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    • 专利摘要:
    aerator and carbonation material gasification methods. The present disclosure is directed generally to the process of gasification of carbonaceous materials for the production of synthesis gas or singas. The present disclosure provides improved gasification methods comprising the addition of a molecular oxygen containing gas and optionally the addition of water to said gasifier. This disclosure is also directed to the process of producing one or more alcohols from said synthesis gas by fermentation or digestion in the presence of at least one microorganism.
    公开号:BR112012025706B1
    申请号:R112012025706-4
    申请日:2011-04-11
    公开日:2019-04-30
    发明作者:Bhagya Chandra Sutradhar；Ching-Whan Ko
    申请人:Ineos Bio Sa；
    IPC主号:
    专利说明:

    “GASIFIER AND GASIFICATION METHODS
    OF CARBONACEOUS MATERIALS ”
    DESCRIPTIVE REPORT
    FIELD OF THE INVENTION [0001] The present disclosure is generally directed to the gasification process of carbonaceous materials to produce synthesis gas or singas. This disclosure is also directed to the process of producing one or more alcohols from said synthesis gas, through fermentation or digestion in the presence of at least one microorganism.
    BACKGROUND [0002] The present disclosure contemplates the production of synthesis gas comprising carbon monoxide (CO), carbon dioxide (CO2), and hydrogen (H2) by means of gasification of carbonaceous materials. The synthesis gas can be used to produce one or more chemical substances through biological or chemical routes. Synthesis gas can also be used to produce energy to generate electricity.
    [0003] In this way, the synthesis gas can be activated by fermentation or digestion by certain microorganisms to produce alcohols (methanol, ethanol, propanol, butanol, etc.), acetic acid, acetates, hydrogen, etc. Several strains of acetogens have been described for use in the production of liquid synthesis gas fuels: Butyribacterium methylotrophicum, Clostridium autoethanogenum, Clostridium carboxidivorans, Clostridium [jungdahlii, Clostridium ragsdalei.
    [0004] US Patent 5,173,429 to Gaddy et al. reveals Clostridium ljungdahlii ATCC No. 49587, an anaerobic microorganism that produces
    Petition 870190009622, of 29/01/2019, p. 10/59
    2/46 ethanol and acetate from gas synthesis. US Patent 5,807,722 to Gaddy et al. discloses a method and apparatus for converting waste gases into useful products, such as organic acids and alcohols using anaerobic bacteria, such as Clostridium Ijungdahlii ATCC No. 55380. US Patent 6,136,577 to Gaddy et al. discloses a method and apparatus for converting waste gases into useful products, such as organic acids and alcohols (particularly ethanol) using anaerobic bacteria, such as Clostridium Ijungdahlii ATCC No. 55988 and 55989. US Patent 6,136,577 to Gaddy et al . discloses a method and apparatus for converting waste gases into useful products, such as organic acids and alcohols (particularly acetic acid) using anaerobic strains of Clostridium ljungdahlii. US Patent 6,753,170 to Gaddy et al. reveals an anaerobic microbial fermentation process for the production of acetic acid. US Patent 7,285,402 to Gaddy et al. reveals an anaerobic microbial fermentation process for the production of alcohol.
    [0005] US Patent Application 20070275447 discloses a bacterial species of clostridia (Clostridium carboxidivorans, ATCC BAA-624, “P7”), which is capable of synthesizing, from waste gases, products that are useful as biofuels. US Patent Application 20080057554 discloses a clostridial bacterial species (Clostridium ragsdalei, ATCC BAA-622, “P11”), which is capable of synthesizing, from waste gases, products that are useful as biofuels.
    [0006] WO 2007/117157 discloses methods of anaerobic fermentation processes that produce acetate as a by-product, in addition to a desired product, and that can use hydrogen and / or carbon dioxide in the fermentation. In this revelation, fermentation is carried out by one or more strains of bacteria selected from Clostridium, Moorella and Carboxydothermus. WO 2009/064200 discloses a class of bacteria that has improved efficiency in ethanol production by anaerobic fermentation of substrates containing carbon monoxide. As revealed, the exemplified bacterium, Clostridium
    Petition 870190009622, of 29/01/2019, p. 11/59
    3/46 autoethanogenum, is capable of producing ethanol and acetate.
    [0007] Synthesis gas can be converted into various chemicals and fuels using chemical catalytic routes, such as processes using catalysts containing copper (Cu) and zinc (Zn) to produce methanol or mixed alcohols, processes using catalysts containing cobalt (Co ) and rhodium (Rh) to produce ethanol and Fischer-Tropsch synthesis to produce olefins, etc. WO 2009/03581 discloses methods of converting synthesis gas into ethanol and / or other larger alcohols using reactors comprising catalysts capable of converting synthesis gas into said catalysts alcohols comprising at least one element of Group IB, at least one element of Group IIB , and at least one member of Group IIIA.
    [0008] WO 2010/002618 discloses a method for producing alcohols from a gas comprising hydrogen and carbon monoxide: passing the gas through a reactor containing a transported catalyst comprising an elemental molybdenum, cobalt and an alkaline or alkaline earth metal and or hydrides thereof.
    [0009] The production of chemical substances or energy in general depends on the quality of the synthesis gas produced, for example, the quantity or concentration of carbon monoxide (CO) and hydrogen (H2) in synthesis gas, as well as the proportion of carbon monoxide for hydrogen (CO / H2).
    [00010] A widely used process of gasifying carbonaceous materials to produce synthesis gas rich in carbon monoxide (CO) and hydrogen (H2) uses an oxygen-deficient or oxygen-deprived atmosphere in the gasifier, which prevents complete carbon conversion and carbonaceous material. However, under oxygen deprived conditions, part of the carbon content of carbonaceous materials often remains as unreacted carbon particles or as soot in the product synthesis gas. Another part of the carbon content of carbonaceous materials remains as unreacted carbon in ash.
    Petition 870190009622, of 29/01/2019, p. 12/59
    4/46 [00011] Incomplete conversion of carbonaceous raw material into carbon monoxide (CO) and hydrogen (H2) means less available carbon monoxide (CO) and hydrogen (H2) for the production of energy or chemicals ( for example, alcohols). The increased amount of particles of unconverted or unreacted carbon or soot in the raw synthesis gas increases the difficulty and cost of cleaning the synthesis gas. The increased amount of unreacted carbon in ash increases the difficulty of processing and the cost of disposing of ash.
    [00012] It would be desirable to have a method of operating the gasifier that maximizes the production of energy or chemicals from the synthesis gas produced from the gasifier, while maintaining the amount of unconverted or unreacted carbon particles in the crude synthesis gas. under desirable low values.
    [00013] It would be desirable to have a method of operating the gasifier that maximizes the production of energy or chemicals from the synthesis gas produced from the gasifier, while maintaining the amount of unconverted or unreacted carbon particles in the crude synthesis gas. and amount of unreacted carbon in the ash at low desirable values.
    [00014] It would be desirable to have a method of operating the gasifier that maximizes the production of energy or chemicals from the synthesis gas produced from the gasifier, while maintaining the amount of soot in the crude synthesis gas at low desirable values.
    [00015] It would be desirable to have a gasifier operating method that maximizes the production of energy or chemicals from the syngas produced from the gasifier, while maintaining the amount of soot in the raw synthesis gas and the amount of carbon not reacted in ashes under desirable low values.
    [00016] The present disclosure provides several new and desirable gasifier designs and methods of operating a
    Petition 870190009622, of 29/01/2019, p. 13/59
    5/46 aerator that are not known in the art. The present disclosure fulfills the needs described above.
    SUMMARY [00017] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce a product gas comprising carbon monoxide, hydrogen, and tar; said method comprises: adding one or more carbonaceous materials, adding a gas containing molecular oxygen and optionally adding water to said gasifier; wherein the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than 0.75. In one embodiment, the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises about 0.75 to about 3.0. As an embodiment, the present disclosure further comprises treating said product gas at a temperature of about 1,750 ° F to about 3,500 ° F in the presence of molecular oxygen, to produce a crude synthesis gas comprising carbon monoxide, hydrogen, and synthesis-carbon gas. In one embodiment, the crude synthesis gas also comprises carbon dioxide.
    [00018] As an embodiment, the present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas using the partial oxidation method; said gasifier comprising a first reaction zone and a second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; in which the amount of total oxygen added to said gasifier
    Petition 870190009622, of 29/01/2019, p. 14/59
    6/46 in pounds per pound of total carbon added to said gasifier comprises more than about 1.25. In one embodiment, the amount of total oxygen added to said first reaction zone of said gasifier in pounds per pound of total carbon added to said gasifier comprises about 1.25 to about 3.5.
    [00019] As an embodiment, the present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas; said gasifier comprising a first reaction zone and a second reaction zone; comprising said method: adding one or more carbonaceous materials in said first gasifier reaction zone; adding gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; wherein the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than about 1.25. In one embodiment, the amount of total oxygen added to said first reaction zone of said gasifier in pounds per pound of total carbon added to said gasifier comprises about 1.25 to about 3.5.
    [00020] The present disclosure provides a method further comprising: subjecting said crude synthesis gas to cooling and cleaning to produce a clean synthesis gas; placing this clean synthesis gas in contact with the biocatalyst in a fermentation vessel to produce an alcohol product mixture.
    [00021] In one embodiment, the ratio of mass of carbon to mass of hydrogen in one or more of said carbonaceous materials comprises 1 to 20. In one embodiment, the ratio of mass of carbon to mass of oxygen in one or more of said carbonaceous materials comprises 1 to 200.
    [00022] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce a gas from
    Petition 870190009622, of 29/01/2019, p. 15/59
    7/46 synthesis using partial oxidation method; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone to the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first gasifier reaction zone; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen in said chamber connecting said first reaction zone to said second reaction zone of said gasifier.
