Hybrid energy conversion system and processes

Abstract

Disclosed are flexible hybrid conversion systems that can be used with a wide spectrum of resources and feedstock. The disclosed systems can be sufficiently versatile to provide many added value products including clean energy, synthetic fuels and chemical products. Processes and system disclosed herein can produce, for example, shaft power and/or electricity from the expansion of species change of hot, hydrogen-laden syngas produced by gasification or steam reforming of inferior feedstock such as coal, bitumen, tar from sands and wastes, including biomass, municipal solid waste (MSW) sewage sludge and certain industrial wastes. This disclosure also teaches innovative system thermal integration methods of endothermic and exothermic processes and reaction enhancement approaches for the economic, clean and flexible production of synthetic gaseous and liquid fuels as well as chemicals.

1 - 12 . (canceled) 
     
     
         13 . A process for converting a carbonaceous and hydrocarbon laden feedstock comprising:
 a first stage in which the feedstock is provided to a Thermochemical fluid bed reactor, the reactor operating at a moderate temperature between about 900° F. and about 1500° F. and operating at a pressure between about 10 psig and about 110 psig;   converting the feedstock to a first product during the first stage, the first product comprising syngas, char, and condensable hydrocarbon vapors; and   separating the syngas, the char, and the condensable hydrocarbon vapors from one another.   
     
     
         14 . The process according to  claim 13 , wherein the energy content of the feedstock is converted to electric power. 
     
     
         15 . The process according to  claim 13 , wherein the feedstock is converted to liquid or gaseous fuel. 
     
     
         16 . The process according to  claim 13 , wherein the feedstock is converted to chemicals. 
     
     
         17 . The process according to  claim 13 , further comprising a second stage, the second stage being carried out at a high temperature between about 1500° F. and about 3000° F., wherein the char and the condensable hydrocarbon vapors are processed in the second stage to form additional syngas. 
     
     
         18 . The process according to  claim 17 , wherein the second stage comprises an entrained flow higher-pressure partial oxidation-based or autothermal gasifier operating at a pressure of up to about 1500 psig. 
     
     
         19 . The process according to  claim 17 , further comprising expanding the additional syngas to generate electricity for heating the Thermochemical process to affect further system energy integration and improve plant overall efficiency and return on investment. 
     
     
         20 . The process according to  claim 17 , further comprising a third stage, wherein the third stage produces electric power from the syngas and the additional syngas. 
     
     
         21 . The process according to  claim 17 , further comprising separating a gaseous compound from the first product. 
     
     
         22 . The process according to  claim 21 , wherein the gaseous compound is hydrogen gas. 
     
     
         23 . The process according to  claim 21 , wherein the gaseous compound is carbon monoxide. 
     
     
         24 . The process according to  claim 21 , wherein the gaseous compound is separated by use of a membrane or a nanofilter. 
     
     
         25 . A method for providing heat to an indirectly heated Thermochemical process comprising utilizing the energy present in the tail gas of an exothermic syngas conversion process to supply indirect heat to a Thermochemical process, the syngas conversion process forming hydrocarbon fuels and other chemicals. 
     
     
         26 . The method according to  claim 25 , wherein energy present in the exothermic heat from the syngas conversion process to make electricity, with the produced electricity used to heat the Thermochemical process. 
     
     
         27 . The method according to  claim 25 , wherein the energy present in the tail gas is converted to electric power that in turn produces indirect heat to the Thermochemical process. 
     
     
         28 . A method for improving the efficiency of a fuel formation process comprising
 forming a first liquid fuel in a moderate pressure formation process;   pressurizing the first liquid fuel to a higher pressure;   utilizing the higher pressure first liquid fuel to form a second fuel or chemical.   
     
     
         29 . The method according to  claim 28 , wherein the first liquid fuel is methanol or DME or both. 
     
     
         30 . The method according to  claim 28 , wherein the second fuel is ethanol. 
     
     
         31 . A method for improving the efficiency of an indirectly heated Thermochemical reaction process comprising utilizing heat transfer tubes in a reactor that have a tapered cross section. 
     
     
         32 . A method for enhancing the residence time of fines and improving the reaction rates in a fluid bed reactor comprising employing down bed material flow conduits, the conduits providing passive dynamic entertainment of low density fines from particulate separation dip legs to lower elevations in the fluid bed reactor. 
     
     
         33 . A method for controlling bed material flow pattern and mean particle size distribution in a fluid bed reactor comprising providing subsonic or supersonic motive jets in the fluid bed, the subsonic or supersonic motive jets employing superheated steam or hot high pressure product gas or both.