ENHANCED METHODS OF SYNTHETIC CHEMICAL AND FUEL PRODUCTION THROUGH INTEGRATED PROCESSING AND EMISSION RECOVERY

Abstract

The process described in this embodiment relates to the field of synthetic fuel and synthetic chemical production through co-processing methods such as pyrolysis, combustion, gasification, distillation, catalytic synthesis, methanol synthesis, hydro-treatment, and hydrogenation, cavitation, bioreaction, and water treatment. The inventions described herein relates to synthetic hydrocarbons derived from various carbonaceous materials such as biomass, solid municipal waste and coal which can be converted into typical industrial products and various unique synthetic fuels. The byproducts of each process are directed to other processes for additional product yield and to reduce waste and emissions.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This disclosure relates generally to enhanced methods of synthetic chemical and fuel production, more particularly, methods of producing joint synthetic fuels and various chemical products. Using multiple production technologies together can optimize production and allow for waste recovery for additional product manufacturing. Various carbon based feed stock, and blends can be broken down to base process compounds through pyrolysis. These compounds are then processed through various known techniques in co-processing methods to yield a variety of synthetic hydrocarbon compounds. One example of how the waste material is used for additional product is the use of carbon dioxide for methanol synthesis which also creates heat and steam that can be used in other process applications.

2. Description of Related Art

Modern civilization is heavily dependent on hydrocarbon fuel and synthetic derived carbon products. These materials include hydrocarbon based fuels used in combustion engines and chemical oils for the production of various products. Due to the recent increase of demand for fuel from emerging countries such as India and China, and the limited production of crude oil, there has been an increase in the price of liquid fuel. In order to increase production of liquid fuel, low cost alternative means of production are needed to meet the ever increasing demand. Many countries have vast amount of available carbonaceous feedstock that can be used for the production of fuels. Biomass, municipal solid waste and coal are carbonaceous and may be used in various processes.

Coal is the most abundant carbonaceous feedstock found in the United States. By some estimates, the amount of coal in the U.S. is projected to last between 200-250 years at current rates of consumption. The combustion of coal produces over half of the electricity generated in the U.S. When used for electricity generation, coal is usually pulverized and burned in a furnace with a boiler. The furnace heat converts the boiler water to steam, which is then used to spin turbines that turn generators to create electricity.

Nevertheless, coal and other carbonaceous feed stock materials can also be converted to gaseous fuels, coal tars, and high carbon feed stocks such as coke or char by a process commonly referred to as low-temperature carbonization (LTC) or also referred to as pyrolysis process of carbonaceous materials. LTC or pyrolysis occurs when heat is applied to a carbonaceous feed stock or a blend of various types of feed stock in the absence of air (to prevent combustion) at temperature (about 450° C.-700° C.) lower than conventional combustion. Pyrolysis leads to the production of a gaseous fuel, referred to as synthetic gas or syngas or light gas, coal tar, mineral oil, water and coke or char. Syngas or light gas is a mixture mainly consisting of methane, carbon monoxide (CO) and hydrogen (H₂) that may be used as a fuel. The resulting syngas can be used for combustion, distilled and processed for various liquid hydrocarbon products, or synthesized into types of fuel. The resulting coal tar is rich in lighter hydrocarbons (organic compounds or liquid organic compounds) than normal coal tar, and therefore it is suitable for processing into fuels. Coal tars are complex and variable mixtures of phenols, polycyclic aromatic hydrocarbons (PAHs), and heterocyclic compounds. The condensed coal tar and oil are then further processed by hydrogenation to remove sulfur and nitrogen species, after which they are processed into fuels. The resulting coke or char can be used as a product, combined with other substances for fertilizer (referred to as terra preta) or a reducing agent or used for any various process methods such as combustion to generate heat or gasification to generate syngas.

The typical use of LTC or pyrolysis is to create one type of feed stock to process use. The other resulting by-product is considered waste and sold to be used by others in other processes. For example, when LTC or pyrolysis is used for the creation of char/coke then the coal tar (hydrocarbon liquids or organic compounds) or syngas are sold to others as a waste product. When LTC or pyrolysis is used for crude oil, syngas and hydrocarbon liquids (or organic compounds) then the resulting char/coke is sold to others as a waste. Full utilization of all products resulted from LTC or pyrolysis can create a synergistic processing method that will increase total product yields.