    [00023] The present disclosure provides a gasifier to produce synthesis gas using partial oxidation method; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone to the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first gasifier reaction zone; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen in said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    [00024] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone to the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first gasifier reaction zone; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier;
    Petition 870190009622, of 29/01/2019, p. 16/59
    8/46 comprising adding gas containing molecular oxygen in said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    [00025] The present disclosure provides a gasifier to produce synthesis gas; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone to the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first gasifier reaction zone; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen in said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    BRIEF DESCRIPTION OF THE FIGURES [00026] Figure 1 (FIG. 1) comprises a schematic diagram illustrating an embodiment of the gasification process for this present disclosure; Figure 1 shows a realization of a gasification process in two stages.
    [00027] Figure 2 (FIG. 2) comprises a schematic diagram illustrating an accomplishment of the ethanol production process by gasifying carbonaceous materials.
    [00028] Figure 3 (FIG. 3) comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the gasifier on carbon-synthesis gas for various amounts of water entering the gasifier.
    [00029] Figure 4 (FIG. 4) comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the gasifier on the quantity of ethanol produced for various amounts of water entering the gasifier.
    Petition 870190009622, of 29/01/2019, p. 17/59
    9/46 [00030] Figure 5 (FIG. 5) comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the first reaction zone of the gasifier on carbon-synthesis gas for various amounts of water entering the gasifier .
    [00031] Figure 6 (FIG. 6) comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the first reaction zone of the gasifier on the quantity of ethanol produced for various amounts of water entering the gasifier.
    DETAILED DESCRIPTION
    Definitions [00032] Unless otherwise defined, the following terms as used throughout that specification for the present disclosure are defined as follows and may include both the singular and the plural form of definitions defined below:
    [00033] The term “about”, modifying any quantity, refers to the variation in that quantity found under real-world conditions, for example, the variation in that quantity found under real-world conditions for maintaining a microorganism culture, for example , in the laboratory, pilot plant, or production unit. For example, an amount of an ingredient or the measure used in a mixture or quantity, when modified by “about” includes the variation and degree of care typically employed in measuring in an experimental condition at the production site or laboratory. For example, the amount of a component of a product, when modified by "about" includes the variation between batches in multiple experiments in the unit or laboratory and the variation inherent in the analytical method. Modified or not by “about”, the quantities include equivalent to those quantities. Any quantity established in this document and modified by "about" can also be used in the present disclosure as the quantity
    Petition 870190009622, of 29/01/2019, p. 18/59
    10/46 not modified by “about”.
    [00034] The term "acetogen" or "acetogenic" refers to a bacterium that generates acetate as a product of anaerobic respiration. This process is different from acetate fermentation, although both occur in the absence of oxygen and produce acetate. These organisms are also referred to as acetogenic bacteria, since all known acetogens are bacteria. Acetogens are found in a variety of habitats, usually those that are anaerobic (lack of oxygen). Acetogens can use a variety of compounds as sources of energy and carbon; The best studied form of acetogenic metabolism involves the use of carbon dioxide as a source of carbon and hydrogen as an energy source.
    [00035] The term "carbon gray" or "carbon gray" or "gray carbon" means the carbon content not converted to ash removed from the gasifier.
    [00036] The term "ash melting temperature" means temperature at which at least a portion of ash or inorganic matter contained in carbonaceous material melts. Typically, this temperature comprises about 1,400 ° F.
    [00037] The term "biocatalyst" means, for the present disclosure, natural catalysts, protein enzymes, living cells, microorganisms and bacteria.
    [00038] The terms "bioreactor", "reactor", or "fermentation bioreactor", include a fermentation device consisting of one or more containers and / or towers or piping scheme, which includes the Continuous Agitated Tank Reactor (CSTR) , the Immobilized Cell Reactor (ICR), the Trickle-Bed Reactor (TBR), the Bubble Column, the Fermenter with Gas lift, the Static Mixer or other device suitable for contacting gas-liquid. Preferably for the method of this disclosure, fermentation bioreactor comprises a growth reactor, which feeds the fermentation broth to a second fermentation bioreactor, in which most of the
    Petition 870190009622, of 29/01/2019, p. 19/59
    11/46 product, ethanol is produced.
    [00039] "Carbonaceous material" as used in this document refers to material rich in carbon, such as coal, and petrochemicals. However, in this specification, carbonaceous material includes any carbon material, whether solid, liquid, gaseous or plasma. Among the numerous items that can be considered carbonaceous material, the present disclosure contemplates: carbonaceous liquid product, carbonaceous industrial liquid recycling, carbonaceous urban solid waste (RSU or rsu), carbonaceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, waste carbonaceous wood, carbonaceous building material, carbonaceous vegetative material, carbonaceous industrial residue, carbonaceous fermentation residue, carbonaceous petrochemical by-products, carbonaceous alcohol production byproducts, carbonaceous coal, tires, plastics, plastic waste, coking tar, fibersoft, lignin , black liquor, polymers, residual polymers, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, crops for energy production, forest processing residues, wood processing residues , livestock waste, re poultry residues, food processing residues, fermentation process residues, ethanol by-products, grain residues, residual microorganisms or combinations thereof. For this disclosure, carbon dioxide and gas containing methane are not considered carbonaceous materials. For the avoidance of doubt, various carbonaceous material (s) can (s) be interpreted (s) in both singular and plural forms, where appropriate, regardless of the use of the word in singular or plural forms as provided in that definition.
    [00040] The term "fermentation" means fermentation of carbon monoxide (CO) for alcohols and acetate. A number of anaerobic bacteria are known to be able to ferment carbon monoxide (CO) to alcohols, including butanol and ethanol, and
    Petition 870190009622, of 29/01/2019, p. 20/59
    12/46 acetic acid, and are suitable for use in the process of the present disclosure. Examples of such bacteria that are suitable for use in the disclosure include those of the genus Clostridium, such as strains of Clostridium ljungdahlii, including those described in WO 2000/68407, EP 117309, US Patent 5,173,429, 5,593,886, and
    6,368,819, WO 1998/00558 and WO 2002/08438, and Clostridium autoethanogenum. Other suitable bacteria include those of the Moorella genus, including Moorella sp HUC22-1, and those of the Carboxydothermus genus. The disclosure of each of these publications is fully incorporated into this document by reference. In addition, other anaerobic acetogenic bacteria can be selected for use in the development process by a person skilled in the art. It will also be appreciated that a mixed culture of two or more bacteria can be used in the process of the present disclosure. A microorganism suitable for use in the present disclosure is Clostridium autoethanogenum, which is commercially available from DSMZ and having the identifying characteristics of the DSMZ 10061 deposit number. Fermentation can be carried out in any suitable bioreactor, such as a tank reactor. continuous stirred (CTSR), bubble column reactor (BCR) or trickle-bed reactor (TBR). In addition, in some preferred embodiments of the development, the bioreactor may comprise a first growth reactor, in which microorganisms are grown, and a second fermentation reactor, to which the growth reactor fermentation broth is fed and in that most of the fermentation product (ethanol and acetate) is produced.
    [00041] The term "fibersoft or" Fibersofi "or" fibrosoft or "fibrousoft" means a type of carbonaceous material that is produced as a result of the softening and concentration of various substances; in one example, a carbonaceous material is produced by steam autoclaving various substances. In another example, fibersoft can comprise steam autoclaving of
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    13/46 urban, industrial, commercial, medical waste, resulting in a muddy and fibrous material.
    [00042] The "Aerator" or "aerator" means countercurrent fixed bed aerator, co-current fixed bed aerator, moving bed, fluidized bed aerator, entrained flow aerator, plasma arc aerator, stage aerator single, multi-stage aerator, two-stage aerator, three-stage aerator, four-stage aerator, five-stage aerator, and combinations thereof.
