Multi-zone reforming methods and apparatus for conversion of devolatilized biomass to syngas

Abstract

The present invention provides improved methods and apparatus for producing syngas from any carbon-containing feed material. In one aspect, a multi-zone reformer system is provided. A first reaction zone can reduce the presence of refractory tars, while a second reaction zone in communication with the first reaction zone can steam-reform methane and other components from the first reaction zone, to generate high-quality syngas suitable for conversion to liquid fuels, such as ethanol. Other embodiments employ a plurality of reaction zones for added system functionality.

1 . A reformer system comprising:
 (a) an input stream comprising refractory tars;   (b) a first zone, in communication with said input stream(s), at a first-zone temperature of at least 1700° F. to reduce the molecular weight of said refractory tars present in said input stream to an average molecular weight of 100 g/mol or less, wherein said first zone has a first output stream;   (c) a second zone, in communication with said first zone, at a second-zone temperature of at least 1900° F. in the presence of steam to steam reform methane, if present in said input stream or in said first output stream, wherein said second zone has a second output stream; and   (d) a separation zone, in communication with said second zone, at a separation-zone temperature of less than 1600° F. to remove at least some solid or liquid species present in said second output stream.   
     
     
         2 . The system of  claim 1 , wherein said first zone is capable of destruction of at least a portion of BTEX species present in said input stream. 
     
     
         3 . The system of  claim 1 , wherein said second zone is capable of steam reforming of at least a portion of BTEX species present in said first output stream. 
     
     
         4 . The system of  claim 4 , wherein said BTEX species include BTEX species present in said input stream. 
     
     
         5 . The system of  claim 4 , wherein said BTEX species include BTEX species produced in said first zone. 
     
     
         6 . The system of  claim 1 , wherein said first zone includes a catalyst suitable for reducing the molecular weight of refractory tars. 
     
     
         7 . The system of  claim 6 , wherein said catalyst is configured on the walls of said first zone. 
     
     
         8 . The system of  claim 1 , wherein said second zone includes a steam-reforming catalyst. 
     
     
         9 . The system of  claim 8 , wherein said steam-reforming catalyst is configured on the walls of said second zone. 
     
     
         10 . The system of  claim 1 , wherein said separation zone includes a filter. 
     
     
         11 . The system of  claim 1 , wherein said separation zone includes a cyclone. 
     
     
         12 . The system of  claim 1 , wherein said input stream is derived from a devolatilization unit that devolatilizes a carbon-containing feedstock. 
     
     
         13 . The system of  claim 12 , wherein said carbon-containing feedstock includes biomass. 
     
     
         14 . A reformer system comprising:
 (a) an input stream comprising refractory tars derived from biomass;   (b) a first zone, in communication with said input stream(s), at a first-zone temperature of at least 1700° F. to reduce the molecular weight of said refractory tars present in said input stream to an average molecular weight of 100 g/mol or less, wherein said first zone has a first output stream;   (c) a second zone, in communication with said first zone, at a second-zone temperature of at least 1900° F. in the presence of steam and configured with a second-zone catalyst to steam reform methane to produce syngas, wherein said second zone has a second output stream; and   (d) a separation zone, in communication with said second zone, at a separation-zone temperature of less than 1600° F. to remove at least some solid or liquid species present in said second output stream.   
     
     
         15 . The system of  claim 14 , wherein said second-zone catalyst is capable of steam reforming said refractory tars, or fragments thereof, to syngas. 
     
     
         16 . The system of  claim 14 , wherein said second-zone catalyst is configured on the walls of said second zone. 
     
     
         17 . The system of  claim 14 , wherein said second-zone catalyst is configured in a packed bed in said second zone. 
     
     
         18 . The system of  claim 14 , wherein said second-zone catalyst is configured in a plurality of microchannels within said second zone. 
     
     
         19 . The system of  claim 14 , wherein said second-zone catalyst is configured in a fluidized bed within said second zone. 
     
     
         20 . A reformer system comprising:
 (a) an input stream derived from biomass;   (b) a first zone, in communication with said input stream(s), at a first-zone temperature of at least 1700° F. to destroy at least a portion of BTEX species present in said input stream, thereby producing BTEX fragments, wherein said first zone has a first output stream;   (c) a second zone, in communication with said first zone, at a second-zone temperature of at least 1900° F. in the presence of steam to steam reform said BTEX fragments into syngas, wherein said second zone has a second output stream; and   (d) a separation zone, in communication with said second zone, at a separation-zone temperature of less than 1600° F. to remove at least some solid or liquid species present in said second output stream.