When coal or other carbonaceous feedstock is burned for electricity production, it releases into the atmosphere green house gases (GHGs) such as carbon dioxide (CO₂) and other harmful pollutants such as oxides of sulfur (So_x) and oxides of nitrogen (NO_x). As concerns of global warming intensify, there is increased pressure to reduce the amount of GHGs released into the atmosphere. One suggested method to reduce the GHGs released into the atmosphere is by sequestering the gaseous emissions in underground storage facilities. However, underground storage of CO₂ and other emissions would increase costs and raise concerns about possible leakage from underground rock formations or possible contamination of water supplies.

However, LTC or pyrolysis process barely produces carbon dioxide (CO₂); thus, LTC or pyrolysis is a cleaner chemical product/fuel production technology than the conventional burning of carbonaceous feedstock. Full utilization of all products resulted from LTC or pyrolysis can significantly reduce the GHGs released into the atmosphere.

The present invention is directed to improved methods and systems through co-generation for producing fuel and chemical products by recovering byproducts including emissions to increase total production yield and reduce the GHGs released into the atmosphere.

Where possible, turbine and generators may be utilized to the creation of electric power for utilization with the processes. The use of this equipment is to enhance the electrical needs of the plant and process for increase in efficient utilization of the process.

SUMMARY OF THE INVENTION

The primary object of the present invention is to provide integrated methods to achieve full utilization of all products resulted from LTC or pyrolysis so as to increase the total product yields. A further object of the present invention is to reduce the green house gases (GHGs) released into the atmosphere. These objects and others are achieved in accordance with the present invention.

The present invention is directed to improved methods and systems through co-generation for the producing fuel and chemical products by recovering all by-products including emissions to increase total fuel/chemical product yields. The present invention is also directed to integrated methods and systems that can significantly reduce the green house gases (GHGs) released into the atmosphere.

In one aspect, the present disclosure is directed to a process of integrating chemical product/fuel production technologies. The process includes integrating three or more chemical product/fuel production technologies such that one or more byproducts of one or more production technologies are applied to other production technologies for additional fuel/chemical product yield and to reduce waste and the GHGs released into the atmosphere.

In another aspect, the present disclosure is directed to a process for integrating chemical product/fuel production facilities. The process includes integrating three or more chemical product/fuel production facilities such that one or more byproducts of one or more production facilities are applied to other production facilities for additional fuel/chemical product yield and to reduce waste and the GHGs released into the atmosphere.

In yet another aspect, the present disclosure is directed to a method of chemical product/fuel production. The method includes producing one or more products and byproducts in a first chemical product/fuel production technology, which may be pyrolysis, and applying said byproducts to other chemical product/fuel production technologies. The byproducts generated by a second and/or a third technology can be utilized by a fourth and/or fifth technology. Consequently, the integrated method increases the overall production of fuel/chemical product yield and reduces waste and the GHGs released into the atmosphere.

In a further aspect, the present disclosure is directed to a facility operating method of chemical product/fuel production. The method includes operating an integrated chemical product/fuel production facility. The integrated chemical product/fuel production facility includes at least three individual production facilities fluidly coupled with each other. Consequently, the method for operating the integrated chemical product/fuel production facility increases the overall production of fuel/chemical product yield and reduces waste and the GHGs released into the atmosphere.

In one embodiment, the present invention is directed to an integrated process of chemical product/fuel production technology that combines LTC or pyrolysis with distillation directly and combustion indirectly. The product, coke/char, resulted from pyrolysis is sold as terra preta for fertilizers. The resulting organic compounds (liquid hydrocarbon) are subjected to distillation, and separated to three products, light gases, medium liquids, and heavy liquids. The medium liquids are stored as fuels. The light gases can be recovered and used as a fuel source in combustion to provide heat for pyrolysis. The heavy liquids may be recycled and charged back to the pyrolysis process. With this integrated process, most of the byproducts resulted from pyrolysis, distillation and combustion are recovered and either recharged back to pyrolysis or co-processed by other technologies. The total quantity of fuel and chemical products is increased and the GHGs released into the atmosphere are reduced. Said embodiment also includes the process to integrate facilities, the method of producing fuel and chemical products, and the method to operate the integrated facility that are associated with the integrated process.