    [00043] The term "microorganism" includes bacteria, fungi, yeast, archaea and protists; microscopic plants (called green algae); and animals, such as plankton, planaria and amoeba. Some also include viruses, but others consider these to be non-life. Microorganisms live in all parts of the biosphere where there is liquid water, including soil, hot springs, on the ocean floor, high in the atmosphere and deep in rocks within the Earth's crust. Microorganisms are critical for recycling nutrients in ecosystems, as they act as decomposers. Microbes are also exploited by people in biotechnology, both in the preparation of traditional food and drink, and in modern technologies based on genetic engineering. It is thought that microorganisms of mixed strains, which may or may not contain strains of various microorganisms, will be used in the present disclosure. In addition, it is thought that targeted evolution can selectively select microorganisms that can be used in the present disclosure. It is further imagined that recombinant DNA technology can create microorganisms using selected strains of existing microorganisms. It is thought that anaerobic (or facultative) acetogenic bacteria, which are capable of converting carbon monoxide (CO) and water or hydrogen (H2) and CO2 into ethanol and acetic acid products, will be used in the present disclosure. Useful bacteria, according to this disclosure, include, without limitation, Acetogenium kivui,
    Petition 870190009622, of 29/01/2019, p. 22/59
    14/46
    Acetobacterium woodii, Acetoanaerobium noterae, Butyribacterium methylotrophicum, Caldanaerobacter subterrau.eus, Caldanaerobacter subterrau.eus pacificus, Carboxydothermus hydrogenoformans, Clostridium aceticum, Clostridium. acetobutylicum, Clostridium AutoetbaH.ogeH.um, Clostridium tbermoaceticum, Imbacterium limosum, Clostridium ljungdahlii PETC, Clostridium ljungdahlii ERI2, Clostridium ljuii.gdahlii C-01, Clostridium rung, Clostridium ljungdai , Moorella tbermacetica, and Peptostreptococcus productus. Other anaerobic acetogenic bacteria are selected for use in these methods by a person skilled in the art. In some embodiments of the present disclosure, several exemplary strains of C. ljungdahlii include the PETC strain (US Patent 5,173,429); strain ER12 (US Patent 5,593,886) and strains C-01 and O-52 (US Patent 6,136,577). These strains are each deposited at the American Type Culture Collection, 10801 University Boulevard, Manassas, Va. 20110-2209, under Accession Number 55383 (formerly ATCC No. 49587), 55380, 55988, and 55989, respectively. Each of the strains of C. ljungdahlii is an anaerobic gram-positive bacterium with a nucleotide content of guanine and cytosine (G + C) of about 22 moles%. These bacteria use a variety of substrates for growth, but not methanol or lactate. These strains differ in their tolerances to carbon monoxide (CO), specific gas uptake rates and specific productivity. In “wild” strains found in nature, very little ethanol production is noted. C. ljungdahlii strains operate ideally at 37 degrees C, and typically produce an ethanol to acetyl (ie, which refers to both free or molecular acetic acid and acetate salts) production ratio of about 1:20 (1 part of ethanol per 20 parts of acetyl) in the “wild” state. Ethanol concentrations are typically only 1-2 g / L. While this ability to produce ethanol is of interest, because of low ethanol productivity, the “wild” bacteria
    Petition 870190009622, of 29/01/2019, p. 23/59
    15/46 can be used to economically produce ethanol on a commercial basis. With less nutrient manipulation, the strains of C. Ijungdahlii mentioned above have been used to produce ethanol and acetyl with a production ratio of 1: 1 (equal parts of ethanol and acetyl), but the concentration of ethanol is less than 10 g / L, a level that results in low productivity, below 10 g / L-day. In addition, crop stability is a problem, primarily due to the relatively high (8-10 g / L) concentration of acetyl (2.5-3 g / L molecular acetic acid) in combination with the presence of ethanol. In addition, as the gas flow is increased in an effort to produce more ethanol, the culture is inhibited, first by molecular acetic acid and then by carbon monoxide (CO). As a result, the crop becomes unstable and fails to capture gas and produce the additional product. Furthermore, the inventors' initial work showed difficulty in producing more than a 2: 1 ratio of ethanol to acetyl in a steady-state operation. A large number of documents describe the use of anaerobic bacteria, other than C. Ijungdahlii, in the fermentation of sugars that do not consume carbon monoxide (CO), CO2 and hydrogen (H2) to produce solvents. In an attempt to provide high ethanol yields, a variety of parameters have been changed, which include: types of nutrients, microorganisms, specific addition of reducing agents, variations in pH, and the addition of exogenous gases.
    [00044] The term "solid urban waste" or "MSW" or "rsu" means waste comprising household, commercial, industrial and / or residual waste.
    [00045] The term "singas" or "synthesis gas" means synthesis gas, which is the name given to a gas mixture that contains varying amounts of carbon monoxide and hydrogen. Examples of production methods include steam reforming of natural gas or hydrocarbons to produce hydrogen, coal gasification and in some types of waste gasification plants in energy. O
    Petition 870190009622, of 29/01/2019, p. 24/59
    The name came from its use as an intermediary in the creation of synthetic natural gas (GNS) and for the production of ammonia or methanol. Synthesis gas is also used as an intermediate in the production of synthetic oil for use as a fuel or lubricant through Fischer-Tropsch synthesis and previously Mobil methanol to process gasoline. Synthesis gas consists mainly of hydrogen, carbon monoxide and very often some carbon dioxide and has less than half the energy density (ie BTU content) of natural gas. Synthesis gas is combustible and is often used as a fuel source or as an intermediary for the production of other chemicals.
    [00046] The term "carbon-synthesis gas" or "Carbon-synthesis gas" or "Carbon-synthesis gas" means the content of carbon particles not converted into crude synthesis gas produced in the gasification process.
    [00047] The term "total carbon input into the aerator" or "total carbon added to the aerator" means the sum of all carbon contained in anything fed into the aerator, for example, carbon contained in one or more carbonaceous materials, as defined above, added to the aerator.
    [00048] The term “entry of total carbon into the first gasification reaction zone” or “total carbon added to the first gasification reaction zone” means the sum of all carbon contained in anything fed to the first gasification reaction zone, for example, carbon contained in one or more carbonaceous materials, as defined above, added to the first gasifier reaction zone.
    [00049] The term "total oxygen input into the aerator" or "total oxygen added to the aerator" means the sum of all oxygen contained in anything fed to the aerator, for example, oxygen contained in gas containing molecular oxygen added to the aerator, oxygen contained in one or more materials
    Petition 870190009622, of 29/01/2019, p. 25/59
    17/46 carbonaceous as defined above, added to the aerator, oxygen contained in any water or steam added to the aerator.
    [00050] The term "entry of total oxygen into the first reaction zone of the aerator" or "total oxygen added to the first reaction zone of the aerator" means the sum of all oxygen contained in anything fed to the first reaction zone of the aerator , for example, oxygen contained in gas containing molecular oxygen added in the first reaction zone of the gasifier, oxygen contained in one or more carbonaceous materials as defined above added in the first reaction zone of the gasifier, oxygen contained in any water or steam added in the first gasifier reaction zone.
    DETAILED DESCRIPTION [00051] The present disclosure will now be described more fully and with reference to the figures, in which various embodiments of the present disclosure are shown. The subject matter of this disclosure can, however, be realized in many different ways and should not be interpreted as being limited to the accomplishments set out in this document.
    [00052] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce a product gas comprising carbon monoxide, hydrogen and tar, comprising said method: adding one or more carbonaceous materials, adding a gas containing molecular oxygen and optionally add water to said gasifier; wherein the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than about 0.75. In one embodiment, the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises about 0.75 for about
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    18/46
    3.0. As embodiments, the present disclosure comprises adding water to said gasifier; comprises adding direct steam to said gasifier; comprises adding water by adding partial direct steam to said gasifier; it comprises adding one or more said carbonaceous materials containing moisture to said gasifier.
    [00053] In one embodiment of the present disclosure, one or more of said carbonaceous materials comprise selection of carbonaceous materials, carbonaceous liquid product, carbonaceous industrial liquid recycling, carbonaceous urban solid waste (RSU or rsu), carbonaceous urban waste, carbonaceous agricultural material , carbonaceous forestry material, carbonaceous wood residue, carbonaceous building material, carbonaceous vegetative material, carbonaceous industrial residue, carbonaceous fermentation residue, carbonaceous petrochemical by-products, carbonaceous alcohol production byproducts, carbonaceous coal, tires, plastics, plastic waste, coke tar, fibersoft, lignin, black liquor, polymers, polymer residue, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, crops for energy production, processing residues forest, waste from processing wood, livestock residues, poultry residues, food processing residues, fermentation residues, ethanol by-products, spent grain, residual microorganisms or combinations thereof. In one embodiment, the carbon content of one or more of said carbonaceous materials comprises about 0.25 to about 1.0 pound per pound of one or more said carbonaceous materials on a water-free basis. In one embodiment, the hydrogen content of one or more of said carbonaceous materials comprises about 0.0 to about 0.25 pound per pound of one or more of said carbonaceous materials on a water-free basis. In one embodiment, the oxygen content of one or more of said carbonaceous materials comprises about 0.0 to about 0.5 pounds per pound of one or more of said carbonaceous materials on a water-free basis.
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    19/46 [00054] In one embodiment, said carbonaceous material comprises a plurality of carbonaceous materials selected from carbonaceous material, carbonaceous liquid product, carbonaceous industrial liquid recycling, carbonaceous urban solid waste (MSW), carbonaceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood residue, carbonaceous building material, carbonaceous vegetative material, carbonaceous petrochemical by-products, carbonaceous coal, plastics, plastic waste, coke tar, fibersoft, tires, lignin, black liquor, polymers, polymer residue, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, crops for energy production, forest processing residues, wood processing residues, livestock residues, livestock residues poultry, food processing waste, waste from production fermentative process, carbonaceous industrial waste, alcohol production residues, ethanol by-products, spent grains, residual microorganisms or combinations of any of these.
    [00055] In one embodiment, the aerator produces ash containing carbon ash and in which said ash comprises less than about 10% carbon ash. In one embodiment, the aerator produces ash containing carbon ash and in which said ash comprises less than about 5% carbon ash.
    [00056] In one embodiment, the present disclosure provides a method for treating said product gas at a temperature of about 1,750 ° F to about 3,500 ° F in the presence of molecular oxygen to produce a crude synthesis gas comprising carbon monoxide carbon, hydrogen, and carbon-synthesis gas. In various embodiments, crude synthesis gas comprises carbon dioxide.
    [00057] In one embodiment, the ratio of mass of carbon to mass of hydrogen in one or more of said carbonaceous materials comprises 1 to 20. In one embodiment, the ratio of mass to carbon of oxygen in one or more of said materials carbonaceous
    Petition 870190009622, of 29/01/2019, p. 28/59
    20/46 comprises 1 to 200.
    [00058] As an embodiment, said crude synthesis gas comprises less than about 0.5 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced.
    [00059] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas using a partial oxidation method; said gasifier comprising a first reaction zone and a second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; wherein the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than about 1.25. In one embodiment, the amount of total oxygen added to said first reaction zone of said gasifier in pounds per pound of total carbon added to said gasifier comprises about 1.25 to about 3.5. In one embodiment, the temperature of said first reaction zone comprises 650-1,450 ° F. In one embodiment, the temperature of said second reaction zone comprises 1,750-3,500 ° F.
