Abstract: The present invention provides several variations for converting biomass, and other carbon-containing feedstocks, into syngas. Some variations include pyrolyzing or torrefying biomass in a devolatilization unit to form a gas stream and char, and gasifying the char. Other variations include introducing biomass into a fluid-bed gasifier to generate a solid stream and a gas stream, followed by a partial-oxidation or reforming reactor to generate additional syngas from either, or both, of the solid or gas stream from the fluid-bed gasifier. Hot syngas is preferably subjected to heat recovery. The syngas produced by the disclosed methods may be used in any desired manner, such as conversion to liquid fuels (e.g., ethanol).

Abstract: The present invention provides several variations for converting biomass, and other carbon-containing feedstocks, into syngas. Some variations include pyrolyzing or torrefying biomass in a devolatilization unit to form a gas stream and char, and gasifying the char. Other variations include introducing biomass into a fluid-bed gasifier to generate a solid stream and a gas stream, followed by a partial-oxidation or reforming reactor to generate additional syngas from either, or both, of the solid or gas stream from the fluid-bed gasifier. Hot syngas is preferably subjected to heat recovery. The syngas produced by the disclosed methods may be used in any desired manner, such as conversion to liquid fuels (e.g., ethanol).

Abstract: Improvements to biodiesel compositions, and methods for making those compositions more efficiently, are provided. Some variations of this invention provide processes for producing biodiesel and at least one C1-C4 alcohol, such as ethanol. Other variations provide certain biodiesel compositions containing C2+ alkyl esters. In some embodiments, biodiesel compositions are produced entirely from renewable resources.

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.

Abstract: The present invention provides methods to increase yields and selectivities to particular alcohols, such as ethanol, during alcohol synthesis from syngas. In some embodiments, a starting catalyst can be activated by contacting with a gas stream under certain preferred activation temperatures, pressures, and compositions.

Abstract: Improved methods of introducing promoters to catalysts are described. The present invention provides a convenient method of uniformly distributing a catalyst promoter, to provide for intimate contact between the promoter and the active catalyst sites. This intimate contact can enhance the activity and/or product selectivity of the promoted catalyst. In some embodiments, the method includes reacting an alkali metal with an alcohol in a non-aqueous medium, contacting the resulting solution with a starting catalyst, and depositing the alkali metal onto the starting catalyst to form an alkali-promoted catalyst.

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: This invention provides a method for producing ethanol and 2-propanol from syngas, the method comprising: (a) converting syngas into methanol using a methanol-synthesis catalyst; (b) converting methanol into ethylene and propylene using a methanol-to-olefins catalyst; and (c) hydrating ethylene into ethanol and propylene into 2-propanol. As taught herein, the combined yield of the ethanol and the 2-propanol from biomass can be at least 100 gallons per dry ton biomass. In certain embodiments, the yield of ethanol is at least 100 gallons per dry ton biomass. In some embodiments, the yield of 2-propanol is at least 50 gallons per dry ton biomass.

Abstract: This invention provides a method for producing ethanol and 2-propanol from syngas, the method comprising: (a) converting syngas into methanol using a methanol-synthesis catalyst; (b) converting methanol into ethylene and propylene using a methanol-to-olefins catalyst; and (c) hydrating ethylene into ethanol and propylene into 2-propanol. As taught herein, the combined yield of the ethanol and the 2-propanol from biomass can be at least 100 gallons per dry ton biomass. In certain embodiments, the yield of ethanol is at least 100 gallons per dry ton biomass. In some embodiments, the yield of 2-propanol is at least 50 gallons per dry ton biomass.

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 invention herein provides methods of activating a catalyst composition. These methods include annealing a catalyst with an inert gas, under effective conditions, and then contacting the annealed catalyst with syngas to produce an activated catalyst. These steps can also be reversed. The activated catalysts can be employed to convert syngas into products, such as alcohols, with improved selectivities and yields.

Abstract: The present invention describes improved methods of introducing promoters to catalysts. This invention provides a method for dispersal of a promoter onto a solid surface. A catalyst material and a deliquescent material can together be contacted with a gas phase comprising a solvent under conditions effective for deliquescence whereby the promoter is dispersed onto the solid surface. This invention combines practical benefits of dry-mixing with the enhanced dispersion that can be realized by solvent-based methods.

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: 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: 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: 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: The present invention features methods and apparatus for the pyrolysis or torrefaction of a carbon-containing feedstock before it is converted to syngas. In some embodiments, biomass is first pretreated by torrefaction and/or pyrolysis, followed by devolatilization and/or steam reforming to produce syngas. Various mixtures of such pretreated biomass, combined with fresh biomass, can be employed to produce syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.

Abstract: The present invention features methods and apparatus for the pyrolysis or torrefaction of a carbon-containing feedstock before it is converted to syngas. In some embodiments, biomass is first pretreated by torrefaction and/or pyrolysis, followed by devolatilization and/or steam reforming to produce syngas. Various mixtures of such pretreated biomass, combined with fresh biomass, can be employed to produce syngas. The syngas can be converted to alcohols, such as ethanol, or to other products.

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: 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, a catalyst is derived from the ash content of the feed material, and this catalyst is used to enhance syngas formation. The syngas can be converted to alcohols, such as ethanol, or to other products.