In another embodiment, the present invention is directed to an integrated process of chemical product/fuel production technology wherein the LTC or pyrolysis process is directly integrated with a feedstock preparation, a combustion process, a distillation process, and a gasification process, and indirectly integrated with an air separation process, a catalytic synthesis process, a hydrotreatment/hydrogenation process, and a methanol synthesis process. By means of this integrated process, most of the byproducts resulted from pyrolysis and other technologies are recovered and either charge back or co-processed by other technologies. The total quantity of fuel and chemical products is increased and the GHGs released into the atmosphere are reduced. Said embodiment also includes the process to integrate facilities, the method of producing fuel and chemical products, and the method to operate the integrated facility that are associated with the integrated process.

In a further embodiment, the present invention is directed to an integrated process of chemical product/fuel production technology wherein the LTC or pyrolysis process directly integrated with a feedstock preparation process, a combustion process, a distillation process, and a gasification process, and indirectly integrated with an air separation process, a catalytic synthesis process, a hydrotreatment/hydrogenation process, a methanol synthesis process, and water treatment process. By way of this integrated process, most of the byproducts resulted from pyrolysis and other technologies are recovered and either charge back or co-processed by other technologies. The total quantity of fuel and chemical products is increased and the GHGs released into the atmosphere are reduced. Said embodiment also includes the process to integrate facilities, the method of producing fuel and chemical products, and the method to operate the integrated facility that is associated with the integrated process.

In yet another embodiment, the present invention is directed to an integrated process of chemical product/fuel production technology wherein the LTC or pyrolysis process directly integrated with a feedstock preparation process, a combustion process, and a cavitation process, and indirectly integrated with an air separation process, a distillation, a methanol synthesis process, and water treatment process. By means of this integrated process, most of the byproducts resulted from pyrolysis and other technologies are recovered and either charge back or co-processed by other technologies. The total quantity of fuel and chemical products is increased and the GHGs released into the atmosphere are reduced. Said embodiment also includes the process to integrate facilities, the method of producing fuel and chemical products, and the method to operate the integrated facility that is associated with the integrated process.

The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.

BRIEF DESCRIPTION OF THE DRAWINGS

Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

FIG. 1 shows a schematic illustration of a high-level exemplary enhanced method for producing joint synthetic fuel and chemical products using multiple production methods synergistically according to the present invention.

FIG. 2 is a schematic illustration of a known pyrolysis process.

FIG. 3 is a schematic illustration of a known combustion process.

FIG. 4 is a schematic illustration of a known distillation process.

FIG. 5 is a schematic illustration of a known gasification process.

FIG. 6 is a schematic illustration of a known water treatment process.

FIG. 7 is a schematic illustration of a known feedstock preparation process.

FIG. 8 is a schematic illustration of a known catalytic synthesis.

FIG. 9 is a schematic illustration of a known hydro treatment and hydrogenation process.

FIG. 10 is a schematic illustration of a known methanol synthesis.

FIG. 11 is a schematic illustration of a known cavitation process.

FIG. 12 is a schematic illustration of a known bio reaction.

FIG. 13 is a schematic illustration of a known air separation process.

FIG. 14 is a schematic illustration of an embodiment of the disclosed enhanced methods for producing joint synthetic fuel and chemical products using multiple production methods including a pyrolysis process integrated with a distillation and combustion processes.

FIG. 15 is a schematic illustration of an embodiment of the disclosed enhanced methods for producing joint synthetic fuel and chemical products using multiple production methods including a LTC (pyrolysis) process directly integrated with a feedstock preparation process, a combustion process, a distillation process, and a gasification process, and indirectly integrated with an air separation process, a catalytic synthesis process, a hydrotreatment/hydrogenation process, and a methanol synthesis process.

FIG. 16 is a schematic illustration of an embodiment of the disclosed enhanced methods for producing joint synthetic fuel and chemical products using multiple production methods including a LTC (pyrolysis) process directly integrated with a feedstock preparation process, a combustion process, a distillation process, and a gasification process, and indirectly integrated with an air separation process, a catalytic synthesis process, a hydrotreatment/hydrogenation process, a methanol synthesis process, and water treatment process.