    [00060] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas; said gasifier comprising a first reaction zone and a second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; wherein the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than about 1.25. In one embodiment, the amount
    Petition 870190009622, of 29/01/2019, p. 29/59
    21/46 of total oxygen added in said first reaction zone of said gasifier in pounds per pound of total carbon added to said gasifier comprises about 1.25 to about 3.5. In one embodiment, the temperature of said first reaction zone comprises 650-1,450 ° F. In one embodiment, the temperature of said second reaction zone comprises 1,750-3,500 ° F.
    [00061] The present disclosure further provides a method comprising: subjecting said crude synthesis gas to cooling and cleaning to produce a clean synthesis gas; placing said synthesis gas in contact with a biocatalyst in a fermentation vessel to produce an alcohol product mixture. In one embodiment, the mass to carbon ratio of hydrogen to mass in one or more of said carbonaceous materials comprises 1 to 20. In one embodiment, the mass to carbon ratio of oxygen to one or more of said carbonaceous materials comprises 1 to 200.
    [00062] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas using partial oxidation method; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone with the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen to said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    [00063] The present disclosure provides a gasifier for producing synthesis gas using the partial oxidation method; said gasifier comprising a first reaction zone, a
    Petition 870190009622, of 29/01/2019, p. 30/59
    22/46 second reaction zone and a chamber connecting the first reaction zone with the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen to said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    [00064] The present disclosure provides a method of gasifying carbonaceous materials in a gasifier to produce synthesis gas; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone with the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen to said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    [00065] The present disclosure provides an aerator to produce synthesis gas; said gasifier comprising a first reaction zone, a second reaction zone and a chamber connecting the first reaction zone with the second reaction zone; comprising said method: adding one or more carbonaceous materials in said first reaction zone of the gasifier; adding a gas containing molecular oxygen and optionally adding water or steam to one or both of said first reaction zone and second reaction zone of said gasifier; comprising adding gas containing molecular oxygen to said chamber connecting said first reaction zone with said second reaction zone of said gasifier.
    Petition 870190009622, of 29/01/2019, p. 31/59
    [00066] In an embodiment of this disclosure, the temperature of said gasifier comprises about 650 ° F to about 3,500 ° F. In one embodiment, the temperature comprises about 650 ° F to about 1,450 ° F. In one embodiment, the temperature of said gasifier comprises about 950 ° F to about 1,400 ° F. In one embodiment, the temperature of said gasifier is about 1,400 ° F. In one embodiment, the temperature of said gasifier comprises about 1,750 ° F to about 2,250 ° F. In one embodiment, the temperature of said gasifier is about 2,250 ° F.
    [00067] In various embodiments of the present disclosure, said tar-containing product gas can be treated to remove or destroy at least a portion of tar contained in said tar-containing product gas using various methods of tar removal described in the published technique, in order to to produce a crude synthesis gas containing less tar or tar free. In one embodiment of the present disclosure, said tar-containing product gas is treated at a temperature of about 1,750 ° F to about 3,500 ° F in the presence of molecular oxygen to remove or produce a crude synthesis gas comprising carbon monoxide, hydrogen and carbon-synthesis gas. In one embodiment of the present disclosure, said tar-containing product gas is treated at a temperature of about 1,750 ° F to about 3,500 ° F in the presence of molecular oxygen to remove or produce a crude synthesis gas comprising carbon dioxide. Presumably in such treatment the tar is destroyed by tar cracking. Presumably in such treatment the tar is destroyed by partial oxidation of tar. In one embodiment, the treatment temperature comprises about 1,750 ° F to about 2,250 ° F. In one embodiment, the treatment temperature is about 2,250 ° F.
    [00068] The operation of the gasifier as above does not complete the combustion of all the carbon introduced in the gasifier to produce carbon dioxide. Presumably, a partial oxidation
    Petition 870190009622, of 29/01/2019, p. 32/59
    24/46 of carbon that is carried out, which increases the production of carbon monoxide. Such partial oxidation can also lead to the formation of unreacted carbon particles or soot (“carbon-synthesis gas”), which remain in the raw synthesis gas. Crude synthesis gas containing a large amount of carbon synthesis gas is undesirable, as it increases the difficulty and cost of cleaning the crude synthesis gas. In the method of this disclosure, said crude synthesis gas comprises less than about 0.5 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced. In one embodiment of the disclosure, said crude synthesis gas comprises less than about 0.25 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced. In one embodiment, said crude synthesis gas comprises less than about 0.125 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced.
    [00069] The operation of the gasifier as above does not complete combustion of all the carbon introduced in the gasifier to produce carbon dioxide. Presumably, an incomplete carbon oxidation is carried out, which increases the production of carbon monoxide. Such incomplete oxidation can also lead to the formation of unreacted carbon particles or soot (“carbon-synthesis gas”), which remain in the raw synthesis gas. Crude synthesis gas containing a large amount of carbon synthesis gas is undesirable, as it increases the difficulty and cost of cleaning the crude synthesis gas. In the method of this disclosure, said crude synthesis gas comprises less than about 0.5 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced. In one embodiment of the disclosure, said crude synthesis gas comprises less than about 0.25 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced. In one embodiment, said crude synthesis gas comprises less than about 0.125 pounds of carbon synthesis gas per 1,000 SCF of crude synthesis gas produced.
    [00070] Gasification of carbonaceous materials to produce gas
    Petition 870190009622, of 29/01/2019, p. 33/59
    25/46 product containing tar and the subsequent treatment of said product gas containing tar at high temperature in the presence of gas containing molecular oxygen (“tar cracking”) to produce crude synthetic gas free of tar or containing less tar can be carried out in multiple and separate process units or in a single unit with multiple zones or reaction chambers or compartments.
    [00071] The gasification of carbonaceous materials to produce tar product containing tar and the subsequent treatment of said tar product containing tar at high temperature in the presence of gas containing molecular oxygen ("partial tar oxidation") to produce crude synthesis gas free of tar or containing less tar can be carried out in multiple and separate process units or in a single unit with multiple zones or reaction chambers or compartments.
    [00072] In one embodiment, of the present disclosure, a gasification unit is used, which comprises two reaction zones: a first reaction zone that produces a product gas containing tar and a second reaction zone, which produces crude synthesis gas tar-free or containing less tar from the tar-containing product gas.
    [00073] In one embodiment of the present disclosure, a multi-stage gasification unit is used, which comprises two reaction zones: a first reaction zone that produces a tar-containing product gas and a second reaction zone that produces gas from tar crude tar-free synthesis or containing less tar from the tar-containing product gas.
    [00074] In one embodiment of the present disclosure, a two-stage gasification unit is used, which comprises two reaction zones: a first reaction zone that produces a gas product containing tar and a second reaction zone that produces gas gross tar-free synthesis or containing less tar from the
    Petition 870190009622, of 29/01/2019, p. 34/59
    26/46 gas product containing tar.
    [00075] In one embodiment of the present disclosure, the temperature in the first reaction zone must not be above the melting point of the inorganic components of the carbonaceous materials that form the ash. This temperature can be called the ash melting temperature. In one embodiment, the first reaction zone is maintained at a temperature of about 650 ° F to about 1,450 ° F. In one embodiment, the first reaction zone is maintained at a temperature of about 950 ° F to about 1,450 ° F. In one embodiment, the first reaction zone is maintained at a temperature of about 1,400 ° F.
    [00076] The temperature in the second reaction zone must be high enough for the tar cracking to take place effectively. In one embodiment, the second reaction zone is maintained at a temperature of about 1,750 ° F to about 3,500 ° F. In one embodiment, the second reaction zone is maintained at a temperature of about 1,750 ° F to about 2,250 ° F. In one embodiment, the second reaction zone is maintained at a temperature of about 2,250 ° F. In addition to maintaining the appropriate temperature, the second reaction zone must be dimensioned in such a way that an appropriate contact time or residence time is provided for the cracking of the tar. Typically, a residence time of about 2 to about 5 seconds is maintained.
    [00077] The temperature in the second reaction zone must be high enough for oxidation to occur effectively. In one embodiment, the second reaction zone is maintained at a temperature of about 1,750 ° F to about 3,500 ° F. In one embodiment, the second reaction zone is maintained at a temperature of about 1,750 ° F to about 2,250 ° F. In one embodiment, the second reaction zone is maintained at a temperature of about 2,250 ° F. In addition to maintaining the appropriate temperature, the second reaction zone must be dimensioned in such a way that an appropriate contact time or residence time is provided for the cracking of the tar. Typically, a time
    Petition 870190009622, of 29/01/2019, p. 35/59
    27/46 residence of about 2 to about 5 seconds is maintained.
    [00078] In one embodiment, the second reaction zone is placed vertically above the first reaction zone. In one embodiment, the second reaction zone is placed vertically below the first reaction zone.
    [00079] Gas containing molecular oxygen is added to the first reaction zone of said gasifier. Molecular oxygen-containing gas is added to the second reaction zone of said gasifier. Molecular oxygen-containing gas is added to both the first and second reaction zones of said gasifier. Molecular oxygen-containing gas can be air, oxygen-enriched air, or pure oxygen. Molecular oxygen-containing gas can contain about 21 volume% to about 100 volume% molecular oxygen.
    [00080] In this disclosure, the total oxygen added to the gasifier is the sum of the oxygen content of one or more carbonaceous materials added to the gasifier, oxygen contained in any water or steam optionally added, and oxygen contained in gas containing molecular oxygen injected both in the first reaction zone or lower chamber as in the second reaction zone or upper chamber of the gasifier; Total carbon added in the aerator is the sum of the carbon content of one or more carbonaceous materials added in the aerator.
