Production of synthetic transportation fuels from carbonaceous material using self-sustained hydro-gasification

Abstract

A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. A slurry of particles of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor under conditions whereby methane rich producer gases are generated and fed into a steam pyrolytic reformer under conditions whereby synthesis gas comprising hydrogen and carbon monoxide are generated. A portion of the hydrogen generated by the steam pyrolytic reformer is fed through a hydrogen purification filter into the hydro-gasification reactor, the hydrogen therefrom constituting the hydrogen from an internal source. The remaining synthesis gas generated by the steam pyrolytic reformer is either used as fuel for a gaseous fueled engine to produce electricity and/or process heat or is fed into a Fischer-Tropsch or similar reactor under conditions whereby a liquid fuel is produced.

1. A process for producing a synthesis gas for use as a gaseous fuel or as feed into Fischer-Tropsch reactor to produce a liquid fuel, the improvement comprising:
 forming a liquid suspension slurry of particles of carbonaceous material in water;  
 feeding said suspension slurry and hydrogen from an internal source into a hydro-gasification reactor under conditions of super-atmospheric pressure without a reaction catalyst and at a temperature under said pressure whereby methane rich producer gases are generated;  
 feeding the methane rich producer gases from the hydro-gasification reactor into a steam pyrolytic reformer under conditions whereby synthesis gas comprising hydrogen end carbon monoxide are generated;  
 feeding a portion of the hydrogen generated by the steam pyrolytic reformer into the hydro-gasification reactor as said hydrogen from an internal source; and  
 either utilizing said synthesis gas generated by the steam pyrolytic reformer for process heat or as fuel for an engine to produce electricity, or feeding said synthesis gas into the Fischer-Tropsch type reactor under conditions whereby a liquid fuel is produced.  
 
     
     
       2. The process of  claim 1  wherein said portion of the hydrogen generated by the steam pyrolytic reformer is obtained through a hydrogen purification filter. 
     
     
       3. The process of  claim 1  wherein said conditions and the relative amounts of said carbonaceous material, hydrogen and water in the hydro-gasification reactor are such that said methane rich producer gases are produced exothermally. 
     
     
       4. The process of  claim 1  in which said liquid slurry of carbonaceous material is formed by grinding said carbonaceous material in water. 
     
     
       5. The process of  claim 1  in which said liquid slurry of carbonaceous material is heated with superheated steam from a steam generator prior to being fed into the hydro-gasification reactor. 
     
     
       6. The process of  claim 5  in which the superheated steam is separated from the slurry, prior to feeding the slurry into the hydro-gasification reactor, and is fed into the steam pyrolytic reformer to react with the methane rich producer gases from the hydro-gasification reactor. 
     
     
       7. The process of  claim 5  in which the slurry, together with the superheated steam, is fed into the hydro-gasification reactor. 
     
     
       8. The process of  claim 7  in which synthesis gas generated by the steam pyrolytic reformer is fed into a Fischer-Tropsch reactor under conditions whereby a liquid fuel is produced. 
     
     
       9. The process of  claim 8  wherein said conditions and the relative amounts of hydrogen and carbon monoxide in the Fischer-Tropsch reactor are such that said liquid fuel is produced exothermally. 
     
     
       10. The process of  claim 9  comprising transferring exothermic heat from one or both of the hydro-gasification reactor and Fischer-Tropsch reactor to one or both of the steam generator and the steam pyrolytic reformer. 
     
     
       11. The process of  claim 9  comprising transferring exothermic heat from the hydro-gasification reactor and Fischer-Tropsch reactor to the steam generator and the steam pyrolytic reformer. 
     
     
       12. The process of  claim 11  in which molten salt loops are used to transfer said exothermic heat. 
     
     
       13. The process of  claim 1  in which said carbonaceous material comprises biomass. 
     
     
       14. The process of  claim 13  in which said biomass comprises municipal solid waste. 
     
     
       15. The process of  claim 8  in which the relative amounts of hydrogen and carbon monoxide in the synthesis gas fed into the Fischer-Tropsch reactor are such that said liquid fuel is substantially cetane. 
     
     
       16. A substantially self-sustaining process for producing a liquid fuel from carbonaceous feed, comprising:
 grinding said carbonaceous material in water to form a suspension slurry of carbonaceous particles;  
 heating the slurry with superheated steam from a steam generator;  
 feeding hydrogen from an internal source, the suspension slurry, and the superheated steam into a hydro-gasification reactor under conditions of a pressure of about 20 to 50 atmospheres without a reaction catalyst and at a temperature in the range of about 700 to 1200 degrees Celsius, and in amounts whereby methane rich producer gases are generated exothermally;  
 feeding the methane rich producer gases from the hydro-gasification reactor and said superheated steam into a steam pyrolytic reformer under conditions whereby synthesis gas comprising hydrogen and carbon monoxide are generated;  
 feeding a portion of the hydrogen generated by the steam pyrolytic reformer, obtained through a hydrogen purification filter, into the hydro-gasification reactor, the hydrogen therefrom constituting said hydrogen from an internal source;  
 feeding the remainder of the synthesis gas generated by the steam pyrolytic reformer into the Fischer-Tropsch reactor under conditions whereby a liquid fuel is produced exothermally; and  
 transferring exothermic heat from the hydro-gasification reactor and Fischer-Tropsch reactor to the steam generator and the steam pyrolytic reformer, whereby said process is substantially self-sustaining.  
 
     
     
       17. The process of  claim 16  in which molten salt loops are used to transfer said exothermic heat. 
     
     
       18. The process of  claim 16  in which said carbonaceous material comprises biomass. 
     
     
       19. The process of  claim 16  in which said biomass comprises municipal solid waste.