FIG. 17 is a schematic illustration of an embodiment of the disclosed enhanced methods for producing joint synthetic fuel and chemical products using multiple production methods including a LTC (pyrolysis) process directly integrated with a feedstock preparation process, a combustion process, and a cavitation process, and indirectly integrated with an air separation process, a distillation, a methanol synthesis process, and water treatment process.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Reference will now be made to exemplary known chemical product/fuel production technologies and exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

FIG. 1 is a schematic illustration of a high-level exemplary embodiment of an enhanced method according to the present invention for producing joint synthetic fuels and various chemical products using multiple synergistic processing methods to achieve full utilization of all products resulting from LTC or pyrolysis and increase total product yields. In general, chemical production technologies (CPTs) 100, 200, 300 and 400 may be known technology to produce chemicals, as well as future technologies that can be used as part of the invention disclosed in this application. The products produced by the energy production technologies may include chemicals, or any type of fuel (solid, liquid, and gaseous) that may be used to produce energy and do work (such, as gasoline, jet fuel, LPG, propane, etc.). Non-limiting examples of CPTs 100, 200, 300 and 400 may include pyrolysis, gasification, combustion, distillation, bioreactors, chemical synthesis and so forth. The general embodiment is that the base CPT of 100 can be used to create the process material for one to three other processes defined as 200, 300 and 400.

Input 001 may be directed into CPT 100 to produce syngas (002), liquid organic compounds (003) and solid materials (004) through pyrolysis. In the process of producing materials from input 001, CPT 100 may also release by-products 202, 302, and 402. CPT 200, 300, and 400 may require additional input to perform their required process as noted with input 201, 301 and 401. For example, if CPT 200 were combustion, then the input of 201 may be oxygen to combust the output of CPT 100 of syngas 002. The resulting output of 202 would then contain the resulting chemicals and waste of CPT 200. The similar progression is duplicated in CPT 300 and 400 where other processes may be used. Any unused waste in output 202, 302 and 402 that is not utilized in their respective process 200, 300 or 400 may be utilized in process 100, 200, 300, and 400. For an example, CPT 300 may be gasification in which hydrogen is a portion of output 302. The hydrogen that is not utilized in catalytic synthesis may be directed to CPT 400 for hydro-treatment and hydrogenation of organic compounds of pyrolysis (004) from CPT 100.

FIG. 2 illustrates a known pyrolysis process which can be defined as CPT 500. Prepaired carbonaceous feedstock or feedstock blends 501 is input to pyrolysis equipment for processing where pyrolysis 502 occurs when heat is applied to the feed stock or feed stock blend 501 in the absence of air (to prevent combustion) then outputs will be low pressure light gases 503, organic compounds 504, and coke/char solid material 505. The output of low pressure light gas 503 is a mixture mainly consisting of methane, carbon monoxide (CO) and hydrogen (H₂) that may be used as a fuel in a further combustion process 506. The output of organic compounds 504 can be used in other process such as distillation 507. The output of char/coke 505 can be used for other process methods such as gasification 508.

FIG. 3 illustrates a known process of combustion which can be defined as CPT 600. The input of low pressure gasses 602 and oxygen 603 are reacted in the form of combustion 604 (exothermic reaction) where the input water 601 is heated. The combustion reaction 604 yields the outputs of off gas 605, steam 606 and heat 607. The resulting steam 606 can be used for processing purposes 609 that need steam to elevate temperatures. The resulting heat 607 can be used for various processes 610 that require elevated temperatures and used to heat water to make steam, which may also be used for processing purposes 609. The resulting off gas such as CO₂ can be recovered 608 and produce products by direct methanol synthesis or into additional feed stock material through photosynthesis in photobioreactors.

FIG. 4 illustrates a known distillation processing of organic compounds into various chemical liquids which can be defined as CPT 700. The input of organic compounds 701 is distilled 702 and yield the outputs of low pressure light gas 703, medium liquids 704, and heavy liquids 705 based on differences in their volatilities. The low pressure light gas 703 that is not able to form into liquids can be used for combustion 706 to generate heat. The various liquid distillates 704, 705 can be stored as separate products or further refined 707, 708 to make specific products. Heavy liquids 705 that may not be considered a product or able to be refined can be directed back to the beginning of the process and mixed with the initial feed stock blend until broken down.