    [00081] In this disclosure, the total oxygen added in the first gasifier reaction zone is the sum of the oxygen content of one or more carbonaceous materials added in the first gasifier reaction zone, the oxygen contained in either optionally added water or steam in the first reaction zone of the gasifier, and the oxygen contained in the gas containing molecular oxygen added in the first reaction zone of the gasifier; the total carbon added in the first reaction zone of the gasifier is the sum of the carbon content of one or more carbonaceous materials added in the first reaction zone of the gasifier.
    Petition 870190009622, of 29/01/2019, p. 36/59
    28/46 [00082] In one embodiment, the total carbon added in the first gasifier reaction zone is equal to the total carbon added in the gasifier.
    [00083] In one embodiment, the total carbon added in the first gasifier reaction zone is not equal to the total carbon added in the gasifier.
    [00084] As an embodiment, the present disclosure also provides a method for producing alcohol, comprising:
    subjecting said raw synthesis gas to cooling and cleaning to produce a clean synthesis gas;
    placing said clean synthesis gas in contact with a biocatalyst in a fermentation vessel to produce an alcohol product mixture.
    [00085] In one embodiment, one or more said alcohols comprise methanol. In one embodiment, one or more said alcohols comprise ethanol. In one embodiment, one or more said alcohols comprise methanol, ethanol, propanol, butanol, and combinations thereof.
    [00086] In one embodiment, an alcohol is selectively recovered from the alcohol product mixture. In one embodiment, the alcohol selectively recovered is ethanol. In one embodiment, the alcohol selectively recovered is butanol.
    [00087] As an embodiment, said biocatalyst comprises: microorganisms; acetogenic bacteria; one or more selected strains of Clostridium, Moorella, and Carboxydothermus or their mixed strains; Clostridium Ijungdahlii. Said Clostridium Ijungdahlii of the present disclosure is selected from the strains consisting of PETC, ERI-2, O-52 and C-01 or their combinations.
    [00088] Figure 1 comprises a schematic diagram illustrating an embodiment of an aerator. Figure 1 shows a schematic diagram of a two-stage gasifier. As a
    Petition 870190009622, of 29/01/2019, p. 37/59
    29/46 realization, Figure 1 presents a schematic diagram of a two-stage gasifier using partial oxidation. Referring now to Figure 1, one or more carbonaceous materials (150) is fed from a feed funnel (100) to the first reaction zone or lower chamber (200) of the gasifier for gasification. Molecular oxygen-containing gas (220) is introduced into the lower chamber to aid gasification. In one embodiment, water or steam can be added to the lower chamber to aid gasification. The amount of oxygen injected into the lower chamber is regulated in order to avoid complete combustion of the carbonaceous material. In other words, the lower chamber is deprived of oxygen. The prevention of complete combustion is also regulated by adjusting the temperature in the lower chamber. A temperature of 750 to 1,450 degrees F is maintained in the lower chamber. In one embodiment, the temperature in the lower chamber is adjusted so as to prevent any ash formed during gasification from melting. In one embodiment, the temperature in the lower chamber is 1,400 ° F. In one embodiment, the amount of molecular oxygen introduced into the lower chamber comprises 10 to 100 mole pounds per ton of carbonaceous material on a water-free or dry basis.
    [00089] A stream of gaseous material produced in the first reaction zone or lower chamber moves to the second reaction zone or upper chamber (400) of the gasifier through the chamber (300) connecting the first reaction zone / lower chamber to the second reaction zone / upper chamber. A stream of ash (250) is removed from the lower chamber. A stream of gaseous material produced in the first reaction zone moves to the second reaction zone (400) of the gasifier through the connection chamber (300) of the gasifier connecting the first reaction zone to the second reaction zone. A stream of ash (250) is removed from the first reaction zone.
    [00090] In one embodiment, steam can be added in the first
    Petition 870190009622, of 29/01/2019, p. 38/59
    30/46 reaction zone / lower chamber (200). In one embodiment, steam can be added to the second reaction zone / upper chamber (400). In one embodiment, steam can be added in the first reaction zone / lower chamber (200) and in the second reaction zone / upper chamber (400). In one embodiment, steam can be added to the chamber by connecting the first reaction zone / lower chamber to the second reaction chamber / upper chamber. In one embodiment, steam can be added to the gas stream (310) going into the chamber connecting the first reaction zone / lower chamber to the second reaction zone / upper chamber.
    [00091] In one embodiment, continuous steam can be added to the first reaction zone / lower chamber (200). In one embodiment, continuous steam can be added to the second reaction zone / upper chamber (400). In one embodiment, continuous steam can be added in the first reaction zone / lower chamber (200) and in the second reaction zone / upper chamber (400). In one embodiment, continuous steam can be added to the chamber (300) connecting the first reaction zone / lower chamber to the second reaction zone / upper chamber. In one embodiment, continuous steam can be added to the gas stream (310) going into the chamber connecting the first reaction zone / lower chamber to the second reaction zone / upper chamber.
    [00092] Presumably, partial oxidation of tar contained in the gaseous material produced in the lower chamber is carried out in the upper chamber. Presumably, the cracking of the tar contained in the gaseous material produced in the lower chamber is carried out in the upper chamber. A gas stream containing molecular oxygen is introduced into the chamber connecting the first reaction zone / lower chamber to the second reaction zone / upper chamber (300) or gasifier constriction throat in order to assist partial oxidation and / or cracking of the tar in the upper chamber. In one embodiment, gas containing molecular oxygen is introduced directly into the
    Petition 870190009622, of 29/01/2019, p. 39/59
    Upper chamber 31/46. Partial tar oxidation is also regulated by adjusting the temperature in the upper chamber of the aerator. The cracking of the tar is also regulated by adjusting the temperature in the upper chamber of the aerator. A temperature of 1,750 to 3,500 ° F is maintained in the upper chamber. In one embodiment, the temperature in the upper chamber is 2,250 ° F. In one embodiment, the amount of molecular oxygen introduced into the upper chamber comprises 10 to 100 mole-pounds per ton of carbonaceous material on a water-free or dry basis.
    [00093] In one embodiment, the upper chamber is positioned vertically above the top of the lower chamber. In one embodiment, the upper chamber is positioned at a level not vertically above the top of the lower chamber. In one embodiment, the lower chamber and the upper chamber are positioned around the same vertical elevation, that is, side by side. A stream of crude synthesis gas (410) is removed from the upper chamber of the gasifier.
    [00094] Figure 2 comprises a schematic diagram illustrating an embodiment of a process for producing ethanol from a carbonaceous material by means of gasifying said carbonaceous material. Referring now to Figure 2, a carbonaceous material (1) is fed into a gasifier (10), in which the carbonaceous material is converted to produce gas or synthesis gas or singas comprising carbon monoxide (CO) and hydrogen (H2 ). A crude synthesis gas product (11) is removed from the gasifier. The crude synthesis gas is hot and may contain gas containing sulfur and other acidic gases, particulate matter, etc. and is subject to cooling and cleaning in a cooling and cleaning process (20). A cold, clean stream of synthesis gas (21) is produced by the cooling and cleaning process, which is introduced into a bioreactor or fermenter or fermenter (30) to produce ethanol. In the bioreactor, microorganisms act on carbon monoxide (CO) and hydrogen (H2) in the synthesis gas to produce ethanol. A chain
    Petition 870190009622, of 29/01/2019, p. 40/59
    32/46 containing ethanol (31) is removed from the bioreactor. The ethanol-containing stream can be further processed to produce fuel grade ethanol (not shown in the diagram).
    [00095] Figure 3 comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the gasifier on carbon-synthesis gas for various amounts of water entering the gasifier. As an embodiment, Figure 3 illustrates that the trend in total carbon-synthesis gas content decreases as oxygen input into the gasifier increases. Figure 3 is a graph of the carbon-synthesis gas in pounds per KSCF of crude synthesis gas produced (y-axis) versus the total oxygen input in pounds per pound of total carbon input (x-axis). Figure 3 is a graph of the synthesis-carbon gas in pounds per thousand SCF of crude synthesis gas produced (y-axis) versus the total oxygen intake in pounds-per-pound of the total carbon intake (x-axis). Figure 3 is a graph of synthesis-carbon gas in pounds per thousand SCF of crude synthesis gas produced (y-axis) versus the total oxygen intake in pounds-per-pound of total carbon intake (x-axis); where the total oxygen inlet is the total oxygen inlet in the aerator and the total carbon inlet is the total carbon inlet in the aerator. For a total oxygen inlet in the gasifier greater than about 1.4 pounds per pound (lb / lb) of the total carbon inlet in the gasifier, the crude synthesis gas comprises less than about one (1) pound (lb) ) of carbon-synthesis gas per thousand standard cubic feet (1,000 SCF or KSCF) of crude synthesis gas produced. For a total oxygen inlet in the gasifier greater than about 1.5 pounds per pound (1lb / lb) of total carbon inlet in the gasifier, the crude synthesis gas comprises less than about 0.3 pounds (lb) of standard synthetic gas per thousand cubic feet (1,000 SCF or KSCF) of crude synthesis gas produced.
