Methods and apparatus for producing syngas and alcohols

Abstract

The present invention features methods and apparatus for the pyrolysis or torrefaction of a carbon-containing feedstock before it is converted to syngas. In some embodiments, biomass is first pretreated by torrefaction and/or pyrolysis, followed by devolatilization and/or steam reforming to produce syngas. Various mixtures of such pretreated biomass, combined with fresh biomass, can be employed to produce syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.

1 . A method of forming syngas, the method comprising the steps of:
 (a) pyrolyzing or torrefying a carbon-containing first feed material to form a pyrolyzed or torrefied first feed material; and   (b) converting the pyrolyzed or torrefied first feed material into syngas.   
     
     
         2 . The method of  claim 1 , further comprising converting a second feed material that has not been pyrolyzed or torrefied into syngas. 
     
     
         3 . The method of  claim 1 , further comprising combining the pyrolyzed or torrefied first feed material with a second feed material that has not been pyrolyzed or torrefied such that both the pyrolyzed or torrefied first feed material and the second feed material are converted into syngas. 
     
     
         4 . The method of  claim 1 , comprising pyrolyzing a carbon-containing first feed material to form a pyrolyzed first feed material, torrefying a carbon-containing feed second material to form a torrefied second feed material, and converting the pyrolyzed first feed material and the torrefied second feed material into syngas. 
     
     
         5 . The method of  claim 1 , further comprising introducing the torrefied first feed material into a pyrolysis reactor to form a pyrolyzed first feed material. 
     
     
         6 . The method of  claim 1 , wherein converting the pyrolyzed or torrefied first feed material into syngas comprises passing the pyrolyzed or torrefied first feed material through a heated reaction vessel to form syngas. 
     
     
         7 . The method of  claim 1 , wherein converting the pyrolyzed or torrefied first feed material into syngas comprises the substeps of:
 (i) devolatilizing the pyrolyzed or torrefied first feed material to form a gas phase and/or solid phase in a devolatilization unit; and   (ii) passing the gas phase and/or solid phase through a heated reaction vessel to form syngas.   
     
     
         8 . The method of  claim 1 , wherein step (a) is conducted in the presence of a catalyst. 
     
     
         9 . A method of forming syngas, the method comprising converting a pyrolyzed or torrefied first feed material and a second carbon-containing feed material that has not been pyrolyzed or torrefied into syngas. 
     
     
         10 . The method of  claim 9 , comprising pyrolyzing a carbon-containing first feed material to form the pyrolyzed first feed material, torrefying a carbon-containing third feed material to form a torrefied third feed material, and converting the pyrolyzed first feed material, the second feed material, and the torrefied third feed material into syngas. 
     
     
         11 . The method of  claim 9 , further comprising combining the pyrolyzed or torrefied first feed material and the second feed material prior to converting the pyrolyzed or torrefied first feed material and the second feed material into syngas. 
     
     
         12 . The method of  claim 9 , wherein the method is conducted, at least in part, in the presence of a catalyst. 
     
     
         13 . The method of  claim 9 , wherein converting the pyrolyzed or torrefied first feed material and the second feed material into syngas comprises the steps of:
 (a) devolatilizing the pyrolyzed or torrefied first feed material and the second feed material to form a gas phase and/or solid phase in a devolatilization unit; and   (b) passing the gas phase and/or solid phase through a heated reaction vessel to form syngas.   
     
     
         14 . The method of  claim 9 , further comprising introducing the torrefied first feed material into a pyrolysis reactor to form a pyrolyzed first feed material. 
     
     
         15 . A method of forming syngas, the method comprising the steps of:
 (a) devolatilizing a pyrolyzed or torrefied first feed material to form a gas phase and solid phase in a devolatilization unit; and   (b) passing the gas phase and solid phase through a heated reaction vessel to form syngas.   
     
     
         16 . The method of  claim 15 , comprising pyrolyzing a carbon-containing feed material, optionally in the presence of a catalyst, to form the first feed material. 
     
     
         17 . The method of  claim 15 , comprising torrefying a carbon-containing feed material, optionally in the presence of a catalyst, to form the first feed material. 
     
     
         18 . The method of  claim 15 , further comprising converting a second feed material that has not been pyrolyzed or torrefied into syngas. 
     
     
         19 . The method of  claim 18 , further comprising combining the pyrolyzed or torrefied first feed material with a second feed material that has not been pyrolyzed or torrefied such that both the pyrolyzed or torrefied first feed material and the second feed material are converted into syngas. 
     
     
         20 . The method of  claim 18 , comprising pyrolyzing a carbon-containing first feed material to form the pyrolyzed first feed material, torrefying a carbon-containing third feed material to form a torrefied third feed material, and converting the pyrolyzed first feed material, the second feed material, and the torrefied third feed material into syngas. 
     
     
         21 . The method of  claim 15 , further comprising combining the pyrolyzed or torrefied first feed material and the second feed material prior to converting the pyrolyzed or torrefied first feed material and the second feed material into syngas. 
     
     
         22 . The method of  claim 15 , further comprising introducing the torrefied first feed material into a pyrolysis reactor to form a pyrolyzed first feed material. 
     
     
         23 . The method of any of  claims 1 ,  9 , or  15 , wherein the method is conducted, at least in part, in one or more modular units. 
     
     
         24 . The method of any of  claims 1 ,  9 , or  15 , further comprising the step of converting the syngas to a product. 
     
     
         25 . The method of  claim 24 , wherein the product is selected from the group consisting of an alcohol, an olefin, an aldehyde, a hydrocarbon, an ether, hydrogen, ammonia, and acetic acid. 
     
     
         26 . The method of  claim 25 , wherein the hydrocarbon is a linear or branched C 5 -C 15  hydrocarbon. 
     
     
         27 . The method of  claim 25 , wherein the alcohol is methanol. 
     
     
         28 . The method of  claim 25 , wherein the alcohol is ethanol.