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 . An apparatus for producing syngas comprising a pyrolysis or torrefaction reactor in communication with a devolatilization unit that is in communication with a heated reaction vessel. 
     
     
         2 . The apparatus of  claim 1 , comprising a pyrolysis reactor. 
     
     
         3 . The apparatus of  claim 1 , comprising a torrefaction reactor. 
     
     
         4 . The apparatus of  claim 1 , comprising both a pyrolysis reactor and a torrefaction reactor. 
     
     
         5 . The apparatus of  claim 1 , wherein the pyrolysis or torrefaction reactor includes a catalyst. 
     
     
         6 . The apparatus of  claim 1 , further comprising a device for combining pyrolyzed feed material with feed material that has not been pyrolyzed. 
     
     
         7 . The apparatus of  claim 1 , further comprising a device for combining torrefied feed material with feed material that has not been torrefied. 
     
     
         8 . An apparatus for producing syngas comprising a pyrolysis or torrefaction reactor in communication with a device for combining a pyrolyzed or torrefied first feed material with a second feed material that has not been pyrolyzed or torrefied, wherein the device is in communication with a syngas reactor for converting the first feed material and the second feed material into syngas. 
     
     
         9 . The apparatus of  claim 8 , comprising a pyrolysis reactor, a torrefaction reactor, or both of these reactors. 
     
     
         10 . The apparatus of  claim 9 , wherein at least one of the reactors includes a catalyst. 
     
     
         11 . The apparatus of  claim 9 , further comprising a device for combining pyrolyzed feed material with torrefied feed material, wherein the device is in communication with (i) the pyrolysis reactor and/or the torrefaction reactor, and (ii) the syngas reactor. 
     
     
         12 . The apparatus of  claim 8 , wherein the syngas reactor comprises a devolatilization unit that is in communication with a heated reaction vessel. 
     
     
         13 . The apparatus of  claim 8 , further comprising a product reactor for converting syngas into a product, wherein the product reactor is in communication with the syngas reactor. 
     
     
         14 . An apparatus for producing syngas comprising a pyrolysis or torrefaction reactor in communication with a devolatilization unit that is in communication with a heated reaction vessel. 
     
     
         15 . The apparatus of  claim 14 , comprising a pyrolysis reactor, a torrefaction reactor, or both of these reactors, optionally comprising a catalyst. 
     
     
         16 . The apparatus of  claim 14 , further comprising a device for combining pyrolyzed feed material with torrefied feed material, wherein the device is in communication with the pyrolysis reactor, the torrefaction reactor, and the syngas reactor. 
     
     
         17 . The apparatus of  claim 14 , further comprising a product reactor for converting syngas into a product, wherein the product reactor is in communication with the syngas reactor. 
     
     
         18 . The apparatus of  claim 17 , wherein the product comprises one or more C 1 -C 4  alcohols. 
     
     
         19 . The apparatus of  claim 18 , wherein the product comprises methanol. 
     
     
         20 . The apparatus of  claim 18 , wherein the product comprises ethanol.