Abstract: The present invention provides a process for producing gasoline components from syngas. Syngas is converted to one or more of methanol, ethanol, mixed alcohols, and dimethyl ether, followed by various combinations of separations and reactions to produce gasoline components with oxygenates, such as alcohols. The syngas is preferably derived from biomass or another renewable carbon-containing feedstock, thereby providing a biorefining process for the production of renewable gasoline.

Abstract: The present invention provides modular and distributed methods and systems to convert biomass feedstocks into synthesis gas (syngas). The syngas can then be turned into liquid chemicals and fuels such as ethanol. The modular units of the invention bring the conversion process to the biomass source, thereby minimizing feedstock transportation costs. The modules are capable of being connected to, and/or disconnected from, each other to easily adjust the overall feedstock capacity. The present invention also provides methods and systems to determine an optimal number and distribution of modular conversion units spatially located within a region of land. The disclosed methods and systems are flexible, efficient, scalable, and are capable of being cost-effective at any commercial scale of operation.

Abstract: This invention features methods and apparatus for producing syngas from any carbon-containing feed material. In some embodiments, a substoichiometric amount of oxygen is used to enhance the formation of syngas. In various embodiments, both oxygen and steam are added during the conversion of the feed material into syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.

Abstract: In one aspect of this invention, catalytic compositions produced by calcining intermediates of the formula [NR4]x[M12M2S8] are provided, wherein M1 is Mo or W; M2 is Co, Ni, or Pd; x is 2 or 3; and R is a C3-C8 alkyl group. Another aspect provides catalytic compositions produced by calcining intermediates of the formula Ax[M12M2S8], wherein A is selected from K, Rb, Cs, Sr, and Ba. Also provided are methods for making the compositions, and methods of using the compositions for the catalytic conversion of syngas into C1-C4 alcohols such as ethanol.

Abstract: This invention features methods and apparatus for producing syngas from any carbon-containing feed material. In some embodiments, a substoichiometric amount of oxygen is used to enhance the formation of syngas. In various embodiments, both oxygen and steam are added during the conversion of the feed material into syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.

Abstract: The present invention provides useful fuel compositions which may be produced substantially from renewable resources, such as biomass, to provide green fuel compositions, methods, and systems. In some embodiments, fuel compositions include dimethyl ether and one or more C2 or larger alcohol, such as ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, isobutanol, or tert-butanol. In some embodiments, fuel compositions include dimethyl ether and one or more C2 or larger hydrocarbons, such as propane, propylene, propyne, and propadiene, n-butane, isobutane, isobutylene, 1-butene, 2-butene, or 1,3-butadiene. Methods of making these novel DME-based fuel compositions, particularly from biomass-derived syngas, are described. Various applications and methods of using the fuel compositions, such as portable cylinder fuels for camping, are disclosed. Additionally, principles of burner design for these fuel compositions are disclosed herein.

Abstract: The present invention provides methods of intercalating a catalyst promoter to form a catalyst composition suitable for converting syngas into alcohols, such as ethanol. Effective conditions for promoter intercalation are provided herein. This invention also provides novel compositions that can be characterized by interplanar spacings of the promoter within the catalyst composition.

Abstract: The disclosed invention provides methods and apparatus for producing one or more C1-C4 alcohols (such as ethanol) from syngas, while simultaneously removing CO2, thereby providing low CO2 yields. The present invention provides reactors for producing one or more C1-C4 alcohols from syngas, the reactors containing a first composition capable of catalyzing the conversion of syngas to C1-C4 alcohols under reaction conditions and a second composition capable of (a) adsorbing CO2 under the reaction conditions and then (b) releasing at least some of the CO2 under different regeneration conditions.

Abstract: In some variations, this invention provides a method of drying and gasifying a carbon-containing feedstock, comprising combusting methane to generate heat and a flue gas; drying the carbon-containing feedstock using part of the flue gas; and gasifying the dried feedstock to generate syngas. Some embodiments provide an apparatus for drying comprising a vessel; a primary channel for flowing the solid feedstock and a gas for drying the solid feedstock; a secondary channel for flowing the gas; and a plurality of internal screens or sieve plates suitable for passage of the gas. Other variations provide an apparatus including a primary vessel having a channel for axially flowing the solid feedstock; a pipe contained within the primary vessel, with a plurality of openings for radially distributing a gas for drying the solid feedstock; and a plurality of exit ports at the walls for removal of the gas from the primary vessel.