FIG. 5 illustrates a known gasification processing of solid char or coke which can be defined as CPT 800. In gasification 804, the input of char/coke 802 are broken into smaller molecular weight molecules, usually by subjecting it to high temperature and pressure, using the inputs of steam 801 and oxygen 803. This process yields various gaseous which are separated 807 into various outputs such as hydrogen 808, carbon dioxide 810 and gaseous feul, referred to as synthetic gas or syngas 812. Syngas 812 is a mixture mainly consisting of carbon monoxide (CO) and hydrogen (H₂), which may be used as a fuel. Syngas 812 is subjected to catalytic synthesis 813 under different conditions of temperature and pressure in the presence of a catalyst to produce different types of liquid fuels or various products. One well known methods of syngas synthesis is the Fischer-Tropsch process. The resulting hydrogen 808 can be used for additional processing for fuel products 809 such as hydrogenation or methanol synthesis. Any resulting CO₂ can be used for methanol synthesis 811. Additional heat and steam may be recovered 805 for utilization for process uses 806 which may include power generation or feedstock preparation.

FIG. 6 illustrates a knwon water treatment process which can be defined as CPT 900. The input of waste water 901 it treated 902 and used to generate the output materials of low pressure light gas 903, water 904, and solid material 905. The low pressure light gas 903 may be used in combustion 906 to provide energy or heat for other process. The output of water 904 may be heated in other process 907 to provide steam. Solid material 905 may be recovered as feedstock for other process 908.

FIG. 7 illustrates a known processing of raw feedstock which can be defined as CPT 1000. The feedstock blend input 1001 is prepared (pulverized and dried) to yield dry feedstock 1003 and water 1004 for further processes 1005 and 1006.

FIG. 8 illustrates a known catalytic synthesis of syngas which can be defined as CPT 1100. The input of syngas 1101 is subjected to catalytic synthesis 1102 under various conditions of temperature and pressure in the presence of various catalysts to yield various types of liquid fuels, such as high pressure light gases 1103, medium liquids 1104, and heavy liquids 1105 for further processes 1106-1108.

FIG. 9 illustrates a known hydro-treatment and hydrogenation of medium liquids which can be defined as CPT 1200. The input of medium liquids 1201 and hydrogen 1202 can be processed to separate unwanted compounds and hydrogen saturate the desired chemicals into various types of fuel such as light fuels 1204, medium fuels 1205 and heavy fuels 1206. Heat or steam may be required for the hydrogen processing.

FIG. 10 illustrates a known process that converts hydrogen and carbon dioxide into methanol through synthesis which can be defined as CPT 1300. When the input of carbon dioxide 1301 reacted with input of hydrogen 1302 the resulting product of this exothermic reaction is light fuel 1304, majorly methanol (CH₃OH), and water (H₂O) in the form of steam 1305. The light fuel is a viable fuel product 1306. The resulting steam can be charged back into the process 1307 where heat or steam is required, such as gasification or for use in feed stock preparation.

FIG. 11 illustrates a known process that converts organic compounds and syngas through controlled cavitation which can be defined as CPT 1400. The input of syngas saturated fluids 1402 is created by mixing organic compounds in the for of a liquid 1401 and syngas 1403 and processed by controlled cavitation 1404 and distillation 1407 to yield light fuels 1408, medium fuels 1410, heavy fuels 1412 and low pressure gas 1405.

FIG. 12 illustrates a known process that occurs in a bioreactor which can be defined as CPT 1500. The input of light 1501, recovered process gases 1502 and a blend of water/nutrients 1503 can be utilized in a bioreactor 1504 to create gases like oxygen and carbon dioxide 1506 as well as water 1505 and biomass 1507. The oxygen and carbon dioxide can be further separated by air separation 1509. The resulted biomass can be used as feedstock 1510. The resulted water can be used in other process 1508.

FIG. 13 illustrates a known air separation process of recovered gases and air into various types of gases which can be defined as CPT 1600. The input of recovered process gases 1601 and air 1602 can be separated 1603 to yield oxygen 1604, carbon dioxide 1606 and a blend of various gases 1605. Oxygen 1604 stripped from air by air separation may be used in other process 1607. For example, oxygen may be introduced into the boiler to burn coal cleanly and completely. Carbon dioxide 1606 may be recycled and used for other process 1609 such as a methanol synthesis process.

FIG. 14 illustrates an embodiment of FIG. 1 and can be defined as CPT 1700 in which prepared feedstock 1701, 1702 and 1703 is processed by pyrolysis 1704 to generate char/coke 1708 which can be utilized as terra preta 1707 while the other organic compounds 1705 can be distilled 1706 to produce light gases 1709, medium liquids 1710, and heavy liquids 1711. The light gases 1709 can be used in combustion 1712 to generate heat 1713 which can be used in various processes. Medium liquids 1710 can be used as fuel 1714 to run engines. The heavy liquids 1711 considered not able to be used as fuel will be recycled and used as feedstock for other processes 1715. In this embodiment 1701-1704 can be defined as CPT 100, while 1708 and 1707 can define CPT 200 as 1705-1713 can define CPT 300 and CPT 400.