    [00096] Figure 4 comprises a schematic diagram illustrating a realization of the effect of entry of total oxygen into the
    Petition 870190009622, of 29/01/2019, p. 41/59
    33/46 aerator on quantity of ethanol produced for various quantities of water entering the aerator. As an embodiment, Figure 4 illustrates that the trend in alcohol production initially increases with an increase in total oxygen intake. Figure 4 is a graph of ethanol produced in pounds per pound from total carbon input (y-axis) versus total oxygen input in pounds per pound from total carbon input (x-axis). Figure 4 is a graph of ethanol produced in pounds per pound from total carbon input (y-axis) versus total oxygen input in pounds per pound from total carbon input (x-axis); where the total oxygen inlet is the total oxygen inlet in the aerator and the total carbon inlet is the total carbon inlet in the aerator. As an embodiment, Figure 4 illustrates that the trend in alcohol production initially increases with an increase in total oxygen intake and then decreases with an increase in total oxygen intake. As an embodiment, Figure 4 illustrates that the trend in ethanol production initially increases with an increase in total oxygen intake. As an embodiment, Figure 4 illustrates that the trend in ethanol production initially increases with an increase in total oxygen intake and then decreases with an increase in total oxygen intake. As an embodiment, Figure 4 illustrates that the trend in ethanol production (pounds of ethanol produced per pound of total carbon input into the gasifier) increases with an increase in the total oxygen input into the gasifier until the total oxygen input is about one pound and a half per pound (lb / lb) of total carbon input into the aerator. As an embodiment, Figure 4 illustrates that the trend in ethanol production (pounds of ethanol produced per pound of total carbon input into the gasifier) increases with an increase in the total oxygen input into the gasifier until the total oxygen input of about one pound and a half (1.5) per pound (lb / lb) of the total carbon inlet in the aerator and the total oxygen inlet in the aerator of more than one pound and a half (1.5) per pound (lb / lb) of the total carbon input in the gasifier, the
    Petition 870190009622, of 29/01/2019, p. 42/59
    34/46 ethanol production (pounds of ethanol produced per pound of total carbon input into the gasifier) decreases with an increase in the total oxygen input into the gasifier.
    [00097] Figure 5 comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen in the first reaction zone of the gasifier on carbon-synthesis gas for various amounts of water entering the gasifier. As an embodiment, Figure 5 illustrates that the trend in the total carbon dioxide gas content of the crude synthesis gas decreases, as the total oxygen entry into the first gasifier reaction zone increases. Figure 5 is a diagram of the carbon synthesis gas in pounds per KSCF of crude synthesis gas produced (y-axis) versus the entry of total oxygen into the first reaction zone in pounds per pound of the total carbon inlet (x-axis). Figure 5 is a graph of carbon synthesis gas in pounds per thousand SCF of crude synthesis gas produced (y-axis) versus the entry of total oxygen into the first reaction zone in pounds-per-pound of total carbon inlet (x-axis) . Figure 5 is a graph of synthesis-carbon gas in pounds per thousand SCF of crude synthesis gas produced (y-axis) versus the entry of total oxygen into the first reaction zone in pounds-per-pound of total carbon entry (x-axis) ); where the entry of total oxygen into the first reaction zone is the entry of total oxygen into the first reaction zone of the gasifier and the entry of total carbon is the entry of total carbon into the gasifier. For a total oxygen inlet in the first gasifier reaction zone greater than about 0.75 pound per lb (lb / lb) of the total carbon inlet in the gasifier, the crude synthesis gas comprises less than about one ( 1) pound (lb) of synthetic carbon gas per thousand standard cubic feet (1,000 SCF) of crude synthesis gas produced. For a total oxygen inlet in the first gasifier reaction zone greater than about 0.9 pound per pound (lb / lb) of the total carbon inlet in the gasifier, crude synthesis gas comprises less than about 0.3 pound (lb) synthesis-carbon gas
    Petition 870190009622, of 29/01/2019, p. 43/59
    35/46 for one thousand standard cubic feet (1,000 SCF or KSCF) of synthesis gas produced.
    [00098] Figure 6 comprises a schematic diagram illustrating a realization of the effect of the entry of total oxygen into the first reaction zone of the gasifier on the quantity of ethanol produced for various amounts of water entering the gasifier. As an embodiment, Figure 6 illustrates that the trend in alcohol production initially increases with an increase in the total oxygen input in the first gasifier reaction zone. Figure 6 is a graph of ethanol produced in pounds per pound from total carbon input (y-axis) versus total oxygen input in the first reaction zone in pounds per pound from total carbon input (x-axis). Figure 6 is a graph of ethanol produced in pounds per pound from total carbon input (y-axis) versus total oxygen input in the first reaction zone in pounds per pound from total carbon input (x-axis); where the entry of total oxygen into the first reaction zone is the entry of total oxygen into the first reaction zone of the gasifier and the entry of total carbon is the entry of total carbon into the gasifier. As an embodiment, Figure 6 illustrates that the alcohol production trend initially increases with the increase in total oxygen input in the first gasifier reaction zone and then decreases with the increase in total oxygen input in the first gasifier reaction zone. . As an embodiment, Figure 6 illustrates that the trend in ethanol production initially increases with an increase in the entry of total oxygen into the first reaction zone of the gasifier. As an embodiment, Figure 6 illustrates that the trend in ethanol production initially increases with the increase in total oxygen input in the first gasifier reaction zone and then decreases with the increase in total oxygen input in the first gasifier reaction zone. . As an embodiment, Figure 6 illustrates that the trend in ethanol production (pounds of ethanol produced per pound of total carbon input into the gasifier) increases with increasing input
    Petition 870190009622, of 29/01/2019, p. 44/59
    36/46 total oxygen in the aerator's first reaction zone to the total oxygen inlet in the aerator's first reaction zone of about 0.9 pounds per pound (lb / lb) of the total carbon inlet in the aerator. As an embodiment, Figure 6 illustrates that the ethanol production trend (pounds of ethanol produced per pound from the total carbon input in the gasifier) increases with the increase in the total oxygen input in the first reaction zone of the gasifier until the input of total oxygen in the aerator's first reaction zone of about 0.9 pounds per lb (lb / lb) of the total carbon intake in the aerator and for total oxygen in the aerator's first reaction zone above 0.9 pounds per pound (lb / lb) of ethanol production (pounds of ethanol produced per pound of total carbon input into the gasifier), decreases with the increase in total oxygen input into the first reaction zone of the gasifier.
    [00099] The above-mentioned descriptions of specific embodiments of the present disclosure are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit disclosure to the precise forms revealed. Of course, many modifications and variations are possible in view of the above teachings. While the achievements were chosen and described in order to better explain the principles of disclosure and their practical applications, thereby allowing others skilled in the art to better use disclosure, various achievements with various modifications, to the extent that they are appropriate to the private use are also possible.
    [000100] In a realization of this revelation, alcohol is produced by contacting the synthesis gas with the biocatalyst in a fermentation vessel to produce an alcohol product mixture. In one embodiment, said alcohol comprises methanol, ethanol, propanol, and butanol or combinations thereof. In one embodiment, said alcohol comprises ethanol. In one embodiment, said biocatalyst comprises acetogenic bacteria. In one embodiment, said biocatalyst
    Petition 870190009622, of 29/01/2019, p. 45/59
    37/46 comprises one or more strains selected from Clostridium, Moorella, and Carboxydothermus or their mixed strains. In one embodiment, said biocatalyst comprises one or more strains of Clostridium [jun.gdahlii. In one embodiment, said Clostridium [jun.gdahlii is selected from strains consisting of PETC, ERI-2, O-52 and C-01 or their combinations. In one embodiment, said biocatalyst comprises one or more strains of Clostridium carboxidivorans. In one embodiment, said biocatalyst comprises one or more strains of Clostridium ragsdalei. In one embodiment, said biocatalyst comprises one or more strains of Clostridium autoethanogenum.
    EXAMPLES [000101] A multistage aerator is contemplated in the present disclosure. As an embodiment, a multistage aerator using the partial oxidation method is contemplated in the present disclosure. The following examples use a two-stage aerator, as shown in Figure 1. The aerator comprises a first stage or first reaction zone or lower chamber and a second stage or second reaction zone or upper chamber. The carbonaceous material is fed into the lower chamber, where air, oxygen-enriched air or pure oxygen can be injected at a controlled rate below a grid. For the examples presented below, pure oxygen is injected into the lower chamber. The temperature of the lower chamber and the oxygen supply are controlled, such that only incomplete oxidation of carbonaceous material occurs, not complete combustion (also described as air or oxygen-free combustion). The temperature of the lower chamber and the oxygen intake are controlled, such that only partial oxidation of carbonaceous material occurs, not complete combustion (also described as air or oxygen-free combustion). A temperature of about 750 to about 1,450 degrees F is maintained in the lower chamber.
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    38/46
    In one embodiment, a temperature of about 1,400 degrees F is maintained in the first stage. In one embodiment, a temperature less than about 1,400 degrees F is maintained in the first stage or lower chamber. The gaseous product from the lower chamber moves to the second stage or upper chamber. Gray is removed from the lower chamber. Pure oxygen is introduced into the upper chamber to raise the temperature to a temperature in the upper chamber of about 1,750 to about 3,500 degrees F in order to crack any tar (such as heavy hydrocarbons) contained in the gas stream of the first stage. Pure oxygen is introduced into the upper chamber to raise the temperature to a temperature in the upper chamber of about 1,750 to about 3,500 degrees F in order to perform partial oxidation of any tar (such as heavy hydrocarbons) contained in the gas stream of the first stage. For the examples shown below, the upper chamber temperature is 2,250 degrees F. A crude producer gas (also called crude synthesis gas or crude singas) containing carbon monoxide (CO), hydrogen (H2) CO2, N2 and other constituents { for example, O2, particulate matter (PM), tar, metals} is produced and removed from the upper chamber. In one embodiment, steam can be injected into the lower chamber. In one embodiment, steam can be injected into the upper chamber.
    [000102] Following gasification, the raw synthesis gas is subjected to cooling and cleaning to produce a product synthesis gas. The product synthesis gas is introduced into a bioreactor or fermenter or fermenter to produce alcohols; methanol; ethanol; propanol; and / or butanol. In the examples below, ethanol is produced in the bioreactor.
    [000103] In the examples below, mathematical models were used to calculate the output of the gasifier or fermenter for various process and raw material conditions instead of the current experience. To calculate the gasifier output, a mathematical model based on CHEMKIN was used.