Abstract: The present invention provides methods and compositions for the chemical conversion of syngas to alcohols. The invention includes catalyst compositions, methods of making the catalyst compositions, and methods of using the catalyst compositions. Certain embodiments teach compositions for catalyzing the conversion of syngas into products comprising at least one C1-C4 alcohol, such as ethanol. These compositions generally include cobalt, molybdenum, and sulfur. Preferred catalyst compositions for converting syngas into alcohols include cobalt associated with sulfide in certain preferred stoichiometries as described and taught herein.

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

Abstract: The present invention provides processes for selectively producing ethanol from syngas. In some variations, the process comprises converting biomass-derived syngas to dimethyl ether, carbonylating the dimethyl ether to methyl acetate, hydrogenating the methyl acetate to methanol and ethanol, and recovering the ethanol product. The methanol is preferably recycled by converting to hydrogen and carbon monoxide for introduction back into the process at distinct points. In certain variations of this invention, fresh syngas feed is introduced downstream of the first unit operation in the sequence. High yields of ethanol from biomass can be achieved according to the disclosed processes.

Abstract: The present invention provides a process for producing gasoline components from syngas. Syngas is converted to one or more of methanol, ethanol, mixed alcohols, and dimethyl ether, followed by various combinations of separations and reactions to produce gasoline components with oxygenates, such as alcohols. The syngas is preferably derived from biomass or another renewable carbon-containing feedstock, thereby providing a biorefining process for the production of renewable gasoline.

Abstract: The present invention provides a process for producing gasoline components from syngas. Syngas is converted to one or more of methanol, ethanol, mixed alcohols, and dimethyl ether, followed by various combinations of separations and reactions to produce gasoline components with oxygenates, such as alcohols. The syngas is preferably derived from biomass or another renewable carbon-containing feedstock, thereby providing a biorefining process for the production of renewable gasoline.

Abstract: The present invention provides a process for producing gasoline components from syngas. Syngas is converted to one or more of methanol, ethanol, mixed alcohols, and dimethyl ether, followed by various combinations of separations and reactions to produce gasoline components with oxygenates, such as alcohols. The syngas is preferably derived from biomass or another renewable carbon-containing feedstock, thereby providing a biorefining process for the production of renewable gasoline.

Abstract: The present invention provides methods and compositions for the chemical conversion of syngas to alcohols. The invention includes catalyst compositions, methods of making the catalyst compositions, and methods of using the catalyst compositions. Certain embodiments teach compositions for catalyzing the conversion of syngas into products comprising at least one C1-C4 alcohol, such as ethanol. These compositions generally include cobalt, molybdenum, and sulfur. Preferred catalyst compositions for converting syngas into alcohols include cobalt associated with sulfide in certain preferred stoichiometries as described and taught herein.

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

Abstract: The invention provides methods and apparatus for selectively producing ethanol from syngas. As disclosed herein, syngas derived from cellulosic biomass (or other sources) can be catalytically converted into methanol, which in turn can be catalytically converted into acetic acid or acetates. Finally, the acetic acid or acetates can be reduced to ethanol according to several variations. In some embodiments, yields of ethanol from biomass can exceed 100 gallons per dry ton of biomass.

Abstract: This invention improves prior methods of making cobalt-molybdenum-sulfide catalysts for alcohol production from syngas. In one aspect, improved methods are provided for making preferred cobalt-molybdenum-sulfide compositions. In another aspect, processes utilizing these catalysts for producing at least one C1-C4 alcohol, such as ethanol, from syngas are described.

Abstract: The present invention provides methods and compositions for the chemical conversion of syngas to alcohols. The invention includes catalyst compositions, methods of making the catalysts, and methods of using the catalysts including techniques to maintain catalyst stability. Certain embodiments teach compositions for catalyzing the conversion of syngas into products comprising at least one C1-C4 alcohol, such as ethanol. These compositions generally include cobalt, molybdenum, and sulfur, and avoid metal carbides both initially and during reactor operation.