FIG. 15 illustrates and embodiment of FIG. 1 and can be defined as CPT 1800 in which the input of raw feedstock 1802 is processed by CPT 1000 (feedstock preparation) to yield water 1801 and feedstock for CPT 500 (pyrolysis). CPT 500 (pyrolysis) yields low pressure gas, char/coke and organic compounds through pyrolysis processing. The low pressure gas, water 1801 and oxygen 1804 are used for CPT 600 (combustion). The char/coke material is used for CPT 800 (gasification). The organic compounds are used for CPT 700 (distillation). CPT 1000 (feedstock preparation) and 500 (pyrolysis) relate to FIG. 1 as CPT 100.

CPT 600 (combustion) yields off gas which is used for CPT 1600 (air separation) as the resulting heat and steam are used for CPT 800 (gasification). CPT 1600 (air separation) utilizes the off gas and air to produce carbon dioxide for CPT 1300 (methanol synthesis) and oxygen for CPT 600 (combustion) and CPT 800 (gasification). Other various gases may be stored as a product 1811 or used in the process 1810. These variations will vary on the initial feedstock and the baseline chemical they yield. CPT 1300 (methanol synthesis) uses hydrogen from CPT 800 (gasification) and carbon dioxide from CPT 1600 (air separation) and CPT 800 (gasification) to yield light fuel and steam that can be utilized in CPT 800 (gasification). CPT 600 (combustion), 1600 (air separation) and 1300 (methanol synthesis) relate to FIG. 1 as CPT 200 through combustion, air separation and methanol synthesis.

CPT 800 (gasification and gas separation) yields carbon dioxide for CPT 1300 (methanol synthesis), hydrogen 806 for CPT 1300 (methanol synthesis) and CPT 1200 (hydrogenation) and syngas 812 for CPT 1100 (catalytic synthesis) through gasification and gas separation. The resulting heat and steam 1807 are recovered for other process use such as CPT 1200 (hydro treatment/hydrogenation). CPT 1100 (catalytic synthesis) uses catalytic synthesis of syngas 812 to yield high pressure gasses for CPT 800 (gasification and gas separation) and various liquids. CPT 800 (gasification and gas separation) and 1100 (catalytic synthesis) relate to FIG. 1 as CPT 300 through gasification and catalytic synthesis.

CPT 700 (distillation) yields low pressure gas for CPT 600 (combustion) 1803, and medium and heavy liquids. Medium liquids can be processed by CPT 1200 (hydro treatment/hydrogenation), which requires hydrogen 1806 and heat/steam 1805, to yield various fuels (light fuels 1815, medium fuels 1816, and heavy fuels 1817) while heavy liquids 1808 may be processed for fuel or recycled to the raw feedstock for processing. The composition of the raw feedstock may yield various heavy liquids and the resulting chemical in 1808 will have to be determined on a plant design basis. CPT 700 (distillation) and 1200 (hydro treatment/hydrogenation) relate to FIG. 1 as CPT 400 through distillation and hydro-treatment/hydrogenation.

FIG. 16 illustrates another embodiment of embodiment of FIG. 1 and can be defined as CPT 1900. This variation is similar to FIG. 15 with the exception that CPT 900 (water treatment) is added between CPT 1000 (feedstock preparation) and CPT 600 (combustion). CPT 900 (water treatment) relates to FIG. 1 as an additional step to CPT 100. FIG. 16 also incorporates CPT 1500 (bioreactor) to CPT 600 (combustion) which will yield gases 1910 used in CPT 1600 (air separation) and biomass that can be used in CPT 1000 (feedstock preparation) as a blend material for raw feedstock 1902. CPT 1500 (bioreactor) relates to FIG. 1 as an additional step to CPT 200.

FIG. 17 illustrates another embodiment of embodiment of FIG. 1 and can be defined as CPT 2000. This variation is similar to FIG. 16 with the exception that CPT 1400 (cavitation) replaces CPT 700 (distillation), CPT 1100 (catalytic synthesis) and CPT 1200 (hydro treatment/hydrogenation). CPT 1400 (catalytic synthesis) relates to FIG. 1 as an alternative CPT 400.