    [000104] The model used a 5% air leak in the chamber
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    39/46 lower or first gasifier reaction zone.
    [000105] The model for the fermentation process involves a process that converts 90% carbon monoxide and a process that converts 40% hydrogen with 95% selectivity for each process to make ethanol.
    Examples 1-29 [000106] Examples 1-29 exemplify gasification of carbonaceous materials containing no or almost no water and no water or steam directly added to the gasifier, as well as gasification of carbonaceous materials containing substantial water and / or quantity substantial amount of water or steam added directly to the aerator. The examples exemplify gasification achievements of simple carbonaceous materials, such as coal, coke tar (coke), plastic, tire, wood, polystyrene (PS), polyethylene terephthalate (PETA) and plurality of carbonaceous material, such as tire mixtures and wood, plastic and wood, plastic and rsu, and coke tar and fibersoft. For all of these examples, the temperature in the first reaction zone is 1,400 ° F and the temperature in the second reaction zone is 2,250 ° F. Relevant carbonaceous material properties, other gasification conditions and product data are summarized in Table I and Table II below.
    [000107] As embodiments, the following are descriptions of mixtures of carbonaceous materials shown in examples 1-29:
    Biomass-VW-15: mixture of 80% by weight of biomass and 20% by weight of construction wood waste or vegetable waste with a water content of 15% by weight of the mixture.
    Coke-fibersoft-10: mixture of 50% mass of coke tar containing no water and 50% wet fibersoft mass containing 20% water mass, providing 10% water mass
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    40/46 for the mixture
    Coke-fibersoft-20: mixture of 50% mass of coke tar (coke) containing no water and 50% wet fibersoft mass containing 40% water mass, providing 20% water mass for the mixture
    Coke-fibersoft-30: mixture of 50% mass of coke tar (coke) containing no water and 50% wet fibersoft mass containing 60% water mass, providing 30% water mass for the mixture
    Pástico-RSU-03: mixture of 90% by weight of plastic containing 0.2% by weight of water and 10% by weight of MSW containing 30% of water providing 3.2% of water for the mixture
    Plastic-MSW-08: mixture of 75% by weight of plastic containing 0.2% by weight of water and 25% by weight of MSW containing 30% of water, providing 7.7% of water for the mixture
    Plastic-MSW-15: mixture of 50% by weight of plastic containing 0.2% by weight of water and 50% by weight of MSW containing 30% of water, providing 15.1% of water for the mixture
    Plastic-wood-04: mixture of 90% plastic mass containing 0.2% water mass and 10% wood mass containing 40% water mass providing 4.2% water mass for the mixture
    Plastic-wood-10: mixture of 75% plastic mass containing 0.2% water mass and 25% wood mass containing 40% water mass, providing 10.2% water mass for the mixture
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    Plastic-wood-20: mixture of 50% plastic mass containing 0.2% water mass and 50% wood mass containing 40% water mass, providing 20.1% water mass for the mixture
    Pneu-madeira-00: mixture of 85% of the mass of the tire without water and 15% of the mass of wood containing 40% of the water and then pre-dried to remove all the water
    Pneu-madeira-03: mixture of 85% mass of tire without water and 15% mass of wood containing 40% mass of water and then pre-dried to 3% mass of water content of mixture
    Tire-wood-04: mixture of 90% of the mass of the tire without water and 10% of the mass of wood containing 40% of the water providing 4.0% of the water for the mixture
    Pneu-madeira-06: mixture of 85% mass of tire without water and 15% mass of wood containing 40% mass of water providing 6.0% mass of water for the mixture
    Pneu-madeira-09: mixture of 85% of the mass of the tire without water and 15% of the mass of the wood containing 40% of the water and then added water to 9% of the water content of the mixture
    Tire-wood-10: mixture of 75% mass of tire without water and 25% mass of wood containing 40% mass of water providing 10% mass of water for the mixture
    Tire-wood-12: mixture of 85% mass of tire without water and 15% mass of wood containing 40% of water and then added water to 15% of water content of mixture
    Tire-wood-15: mixture of 85% non-tire mass
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    42/46 containing water and 15% wood mass containing 40% water mass and then added water to 15% mixture water content
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    Table I. Properties of Carbonaceous Materials And Conditions of
    Gasification Processes for Examples 1-29
    ExNo. MaterialCarbonaceousFed Composition of Fed Carbonaceous Material Other Foods inAerator, libramols / DT Carbon% inpasta* Oxygen% of mass * Hydrogen mass% * Gray% of mass * Others% inpasta* Water% of mass * Steam O2(FZ) O2(SZ) 1 Biomass-VW-15 46.6 40.3 5.7 6.9 0.5 15.0 12.3 14.0 13,5 2 coal 64.8 9.2 4.5 16.1 21.5 0.0 0.0 12.1 18,0 3 Coquefibersoft-10 69.6 14.6 5.9 7.7 2.2 10.0 0.0 18.0 27,1 4 Coquefibersofi-20 73.0 12.4 5.8 6.6 2.2 20.0 0.0 25.4 26,4 5 Coquefibersofi-30 77.5 9.7 5.7 5.1 2.0 30.0 0.0 33.9 25,3 6 Coke tar 91.7 0.8 5.5 0.3 2.0 0.0 0.0 12.8 24,9 7 Plastic 73.0 10.6 9.5 3.4 6.9 0.2 0.0 24.3 29,8 8 Plastic-RSU-03 70.6 12.0 9.3 4.8 3.3 3.2 0.0 25.0 29,2 9 Plastic-RSU-08 66.8 14.3 8.9 7.0 3.0 7.7 0.0 27.0 26,7 10 Plastic-RSU-15 59.4 18.5 8.2 11.3 2.6 15.1 0.0 26.3 21,0 11 Plastic-wood-04 71.5 12.7 9.3 3.3 3.2 4.2 0.0 25.4 29,2 12 Plastic-wood-10 69.1 16.1 8.9 3.1 2.8 10.2 0.0 27.0 26,7 13 Plastic-wood-20 64.2 22.8 8.0 2.7 2.3 20.1 0.0 28.2 21,6 14 PETA 62.5 33.1 4.1 0.1 0.3 0.2 0.0 10.0 22,8 15 Polystyrene 86.8 3.9 8.4 0.5 0.9 0.2 0.0 30.7 30,7 16 Tire 64.2 4.4 5.0 25.6 26.4 0.0 0.0 11.5 16,8
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    17 Tire 64.2 4.4 5.0 25.4 1.0 0.0 50.0 26.7 20,9 18 Tire 64.2 4.4 5.0 25.4 1.0 0.0 60.0 28.5 20,0 19 Tire 64.2 4.4 5.0 25.4 1.0 0.0 70.0 30.1 19,3 20 Tire-wood-00 62.8 8.1 5.0 23.1 24.1 0.0 0.0 11.3 17,7 21 Tire-wood-03 62.8 8.1 5.0 23.1 1.0 3.0 0.0 13.4 19,9 22 Tire-wood-04 63.3 6.8 5.0 23.9 1.0 4.0 0.0 14.2 12,9 23 Tire-wood-06 62.8 8.1 5.0 23.1 1.0 6.0 0.0 15.4 22,2 24 Tire-wood-09 62.8 8.1 5.0 23.1 1.0 9.0 0.0 17.4 23,9 25 Tire-wood-10 61.7 10.9 5.1 21.4 0.9 10.0 0.0 17.6 23,6 26 Tire-wood-12 62.8 8.1 5.0 23.1 1.0 12.0 0.0 19.4 24,0 27 Tire-wood-15 62.8 8.1 5.0 23.1 1.0 15.0 0.0 21.4 23,3 28 wood 49.5 43.1 5.4 1.5 2.0 0.0 0.0 6.3 17,4 29 wood 49.5 43.1 5.5 1.5 0.4 40.0 0.0 24.5 13,3
    NOTE: * indicates dry or water-free base; DT means ton of dry or water-free carbonaceous material
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    Table II. Gasification Products and Fermentation Processes
    Subsequent to Examples 1-29
    ExNo. food Synthesis Gas ComponentsGross Produced, pound-mols / DT Volume of Crude Synthesis Gas, KSCF / DT GrayCarbon, libramols / DT Ethanol, libramols / DT CO H2 CO2 H2O Synthesis gasCarbon 1 Biomass-VW-15 59.1 49.3 17.9 38.8 0.1 60321 0.574 11.5 2 coal 67.5 42.7 0.1 0.1 38.9 55782 1,340 12.3 3 Coquefibersoft -10 108.9 67.8 1.6 2.6 4.8 68505 0.942 19.8 4 Coke-fibersoft -20 112.6 72.7 7.5 12.6 1.1 76228 0.546 20.6 5 Coke-fibersoft -30 113.0 77.4 15.2 27.0 0.5 86109 0.422 21.0 6 Coke tar 77.9 61.2 0.1 0.1 74.9 78465 0.025 15.0 7 Plastic 111.2 93.1 0.8 1.9 9.4 79625 0.284 21.7 8 Plastic-RSU-03 111.4 91.5 2.1 4.5 3.8 78546 0.399 21.7 9 Plastic-RSU-08 104.4 87.1 4.9 10.6 1.4 76746 0.586 20.4 10 Plastic-RSU-15 87.4 77.4 10.2 23.5 0.5 73293 0.942 17.4 11 Plastic-wood-04 112.3 91.7 2.6 5.4 3.2 79187 0.284 21.8 12 Plastic-wood-10 107.5 87.9 6.2 13.2 1.2 79482 0.266 20.9 13 Plastic-wood-20 92.8 78.1 13.6 29.7 0.4 78874 0.225 18.2 14 PETA 98.6 40.1 1.4 1.5 4.4 53409 0.004 16.6 15 Polystyrene 118.7 83.9 0.4 0.6 25.8 84425 0.038 22.2 16 Tire 58.2 49.4 0.0 0.1 46.8 56564 2,098 11.4 17 Tire 91.4 72.5 13.1 27.0 0.4 75191 2,098 17.6
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    18 Tire 88.3 74.0 16.3 35.5 0.3 78833 2,098 17.3 19 Tire 85.3 75.3 19.3 44.2 0.2 82470 2,098 16.9 20 Pneumatic-00 64.1 49.9 0.1 0.1 38.6 55973 1,924 12.3 21 Pneumatic-03 75.3 53.2 0.1 0.2 27.4 57335 1,924 14.1 22 Tire-wood-04 77.1 54.0 0.1 0.3 26.3 57949 1,990 14.4 23 Tire-wood-06 86.4 56.6 0.3 0.5 16.0 58779 1,924 15.9 24 Tire-wood-09 95.2 59.6 0.9 1.4 6.6 60300 1,924 17.3 25 Tire-wood-10 95.8 59.5 2.0 3.2 3.0 60202 2,168 17.4 26 Tire-wood-12 97.7 61.2 2.4 3.9 2.6 61867 1,924 17.8 27 Tire-wood-15 96.9 62.2 4.4 7.4 1.4 63527 1,924 17.7 28 wood 75.8 44.9 6.7 10.2 0.6 50387 0.127 13.6 29 wood 48.7 46.2 33.6 82.9 0.0 77345 0.127 9.9
    [000108] All published documents are incorporated by reference into this document. Numerous modifications and variations of the present disclosure are included in the Descriptive Report identified above and are expected to be evident to a person skilled in the art. Such modifications and alterations to the compositions and methods of the present disclosure are believed to fall within the scope of the Claims appended hereto. Consequently, various modifications, adaptations and alternatives can occur to a person skilled in the art, without departing from the spirit and scope of this document.
