Device and method for reforming a voc gas

Abstract

A device and method for producing a reformate fuel from a hydrocarbon gas source. Gases ( 102 ) having low concentrations of hydrocarbons are concentrated using a concentrator ( 120 ) into a gaseous ( 123 ) or liquid ( 131 ) concentrated VOC fuel. The concentrated VOC fuel is then converted into a reformate ( 145 ) using a reformer ( 140 ). The reformate ( 145 ) is more easily consumed by an energy conversion device ( 160 ) such as a combustion engine, fuel cell, sterling engine or similar device that converts chemical energy into kinetic or electrical energy. The reformer ( 140 ) enables complex hydrocarbon fuels that are not normally suitable for use in an energy conversion device ( 160 ) to be converted into a reformate ( 145 ). The reformate ( 145 ) may be directly supplied into the energy conversion device ( 160 ).

1 . A device for producing a reformate comprising: 
 a concentrator concentrating a dilute VOC gas stream into a concentrated VOC fuel; and    a reformer reforming said concentrated VOC fuel into reformate.    
   
   
       2 . The device of  claim 1 , wherein said concentrator includes an adsorbent media adsorbing said dilute VOC gas stream.  
   
   
       3 . The device of  claim 2 , wherein said concentrator comprises an adsorbing chamber where said dilute VOC gas stream is adsorbed on said adsorbent media and a desorbing chamber where said adsorbed VOC gas stream is desorbed.  
   
   
       4 . The device of  claim 2 , wherein said adsorbent media is selected from the group comprising activated carbon, zeolite, synthetic resin and mixtures thereof.  
   
   
       5 . The device of  claim 1 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 15,000 ppm.  
   
   
       6 . The device of  claim 5 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 200,000 ppm.  
   
   
       7 . The device of  claim 3 , further comprising a sweep gas desorbing adsorbed VOC.  
   
   
       8 . The device of  claim 7 , wherein said sweep gas is steam.  
   
   
       9 . The device of  claim 7 , wherein said inert gas is nitrogen.  
   
   
       10 . The device of  claim 7 , wherein said sweep gas is gaseous fuel.  
   
   
       11 . The device of  claim 9 , further comprising a condenser condensing said concentrated VOC fuel into a liquid.  
   
   
       12 . The device of  claim 2 , wherein said adsorbent media is in a fluidized bed.  
   
   
       13 . The device of  claim 2 , wherein said adsorbent media is affixed to a rotating wheel.  
   
   
       14 . The device of  claim 2 , wherein said adsorbent media is contained in fixed beds.  
   
   
       15 . The device of  claim 1 , further comprising a cooler cooling said reformate.  
   
   
       16 . The device of  claim 1 , wherein said reformate contains H 2  gas and oxides of carbon.  
   
   
       17 . The device of  claim 1 , wherein the device contains filters that filter particulates from the dilute VOC gas stream.  
   
   
       18 . The device of  claim 1 , wherein said dilute VOC gas stream comprises straight chain hydrocarbons, branched hydrocarbons, aromatic hydrocarbons, oxygenated hydrocarbons and mixtures thereof.  
   
   
       19 . The device of  claim 1 , wherein said dilute VOC gas stream is between 1 ppm and 5000 ppm VOC.  
   
   
       20 . The device of  claim 1 , wherein said dilute VOC gas stream is paint exhaust.  
   
   
       21 . The device of  claim 1 , wherein said dilute VOC gas stream is gasoline vapor.  
   
   
       22 . The device of  claim 1 , wherein said dilute VOC gas stream is formaldehyde and acidic acid.  
   
   
       23 . An energy producing device receiving a dilute VOC gas stream comprising: 
 a concentrator that concentrates the VOC into concentrated VOC fuel;    a sweep gas injector injecting sweep gas into the concentrator to remove the concentrated VOC fuel;    a reformer converting said sweep gas and concentrated VOC fuel into reformate; and    an energy conversion device consuming said reformate to produce energy    
   
   
       24 . The device of  claim 23 , wherein said concentrator includes an adsorbent media adsorbing said dilute VOC gas stream.  
   
   
       25 . The device of  claim 24 , wherein said concentrator comprises an adsorbing chamber where said dilute VOC gas stream is adsorbed on said adsorbent media and a desorbing chamber where said adsorbed VOC gas stream is desorbed.  
   
