Multi-stage system for processing hydrocarbon fuels

Abstract

A multi-stage system converts a hydrocarbon material to an intermediate product in a first stage and a final product in a final stage. The first stage includes a first reaction chamber configured to receive hydrocarbon and process gas. In the presence of energy, the first stage will convert the feedstock into an intermediate product for delivery to a second stage. The second stage includes a second reaction chamber configured to receive the intermediate product and a process gas. When the intermediate product and process gases are fed into the reaction chamber in the presence of energy, a plasma is formed in the second reaction chamber and converts the intermediate product into a liquid fuel.

1 . A system for converting hydrocarbon materials into a product, comprising:
 one or more hydrocarbon feedstock sources;   one or more process gas sources;   one or more energy generators; and   a first stage comprising a first reaction chamber that is configured to receive feedstock from one or more of the feedstock sources and process gas from one or more of the process gas sources and, in the presence of energy from one or more of the energy generators, convert the feedstock into an intermediate product for delivery to a second stage.   
     
     
         2 . The system of  claim 1 , further comprising the second stage, wherein the second stage comprises:
 a second reaction chamber that is configured to receive the intermediate product from the first stage and one or more of the process gases from the one or more process gas sources;   wherein when the intermediate product and process gas are fed into the second reaction chamber in the presence of energy from one or more of the energy generators, microwave or electrical discharges are formed in the second reaction chamber to enhance or promote conversion of the intermediate product into a liquid fuel.   
     
     
         3 . The system of  claim 2 , comprising at least one intermediate stage between the first stage and the second stage in which, during operation, the intermediate product from the first stage is processed for receiving in the second stage. 
     
     
         4 . The system of  claim 1 , wherein the one or more energy generators comprise a microwave generator. 
     
     
         5 . The system of  claim 4 , wherein the intermediate product comprises coke. 
     
     
         6 . The system of  claim 4 , wherein at least one characteristic of the first set of discharge conditions has a value that is different than a value of the same characteristic of the second set of discharge conditions. 
     
     
         7 . The system of  claim 2 , further comprising a waveguide that is configured to deliver energy from the one or more energy generators to the first reaction chamber, the second reaction chamber, or both. 
     
     
         8 . The system of  claim 2 , further comprising at least one storage chamber configured to store the intermediate product before the intermediate product is passed to second reaction chamber. 
     
     
         9 . The system of  claim 1 , wherein the intermediate product has a different chemical composition from the final product. 
     
     
         10 . The system of  claim 1 ,
 wherein this first stage is configured to, when converting the feedstock into an intermediate product, also activate or ionize the process gas for delivery into the second stage;   when the intermediate product and process gas are fed into the second reaction chamber in the presence of microwave energy, a plasma is formed in the second reaction chamber to enhance or promote conversion of the intermediate product into the liquid fuel.   
     
     
         11 . A method for converting hydrocarbon materials into a product, comprising:
 receiving, in a first reaction chamber, a hydrocarbon feedstock;   receiving, in the first reaction chamber, a process gas;   forming, in the first reaction chamber, a first set of discharge conditions in the presence of energy from a microwave generator;   converting, in the first reaction chamber, the hydrocarbon feedstock into an intermediate product for delivery to a second reaction chamber;   delivering the intermediate product to the second reaction chamber;   forming, in the first reaction chamber, a second set of discharge conditions in the presence of energy from a microwave generator; and   converting, in the second reaction chamber, the intermediate product into a final product.   
     
     
         12 . The method of  claim 11 , further comprising processing the intermediate product before delivering the intermediate product to the second reaction chamber. 
     
     
         13 . The method of  claim 11 , wherein converting the hydrocarbon feedstock into the intermediate product comprises providing the hydrocarbon feedstock thermal energy using the first set of discharge conditions to form coke. 
     
     
         14 . The method of  claim 11 , wherein the intermediate product has a different chemical composition from the final product. 
     
     
         15 . The method of  claim 11 , wherein the process gas received in the first reaction chamber is different from the process gas delivered to the second reaction chamber. 
     
     
         16 . The method of  claim 16 , wherein the process gas received in the first reaction chamber is the same as the process gas delivered to the second reaction chamber. 
     
     
         17 . The method of  claim 11 :
 further comprising, when converting the feedstock into an intermediate product, also activating or ionizing the process gas for delivery into the second stage;   when the intermediate product and process gas are fed into the second reaction chamber in the presence of microwave energy, a plasma is formed in the second reaction chamber to enhance or promote conversion of the intermediate product into the final product.