It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed methods of chemical production without departing from the scope of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.

While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled.

Claims

1. A process of producing synthetic fuels and chemical products comprising:

a. integrating three or more fuel/chemical production processes such that one or more byproducts of one or more production processes are applied to other processes for additional product yield and to reduce waste and emissions;

b. a raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal; and

c. integrating three or more facilities that utilize said chemical product/fuel production processes such that one or more byproducts produced at one or more said facilities are used in the production of fuel/chemical product at other said facilities for additional product yield and to reduce waste and emissions;

d. operating the integrated fuel/chemical production processes to produce synthetic fuel and chemical products such that one or more byproducts of one or more production processes are utilized in an operation of other fuel/chemical production processes.

2. The process of claim 1, wherein said fuel/chemical production processes are selected from the group consisting of feedstock preparation, pyrolysis, combustion, distillation, gasification, water treatment, catalytic synthesis, hydro-treatment/hydrogenation, methanol synthesis, cavitation, bio-reaction, and air separation.

3. The process of claim 2, wherein the raw feedstock is prepared and input to pyrolysis process.

4. The process of claim 1, wherein the integrated process provides various chemical products such as lubricant, dye, char/coke, gas fuel and synthetic liquid fuel.

5. The process of claim 1, wherein heat, steam, water, hydrogen, carbon dioxide, and oxygen generated by the integrated process are recycled and used by the integrated process.

6. The process of claim 2, wherein the pyrolysis process provides char/coke to the carbonaceous feedstock gasification; the pyrolysis facility and the gasification facility are located in proximity to each other to reduce operating costs.

7. The process of claim 2, wherein the pyrolysis process provides organic compounds to the distillation process; the pyrolysis facility and the distillation facility are located in proximity to each other to reduce operating costs.

8. The process of claim 2, wherein the pyrolysis process provides light gas to combustion process; the pyrolysis facility and the combustion facility are located in proximity to each other to reduce operating costs.

9. The process of claim 8, wherein the combustion process is coupled with air separation such that the off gas produced in combustion is separated and carbon dioxide obtained from separation is used in methanol synthesis; the oxygen resulted from air separation is used in gasification or combustion.

10. The process of claim 8, wherein the combustion process is coupled with bioreactor such that the off gas produced in combustion is used by bioreactor.

11. The process of claim 7, wherein the distillation process is coupled with hydrotreatment/hydrogenation such that the medium liquids obtained from distillation is converted to synthetic fuels by hydrotreament/hydrogenation.

12. The process of claim 6, wherein the gasification/gas separation process is coupled with catalytic synthesis and hydrotreatment/hydrogenation such that the syngas produced by gasification is converted to synthetic fuel by catalytic synthesis followed hydrotreatment/hydrogenation.

13. The process of claim 6, wherein the gasification/gas separation process is coupled with cavitation such that the syngas produced by gasification is converted to synthetic fuel by cavitation.

14. The process of claim 6, wherein the gasification/gas separation process is coupled with methanol sysnthesis such that the carbon dioxide and hydrogen obtained from gasification are converted to methanol by methanol synthesis.

15. The process of claim 6, wherein the gasification/gas separation process is coupled with hydrotreatment/hydrogenation such that the hydrogen obtained from gasification is used in hydrotreatment/hydrogenation.

16. A process of producing synthetic fuels and chemical products comprising:

a. Integrating multiple processes including feedstock preparation, pyrolysis, distillation, and combustion;

b. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;

c. a set of by-products of pyrolysis includes organic compounds and char/coke, the organic compounds are input to distillation, the char/coke is used for terra preta;

d. a set of by-products of distillation includes light gas, medium liquids, and heavy liquids, the light gas is input to combustion to generate heat, the medium liquids is used/stored as synthetic fuel, the heavy liquids is recycled as feedstock;

e. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and

f. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.