   
       26 . The device of  claim 24 , wherein said adsorbent media is selected from the group comprising activated carbon, zeolite, synthetic resin and mixtures thereof.  
   
   
       27 . The device of  claim 23 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 15,000 ppm.  
   
   
       28 . The device of  claim 27 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 200,000 ppm.  
   
   
       29 . The device of  claim 23 , wherein said sweep gas is steam.  
   
   
       30 . The device of  claim 23 , wherein said sweep gas is a gaseous fuel.  
   
   
       31 . The device of  claim 23 , wherein said sweep gas is inert.  
   
   
       32 . The device of  claim 31 , wherein said sweep gas is nitrogen.  
   
   
       33 . The device of  claim 24 , wherein said adsorbent media is in a fluidized bed.  
   
   
       34 . The device of  claim 24 , wherein said adsorbent media is affixed to a rotating wheel.  
   
   
       35 . The device of  claim 24 , wherein said adsorbent media is contained in fixed beds.  
   
   
       36 . The device of  claim 23 , further comprising a cooler cooling said reformate.  
   
   
       37 . The device of  claim 23 , wherein said reformate contains H 2  gas and oxides of carbon.  
   
   
       38 . The device of  claim 23 , wherein the device contains filters that filter particulates from the dilute VOC gas stream.  
   
   
       39 . The device of  claim 23 , wherein said dilute VOC gas stream comprises straight chain hydrocarbons, branched hydrocarbons, aromatic hydrocarbons, oxygenated hydrocarbons and mixtures thereof.  
   
   
       40 . The device of  claim 23 , wherein said dilute VOC gas stream is between 1 ppm and 5000 ppm VOC.  
   
   
       41 . The device of  claim 23 , wherein said dilute VOC gas stream is paint exhaust.  
   
   
       42 . The device of  claim 23 , wherein said dilute VOC gas stream is gasoline vapor.  
   
   
       43 . The device of  claim 23 , wherein said dilute VOC gas stream is formaldehyde and acidic acid.  
   
   
       44 . The device of  claim 23 , further comprising a second fuel, whereby said energy conversion device consumes a fuel mixture of said reformate and said second fuel.  
   
   
       45 . The device of  claim 44 , further comprising a controller controlling the proportion of said reformate and said second fuel supplied to said energy conversion device.  
   
   
       46 . The device of  claim 45 , further comprising a signal proportional to the amount of said reformate supplied to said energy conversion device, wherein said controller varies the amount of said second fuel in response to said reformate.  
   
   
       47 . The device of  claim 44 , wherein said second fuel is between 0 and 90% of said fuel mixture.  
   
   
       48 . The device of  claim 23 , wherein said energy conversion device is a Stirling engine.  
   
   
       49 . The device of  claim 23 , wherein said energy conversion device is a fuel cell.  
   
   
       50 . The device of  claim 23 , wherein said energy conversion device is an internal combustion engine.  
   
   
       51 . The device of  claim 23 , wherein said energy conversion device is a gas turbine.  
   
   
       52 . The device of  claim 23 , wherein said energy is electricity.  
   
   
       53 . The device of  claim 52 , further comprising electric switchgear and a power grid where the switchgear conditions the electrical energy to make it compatible with the power grid.  
   
   
       54 . A device producing energy comprising: 
 VOC gas stream directing devices that direct the dilute VOC gas stream;    a concentrator that concentrates the VOC into concentrated VOC fuel;    a inert gas injector injecting inert gas into the concentrator to remove the concentrated VOC fuel;    a condenser condensing liquid VOC from said concentrated VOC fuel;    a reformer converting said liquid VOC into reformate; and    an energy conversion device consuming said reformate to produce energy    
   
   
       55 . The device of  claim 54 , wherein said concentrator includes an adsorbent media adsorbing said dilute VOC gas stream.  
   
   
       56 . The device of  claim 55 , wherein said concentrator comprises an adsorbing chamber where said dilute VOC gas stream is adsorbed on said adsorbent media and a desorbing chamber where said adsorbed VOC gas stream is desorbed.  
   
   
       57 . The device of  claim 55 , wherein said adsorbent media is selected from the group comprising activated carbon, zeolite, synthetic resin and mixtures thereof.  
   
