set at the same T start . 
     
     
         59 . The method of  claim 44 , wherein all of the processing stations are set at the same T start . 
     
     
         60 . The method of  claim 44 , wherein the T start  is a substantially constant temperature. 
     
     
         61 . The method of  claim 44 , wherein the non-volatile component is thermally conductive. 
     
     
         62 . The method of  claim 44 , wherein the non-volatile component at the Nth processing station comprises char. 
     
     
         63 . The method of  claim 44 , wherein the Nth processing station comprise an input capable of receiving an external source of water, carbon dioxide or methane, or internally provided recycled water or combustible gases arising from the catalyst treatment. 
     
     
         64 . The method of  claim 44 , wherein the dehydration catalyst comprises any acid catalyst or combination of acid catalysts. 
     
     
         65 . The method of  claim 44 , wherein the olefin oligomerization catalyst is a dehydration catalyst. 
     
     
         66 . The method of  claim 44 , wherein water, carbon dioxide, and methanol generated in the system are used in the conversion of the non-volatile components to syngas. 
     
     
         67 . The method of  claim 44 , wherein the non-volatile component from a station comprises feedstock for the next station. 
     
     
         68 . The method of  claim 44 , wherein the diesel or jet fuel produced comprises one or more kerosene components. 
     
     
         69 . The method of  claim 44 , wherein the diesel or jet fuel produced comprises one or more jet fuel components. 
     
     
         70 . The method of  claim 44 , wherein the diesel or jet fuel produced comprises one or more diesel fuel components. 
     
     
         71 . The method of  claim 49 , wherein internally generated water, carbon dioxide, methanol are used as reactants in the conversion of the carbonaceous material to syngas. 
     
     
         72 . The method of  claim 44 , wherein the processing station is selected from the group consisting of a pyrolysis reactor, a fixed bed reactor, a fluidized bed reactor, a circulating bed reactor, a bubbling fluid bed reactor, a vacuum moving bed reactor, an entrained flow reactor, a cyclonic reactor, a vortex reactor, a rotating cone reactor, an auger reactor, an ablative reactor, a microwave assisted pyrolysis reactor, a plasma assisted pyrolysis reactor, a chamber in a biomass fractionating system, gasifier, and a vacuum moving bed reactors. 
     
     
         73 . A method for converting char to diesel or jet fuel, comprising:
 dispensing char into a plurality of processing stations (N);   subjecting char within the station to at least one starting temperature (T start ) to produce syngas;   
       directing the syngas to at least one catalyst reactor designed to perform one or more of the processes selected from the group consisting of syngas conversion catalysts, methanol synthesis catalyst, DME synthesis catalysts, dehydration, olefin oligomerization and hydrotreating;
 collecting the diesel or jet fuel produced in the at least one catalyst reactor. 
 
     
     
         74 . The method of  claim 73 , further comprising additional catalyst reactors. 
     
     
         75 . The method of  claim 74 , wherein the additional catalyst reactors are used in series. 
     
     
         76 . The method of  claim 74 , wherein the additional catalyst reactors are used in parallel. 
     
     
         77 . The method of  claim 73 , wherein the processing station is selected from the group consisting of a pyrolysis reactor, a fixed bed reactor, a fluidized bed reactor, a circulating bed reactor, a bubbling fluid bed reactor, a vacuum moving bed reactor, an entrained flow reactor, a cyclonic reactor, a vortex reactor, a rotating cone reactor, an auger reactor, an ablative reactor, a microwave assisted pyrolysis reactor, a plasma assisted pyrolysis reactor, a chamber in a biomass fractionating system, gasifier, and a vacuum moving bed reactors. 
     
     
         78 . The method of  claim 73 , further comprising using a temperature controller for incrementing an individual processing station temperature by increments (ΔT). 
     
     
         79 . The method of  claim 73 , wherein N ranges from 2 to 1000, and wherein T start  ranges from 100° C. to 1000° C. 
     
     
         80 . The method of  claim 78 , wherein the temperature increment (ΔT) ranges from 0° C. to 200° C. 
     
     
         81 . The method of  claim 73 , further comprising introducing co-feed to the volatile components or to at least one of the processing stations, wherein the co-feed is selected from the group consisting of alcohols, aldehydes, ketones, ethers, carboxylic acids, and hydrocarbons. 
     
     
         82 . The method of  claim 73 , wherein the Nth processing station receives an external source of water, carbon dioxide or methane, or internally provided recycled water or combustible gases arising from the catalyst treatment. 
     
     
         83 . The method of  claim 73 , wherein the dehydration catalyst comprises any acid catalyst or combination of acid catalysts. 
     
     
         84 . The method of  claim 73 , wherein the olefin oligomerization catalyst is a dehydration catalyst. 
     
     
         85 . The method of  claim 73 , wherein the renewable fuel comprises one or more kerosene components, or one or more jet fuel components.