17. A process of producing synthetic fuels and chemical products comprising:

a. Integrating multiple processes including feedstock preparation, pyrolysis, distillation, combustion and gasification/gas separation, air separation, methanol synthesis, catalytic synthesis, hydrogreatment/hydrogenation;

b. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;

c. a set of by-products of pyrolysis includes LP light gas, organic compounds, and char/coke, the LP light gas is input to combustion, the organic compounds are input to distillation, the char/coke is input to gasification;

d. a set of by-products of combustion includes off gas, steam, and heat, the offgas is input to air separation, the steam and heat is input to gasification;

e. a set of by-products of distillation includes LP light gas, heavy liquids, and medium liquids, the LP light gas is input to combustion, the medium liquids is input to hydrotreatment/hydrogenation, the heavy liquids is input for various uses;

f. a set of by-products of gasification/gas separation includes carbon dioxide, hydrogen, syngas, and heat/stream, the carbon dioxide and hydrogen are input to methanol synthesis, the syngas is input to catalytic synthesis, the heat and steam is input to catalytic synthesis and hydrotreatement/hydrogenation, the hydrogen is also input to hydrotreatment/hydrogenation;

g. a set of by-products of air separation includes oxygen, carbon dioxide, and various gases, oxygen is input to gasification and combustion, carbon dioxide is input to methanol synthesis, the various gases is input for other processes or can be used/stored as synthetic fuel;

h. a set of by-products of methanol synthesis includes light fuel and steam, the light fuel can be used/stored as synthetic fuel, the steam is input to gasification;

i. a set of by-products of catalytic synthesis includes HP light gas, heavy liquids, and medium liquids, HP light gas is input to gas separation and can produce carbon dioxide, the heavy liquids are for various uses, the medium liquids is input to hydrotreatment/hydrogenation and can produce various fuels of different density;

j. a set of by-products of hydrotreatment/hydrogenation includes light fuels, medium fuels, and heavy fuels, all these fuels can be used/stored as synthetic fuel;

k. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and

l. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.

18. The process of producing synthetic fuels and chemical products in claim 8 further comprising a water treatment process and a bio-reaction process, wherein

a. a waste water is treated by the water treatment process to yield a set of product which includes LP light gas, water, and solid material, LP light gas and water are input to combustion, solid material is further treated by the feedstock preparation so as to input to pyrolysis;

b. a set of by-products of bio-reaction includes carbon dioxide and oxygen which are separated to oxygen and other gases by air separation, oxygen can be further used in gasification;

c. the off-gas produced in the process of combustion is input to bio-reactor instead of air separation;

d. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and

e. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.

19. A process of producing synthetic fuels and chemical products comprising:

a. Integrating multiple processes including feedstock preparation, water treatment, pyrolysis, combustion, gasification/gas separation, cavitation, air separation, and methanol synthesis;

b. a waste water is treated by the water treatment process to yield a set of products which includes LP light gas, water, and solid material, LP light gas and water are input to combustion, solid material is further treated by the feedstock preparation so as to input to pyrolysis;

c. a raw feedstock is dried to yield dry feedstock which is input to pyrolysis process, the raw feedstock includes various carbonaceous materials such as biomass, solid municipal waste and coal;

d. a set of by-products of pyrolysis includes LP light gas, organic compounds, and char/coke, the LP light gas is input to combustion, the organic compounds are input to cavitation, the char/coke is input to gasification;

e. a set of by-products of combustion includes off gas, steam, and heat, the offgas is input to the bio-reactor, the steam and heat is input to gasification;

f. a set of by-products of gasification/gas separation includes carbon dioxide, hydrogen, syngas, and heat/stream, the carbon dioxide and hydrogen are input to methanol synthesis, the syngas is input to cavitation, the heat and steam is input to catalytic synthesis and hydrotreatement/hydrogenation, the hydrogen is also input to hydrotreatment/hydrogenation;

g. a set of by-products of cavitation/distillation includes LP light gas, light fuels, medium fuels, and heavy fuels, the LP light gas is input to combustion, the light fuels, medium fuels, and heavy fuels are used/stored as synthetic fuels;

h. a set of by-products of bio-reaction includes carbon dioxide and oxygen which are separated to oxygen and other gases by air separation, oxygen can be further used in gasification;

i. a set of by-products of air separation includes oxygen, carbon dioxide, and various gases, oxygen is input to gasification and combustion, carbon dioxide is input to methanol synthesis, the various gases is input for other processes or can be used/stored as synthetic fuel;

j. a set of by-products of methanol synthesis includes light fuel and steam, the light fuel can be used/stored as synthetic fuel, the steam is input to gasification;

k. integrating facilities that utilize said integrated processes to produce synthetic fuel and chemical products for additional product yield and to reduce waste and emissions; and

l. operating said integrated processes to produce synthetic fuels and chemical products for additional product yield and to reduce waste and emissions.