   
       58 . The device of  claim 54 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 15,000 ppm.  
   
   
       59 . The device of  claim 58 , wherein said concentrator concentrates said concentrated VOC fuel to a concentration greater than 200,000 ppm.  
   
   
       60 . The device of  claim 55 , wherein said adsorbent media is in a fluidized bed.  
   
   
       61 . The device of  claim 55 , wherein said adsorbent media is affixed to a rotating wheel.  
   
   
       62 . The device of  claim 55 , wherein said adsorbent media is contained in fixed beds.  
   
   
       63 . The device of  claim 54 , further comprising a cooler cooling said reformate.  
   
   
       64 . The device of  claim 54 , wherein said reformate contains H 2  gas and oxides of carbon.  
   
   
       65 . The device of  claim 54 , wherein the device contains filters that filter particulates from the dilute VOC gas stream.  
   
   
       66 . The device of  claim 54 , wherein said dilute VOC gas stream is selected from the group comprising straight chain hydrocarbons, branched hydrocarbons, aromatic hydrocarbons, oxygenated hydrocarbons and mixtures thereof.  
   
   
       67 . The device of  claim 54 , wherein said dilute VOC gas stream is between 1 ppm and 5000 ppm VOC.  
   
   
       68 . The device of  claim 54 , wherein said dilute VOC gas stream is paint exhaust.  
   
   
       69 . The device of  claim 54 , wherein said dilute VOC gas stream is gasoline vapor.  
   
   
       70 . The device of  claim 54 , wherein said dilute VOC gas stream is formaldehyde and acidic acid.  
   
   
       71 . The device of  claim 54 , further comprising a second fuel, whereby said energy conversion device consumes a fuel mixture of said reformate and said second fuel.  
   
   
       72 . The device of  claim 71 , further comprising a controller controlling the proportion of said reformate and said second fuel supplied to said energy conversion device.  
   
   
       73 . The device of  claim 72 , further comprising a signal proportional to the amount of said reformate supplied to said energy conversion device, wherein said controller varies the amount of said second fuel in response to said reformate.  
   
   
       74 . The device of  claim 71 , wherein said second fuel is between 0 and 90% of said fuel mixture.  
   
   
       75 . The device of  claim 54 , wherein said energy conversion device is a Stirling engine.  
   
   
       76 . The device of  claim 54 , wherein said energy conversion device is a fuel cell.  
   
   
       77 . The device of  claim 54 , wherein said energy conversion device is an internal combustion engine.  
   
   
       78 . The device of  claim 54 , wherein said energy conversion device is a gas turbine.  
   
   
       79 . The device of  claim 54 , wherein said energy is electricity.  
   
   
       80 . The device of  claim 79 , further comprising electric switchgear and a power grid where the switchgear conditions the electrical energy to make it compatible with the power grid.  
   
   
       81 . The device of  claim 54 , wherein said inert gas is nitrogen.  
   
   
       82 . A method of making a reformate comprising; 
 concentrating a dilute VOC gas stream into a concentrated VOC fuel; and    reforming said concentrated VOC fuel into said reformate.    
   
   
       83 . The method of  claim 82 , further comprising the step of adsorbing said dilute VOC gas stream on an adsorbent media.  
   
   
       84 . The method of  claim 83 , further comprising the step of heating said adsorbent media to cause said adsorbed VOC to desorb.  
   
   
       85 . The method of  claim 84 , further comprising the step of injecting a sweep gas into said concentrator to cause said adsorbed VOC to desorb.  
   
   
       86 . The method of  claim 85 , wherein said sweep gas is steam.  
   
   
       87 . The method of  claim 85 , wherein said sweep gas is inert.  
   
   
       88 . The method of  claim 87 , wherein said inert gas is nitrogen.  
   
   
       89 . The method of  claim 85 , wherein said sweep gas is a gaseous fuel.  
   
   
       90 . The method of  claim 87 , further comprising the step of condensing said concentrated VOC fuel into a liquid.  
   
   
       91 . The method of  claim 83 , wherein said adsorbent media is in a continuous loop.  
   
   
       92 . The method of  claim 82 , further comprising the step of cooling said reformate.  
   