    权利要求:
    Claims (18)
    [1]
    1 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, to produce a product gas comprising carbon monoxide, hydrogen and tar;
    comprising said method:
    add one or more carbonaceous materials, add a gas containing molecular oxygen and, optionally, add water to said gasifier;
    characterized in that the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than 2.0 and less than 3.0;
    wherein the gasifier produces produces ash comprising ash carbon and wherein said ash comprises less than 10% ash carbon;
    wherein said product gas is treated at a temperature of 954 ° C (1,750 ° F) to 1,927 ° C (3,500 ° F) in the presence of molecular oxygen to produce a crude singas comprising carbon monoxide, hydrogen and carbon of singas;
    wherein said raw singas comprises less than 0.5 pounds of carbon from singas per 1,000 cubic feet of produced raw singas;
    wherein said product gas comprises a CO to CO2 ratio greater than 1.4; and in which the aforementioned volume of gross singas is in the range of 50,387 to 89,109 KSCF / DT.
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    [2]
    2/5
    2 - Non-Catalytic Method of Gasifying Carbonaceous Materials in
    Aerator according to Claim 1, characterized in that it comprises adding water to said aerator.
    [3]
    3 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 1, characterized in that it comprises directly adding steam to said aerator.
    [4]
    4 - Non-Catalytic Method of Gasifying Carbonaceous Materials in Gasifier, according to Claim 1, characterized in that it comprises adding water, by partial addition of direct steam to said gasifier.
    [5]
    5 - Non-Catalytic Method of Gasifying Carbonaceous Materials in Gasifier, according to Claim 1, characterized in that it comprises adding one or more of said carbonaceous materials containing moisture to said gasifier.
    [6]
    6 - Non-Catalytic Method of Gasifying Carbonaceous Materials in Gasifier, according to Claim 1, characterized in that one or more of said carbonaceous materials comprises the selection from carbonaceous material, carbonaceous liquid product, industrial carbonaceous liquid recycling, municipal solid waste carbonaceous (MSW), carbonaceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood waste, carbonaceous building material, carbonaceous vegetative material, carbonaceous petrochemical co-products, carbonaceous coal, plastic waste, coke oven tar , fibersoft, tires, lignin, black liquor, polymers, disposal polymers, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, energy crops, forest processing residues, waste from wood processing, waste cattle, poultry waste, waste from processing
    Petition 870190009622, of 29/01/2019, p. 6/59
    3/5 food, fermentation process residues, carbonaceous industrial residues, alcohol production residues, ethanol by-products, disposal grains, disposal microorganisms or their combinations.
    [7]
    7 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 1, characterized in that the carbon content of one or more of said carbonaceous materials comprises 0.25 to 1.0 pounds per pound of one or more of the carbonaceous materials on a water-free basis.
    [8]
    8 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 1, characterized in that the hydrogen content of one or more of said carbonaceous materials comprises from 0.0 to 0.25 pounds per pound of one or more of said carbonaceous materials on a water-free base.
    [9]
    9 - Non Catalytic Method of Gasifying Carbonaceous Materials in Gasifier, according to Claim 1, characterized in that the oxygen content of one or more of said carbonaceous materials comprises 0.0 to 0.5 pounds per pound of one or more of the carbonaceous materials on a water-free basis.
    [10]
    10 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 1, characterized in that the aerator produces ash comprising ash carbon and that said ash comprises less than 5% ash carbon.
    [11]
    11 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 1, characterized in that the mass ratio of carbon to hydrogen in one or more of said carbonaceous materials comprises from 1 to 20.
    [12]
    12 - Non Catalytic Method of Gasifying Carbonaceous Materials in
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    4/5
    Gasifier according to Claim 1, characterized in that the mass ratio of carbon to oxygen in one or more of said carbonaceous materials comprises from 1 to 200.
    [13]
    13 - Non Catalytic Method of Gasifying Carbonaceous Materials in
    Gasifier, to produce crude synthesis gas;
    said gasifier comprising a first reaction zone and a second reaction zone;
    comprising said method:
    adding one or more carbonaceous materials to said first gasification reaction zone;
    adding a gas containing molecular oxygen and, optionally, adding water or water vapor to one or both of said first reaction zone and second reaction zone of said gasifier;
    characterized in that the amount of total oxygen added to said gasifier in pounds per pound of total carbon added to said gasifier comprises more than 2.0 and less than 3.0;
    wherein said raw singas comprises less than 0.5 pounds of carbon from singas per 28.3 m 3 (1,000 scf) of produced raw singas;
    wherein said singas comprises a CO to CO2 ratio greater than 1.4;
    and where the aforementioned gross singles volume ranges from 50,387 to 86,109 KSCF / DT.
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    5/5
    [14]
    14 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 13, characterized in that said temperature of the first reaction zone comprises 343788 ° C (650-1450 ° F).
    [15]
    15 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 13, characterized in that said temperature of the second reaction zone comprises 9541.927 ° C (1,750-3,500 ° F).
    [16]
    16 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 13, characterized in that it further comprises:
    subjecting said crude synthesis gas to cooling and cleaning to produce a clean synthesis gas;
    contacting said clean synthesis gas with a biocatalyst in a fermentation vessel for the production of an alcohol product mixture.
    [17]
    17 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 13, characterized in that the mass ratio of carbon to hydrogen in one or more of said carbonaceous materials comprises from 1 to 20.
    [18]
    18 - Non-Catalytic Method of Gasifying Carbonaceous Materials in an Aerator, according to Claim 13, characterized in that the mass ratio of carbon to oxygen in one or more of said carbonaceous materials comprises from 1 to 200.
    类似技术:
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    同族专利:
    公开号 | 公开日
    US20140038278A1|2014-02-06|
    US20110248218A1|2011-10-13|
    KR101781242B1|2017-09-22|
    RU2568721C2|2015-11-20|
    JP2013523991A|2013-06-17|
    EP2558555A2|2013-02-20|
    CA2795832A1|2011-10-20|
    MX344829B|2017-01-05|
    EP2558555B1|2018-06-06|
    WO2011129878A2|2011-10-20|
    ZA201208513B|2015-11-25|
    RU2012147912A|2014-05-20|
    US8580152B2|2013-11-12|
    WO2011129878A3|2012-01-19|
    MX2012011896A|2012-11-30|
    CA2795832C|2018-12-04|
    CN102939360A|2013-02-20|
    KR20130054266A|2013-05-24|
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    法律状态:
    2017-09-05| B15I| Others concerning applications: loss of priority|
    2017-10-03| B12F| Other appeals [chapter 12.6 patent gazette]|
    2018-03-06| B25C| Requirement related to requested transfer of rights|Owner name: INEOUS USA LLC (US) |
    2018-06-05| B25A| Requested transfer of rights approved|Owner name: NEOS BIO SA (US) |
    2018-11-27| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2019-02-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2019-04-09| B09X| Republication of the decision to grant [chapter 9.1.3 patent gazette]|Free format text: REPUBLIQUE-SE, POR FALTA DA INCLUSAO LISTA DE SEQUENCIA NA PUBLICACAO ANTERIOR |
    2019-04-30| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/04/2011, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/04/2011, OBSERVADAS AS CONDICOES LEGAIS |
    2020-08-04| B25D| Requested change of name of applicant approved|Owner name: JUPENG BIO SA (CH) |
    2020-08-18| B25G| Requested change of headquarter approved|Owner name: JUPENG BIO SA (CH) |
    2020-09-01| B25A| Requested transfer of rights approved|Owner name: JUPENG BIO (HK) LIMITED (CN) |
    优先权:
    申请号 | 申请日 | 专利标题
    US12/798,852|US8580152B2|2010-04-13|2010-04-13|Methods for gasification of carbonaceous materials|
    US12/798,852|2010-04-13|
    PCT/US2011/000655|WO2011129878A2|2010-04-13|2011-04-11|Methods for gasification of carbonaceous materials|
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