Multi-step process for conversion of carbonaceous feedstocks to renewable liquid fuels and commodity products

Abstract

A system and method of thermally processing carbonaceous materials, and especially sustainably cultivated woody biomass or cellulosic biomass sorted from municipal solid waste, to produce green fuel, such as diesel, sustainable aviation fuel and other beneficial by-products, including biochar. Synthesis gas is made by gasifying sustainably grown biomass, the thermal energy from which is used to create steam for treatment of biochar by-product to produce higher value activated carbon. Oxygen for the gasifier and hydrogen for a Fischer Tropsch (FT) or other catalytic synthesis stage of the process are generated by electrolysis of water using sustainably produced electricity. The gasification and electrolysis processes are operated to produce a 2:1 ratio of hydrogen to carbon monoxide needed for FT or other catalytic synthesis. The hydrocarbon product is distilled as required to produce either green alcohols or green diesel fuel and sustainable aviation fuel.

What is claimed is: 
     
         1 . A method of thermally converting biomass to liquid fuels comprising the steps of:
 a. providing sustainable biomass comprising biomass, plastic, RFNBO qualified feedstock, or combinations thereof, for thermal conversion to synthesis gas;   b. providing hydrogen;   c. thermally converting the biomass to form synthesis gas;   d. reforming the synthesis gas;   e. cooling and cleaning the synthesis gas;   f. combusting a portion of the reformed, cooled, and cleaned synthesis gas;   g. recovering heat of the synthesis gas by transferring it into a synthesis gas generator;   h. compressing the synthesis gas to a predetermined pressure and temperature prior to introducing the synthesis gas into a catalytic conversion process unit;   i. blending the hydrogen with the synthesis gas to a 2:1 molar ratio of hydrogen to carbon monoxide;   j. feeding the blended hydrogen and synthesis gas to the catalytic conversion process unit; and   k. converting the synthesis gas to liquid fuel via a Fisher-Tropsch process.   
     
     
         2 . The method of  claim 1 , further comprising the step of generating process steam using excess energy from the synthesis gas generated after the heat recovery step. 
     
     
         3 . The method of  claim 1 , further comprising the step of cleaning the synthesis gas prior to exhausting it to the atmosphere. 
     
     
         4 . The method of  claim 1 , further comprising the step of cooling and storing a solid product generated by gasification and/or pyrolytic generation of the synthesis gas. 
     
     
         5 . The method of  claim 1 , wherein the hydrogen is provided electrolytically by an electrolyzer. 
     
     
         6 . The method of  claim 5 , wherein the blending step is accomplished by controlling the parameters of a gasifier and the electrolyzer. 
     
     
         7 . The method of  claim 1  further comprising the step of reducing the particle size of the biomass by mechanical shredding, extrusion, washing, grinding, or combinations thereof. 
     
     
         8 . The method of  claim 1 , wherein the hydrogen is provided from a natural source thereof. 
     
     
         9 . The method of  claim 1 , wherein the biomass is a monofuel. 
     
     
         10 . The method of  claim 1 , wherein the biomass comprises feedstock combined with plastic or other RFNBO qualified materials. 
     
     
         11 . The method of  claim 1 , wherein the biomass is recovered from municipal solid waste. 
     
     
         12 . The method of  claim 1 , wherein the synthesis gas is produced in an augured kiln. 
     
     
         13 . The method of  claim 1 , wherein the synthesis gas is produced in a co-current rotary kiln. 
     
     
         14 . The method of  claim 1 , wherein the synthesis gas is produced in a countercurrent rotary kiln. 
     
     
         15 . The method of  claim 1 , wherein the synthesis gas is produced in a fluidized bed gasifier. 
     
     
         16 . The method of  claim 1 , wherein the synthesis gas is produced in an entrained bed gasifier. 
     
     
         17 . The method of  claim 1 , wherein the synthesis gas is reformed using steam plasma. 
     
     
         18 . The method of  claim 1 , wherein the synthesis gas is reformed using cold plasma catalysis. 
     
     
         19 . The method of  claim 1 , wherein the synthesis gas is reformed using hydrogen plasma. 
     
     
         20 . The method of  claim 1 , wherein in step (b), oxygen is provided in addition to hydrogen.