   
       93 . The method of  claim 82 , wherein said reformate contains H 2  gas and oxides of carbon.  
   
   
       94 . The method of  claim 82 , further comprising the step of filtering said dilute VOC gas stream prior to said concentrating step.  
   
   
       95 . The method of  claim 82 , wherein said dilute VOC gas stream is selected from the group comprising straight chain hydrocarbons, branched hydrocarbons, aromatic hydrocarbons, oxygenated hydrocarbons and mixtures thereof.  
   
   
       96 . The method of  claim 82 , wherein said dilute VOC gas stream is between 1 ppm and 5000 ppm VOC.  
   
   
       97 . The method of  claim 82 , wherein said dilute VOC gas stream is paint exhaust.  
   
   
       98 . The method of  claim 82 , wherein said dilute VOC gas stream is gasoline vapor.  
   
   
       99 . The method of  claim 82 , wherein said dilute VOC gas stream is formaldehyde and acidic acid.  
   
   
       100 . A method of supplying reformate to an energy conversion device comprising the steps of: 
 adsorbing VOC from a dilute VOC gas stream onto an adsorbent media;    desorbing said VOC to form a concentrated VOC fuel stream;    reforming said concentrated VOC fuel stream into a reformate; and    supplying said reformate to the energy conversion device.    
   
   
       101 . The method of  claim 100 , further comprising the step of heating said adsorbent media to cause said adsorbed VOC to desorb.  
   
   
       102 . The method of  claim 101 , further comprising the step of injecting sweep gas into said concentrator to cause said adsorbed VOC to desorb.  
   
   
       103 . The method of  claim 102 , wherein said sweep gas is steam.  
   
   
       104 . The method of  claim 102 , wherein said sweep gas is inert.  
   
   
       105 . The method of  claim 102 , wherein said sweep gas is a gaseous fuel.  
   
   
       106 . The method of  claim 104 , further comprising the step of condensing said concentrated VOC fuel into a liquid.  
   
   
       107 . The method of  claim 100 , wherein said adsorbent media is in a continuous loop.  
   
   
       108 . The method of  claim 100 , further comprising the step of cooling said reformate.  
   
   
       109 . The method of  claim 100 , wherein said reformate contains H 2  gas and oxides of carbon.  
   
   
       110 . The method of  claim 100 , further comprising the step of filtering said dilute VOC gas stream prior to said concentrating step.  
   
   
       111 . The method of  claim 100 , wherein said dilute VOC gas stream is selected from the group comprising straight chain hydrocarbons, branched hydrocarbons, aromatic hydrocarbons, oxygenated hydrocarbons and mixtures thereof.  
   
   
       112 . The method of  claim 100 , wherein said dilute VOC gas stream is between 1 ppm and 5000 ppm VOC.  
   
   
       113 . The method of  claim 100 , wherein said dilute VOC gas stream is paint exhaust.  
   
   
       114 . The method of  claim 100 , wherein said dilute VOC gas stream is gasoline vapor.  
   
   
       115 . The method of  claim 100 , wherein said dilute VOC gas stream is formaldehyde and acidic acid.  
   
   
       116 . The method of  claim 100 , further comprising directing a second fuel to said energy conversion device, whereby said energy conversion device consumes a fuel mixture of said reformate and said second fuel.  
   
   
       117 . The method of  claim 116 , further comprising controlling the proportion of said reformate and said second fuel supplied to said energy conversion device.  
   
   
       118 . The method of  claim 117 , further comprising measuring the amount of said reformate supplied to said engine, wherein a controller varies the amount of said second fuel in response to the amount of said reformate.  
   
   
       119 . The method of  claim 116 , wherein said second fuel is between 0 and 90% of said fuel mixture.  
   
   
       120 . The method of  claim 100 , wherein said energy conversion device is a Stirling engine.  
   
   
       121 . The method of  claim 100 , wherein said energy conversion device is a fuel cell.  
   
   
       122 . The method of  claim 100 , wherein said energy conversion device is an internal combustion engine.  
   
   
       123 . The method of  claim 100 , wherein said energy conversion device produces electricity.  
   
   
       124 . The method of  claim 123 , further comprising supplying said electricity to a power grid.  
   
   
       125 . The method of  claim 104 , wherein said inert gas is nitrogen.