US6187465B1
Expired / Lapsed
US
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Process and system for converting carbonaceous feedstocks into energy without greenhouse gas emissions
Assignee: Raven SR Inc
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Filing: 1998-11-05
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Granted: 2001-02-13
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Expires: 2018-11-05
Abstract
Abstract The process and system of the invention converts carbonaceous feedstock from fossil fuels and other combustible materials into electrical energy without the production of unwanted greenhouse emissions. The process and system uses a combination of a gasifier to convert the carbonaceous feedstock and a greenhouse gas stream into a synthesis gas comprising carbon monoxide and hydrogen. One portion of the synthesis gas from the gasifier becomes electrochemically oxidized in an electricity-producing fuel cell into an exit gas comprising carbon dioxide and water. The latter is recycled back to the gasifier after the water is condensed out. The second portion of the synthesis gas from the gasifier is converted into useful hydrocarbon products.
Inventors
- 👤 Terry R. Galloway
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 10:35
CPC Classifications
H; H01; H01M; H01M8/00; H01M8/06; H01M8/0606; H01M8/0612; H01M8/0625; H01M8/0631; H01M8/04; H01M8/04082; H01M8/04089; H01M8/04097; H01M8/04119; H01M8/04156; H01M8/04164; H01M8/10; H01M8/12; H01M2008/1293; H01M2250/00; H01M2250/10; H01M2300/00; H01M2300/0017; H01M2300/0065; H01M2300/0068; H01M2300/0071; H01M2300/0074; H01M2300/0082; H01M8/0662; H01M8/0675; Y; Y02; Y02B; Y02B90/00; Y02B90/10; Y02E; Y02E60/00; Y02E60/30; Y02E60/50; Y02P; Y02P30/00; Y02P90/00; Y02P90/40
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
150 words
A process for convering carbonaceous feedstock into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing hazardous waste, carbonaceous-containing medical waste, and mixtures thereof and a greenhouse gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen; (b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a fuel cell to a first half-cell exit comprising carbon dioxide and water; (c) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said greenhouse gas stream in step (a); and (d) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell completing the circuit and resulting in the production of electrical energy.
Claim 2
Dependent Claim
150 words
A process for convering carbonaceous feedstock into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing hazardous waste, carbonaceous-containing medical waste, and mixtures thereof and a greenhouse gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen; (b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a fuel cell to a first half-cell exit comprising carbon dioxide and water; (c) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said greenhouse gas stream in step (a); and (d) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell completing the circuit and resulting in the production of electrical energy.
Claim 3
Dependent Claim
13 words
The process of claim 1 wherein said greenhouse gas stream is carbon dioxide.
Claim 4
Dependent Claim
21 words
The process of claim 1 wherein the production of electrical energy takes place in an electric power producing fossil fuel plant.
Claim 5
Dependent Claim
17 words
The process of claim 1 wherein the production of electrical energy takes place in a petroleum refinery.
Claim 6
Dependent Claim
17 words
The process of claim 1 wherein the production of electrical energy takes place in a petrochemical plant.
Claim 7
Dependent Claim
30 words
The process of claim 1 wherein said gasification unit contains a fluidized catalytic bed and operates at temperatures in the range of about 400° to about 700° C. (750-1300° F.).
Claim 8
Dependent Claim
26 words
The process of claim 1 wherein a portion of said synthesis gas from said gasification unit is converted in a chemical reactor into useful hydrocarbon products.
Claim 9
Dependent Claim
13 words
The process of claim 7 wherein said chemical reactor is a Fischer-Tropsch reactor.
Claim 10
Dependent Claim
23 words
The process of claim 8 wherein a major portion of the water is condensed from said first half-cell exit gas using a condenser.
Claim 11
Dependent Claim
57 words
The process of claim 9 wherein hydrogen and at least a portion of the condensed water is passed to said gasification unit in an amount to adjust the hydrogen to carbon ratio of the combined carbonaceous feedstock and greenhouse gas stream is sufficient to result in a synthesis gas having an optimum ratio for the Fischer-Tropsch reactor.
Claim 12
Dependent Claim
24 words
The process of claim 10 wherein said synthesis gas has a hydrogen to carbon ratio in the range of about 1.75 to about 2.25.
Claim 13
Dependent Claim
47 words
The process of claim 8 wherein the amount of greenhouse gas stream is adjusted in step (a) so that the combined carbonaceous feedstock and greenhouse gas stream to said gasification unit has a hydrogen to carbon monoxide ratio in the range of about 1.75 to about 2.25.
Claim 14
Dependent Claim
28 words
The process of claim 1 wherein the oxygen-containing gas in step (d) is air and the nitrogen that remains after the electrical reduction is exited into the atmosphere.
Claim 15
Dependent Claim
22 words
The process of claim 1 wherein said first half-cell of said fuel cell contains an electrolyte surrounding a porous catalytic anode electrode.
Claim 16
Dependent Claim
22 words
The process of claim 14 wherein said second half-cell of said fuel cell contains an air electrolyte surrounding a catalytic cathode electrode.
Claim 17
Dependent Claim
33 words
The process of claim 15 wherein said first and second half-cells of said fuel cell are separated by an ionically conducting membrane that will not allow passage of components from the respective half-cells.
Claim 18
Independent Claim
188 words
A system for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions which comprises: (a) a gasification unit having an inlet for a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing hazardous waste, carbonaceous-containing medical waste, and mixtures thereof and a greenhouse gas stream, a catalyst for converting the combined feedstock into synthesis gas comprising carbon monoxide and hydrogen, and an outlet for the synthesis gas; (b) a fuel cell for the production of electrical energy comprising a first half-cell having an inlet in fluid communication with the synthesis gas and an anode for electrochemically oxidizing synthesis gas into a first half-cell exit gas of carbon dioxide and water, a second half-cell having a cathode for electrochemically reducing an oxygen-containing gas, and a membrane separating said first and second half cells that will not allow passage of components from the respective half-cells; and (c) a passage means for passing the carbon dioxide from said first half-cell to serve as at least a portion of the greenhouse gas stream for said gasification unit.
Claim 19
Independent Claim
188 words
A system for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions which comprises: (a) a gasification unit having an inlet for a carbonaceous feedstock selected from the group consisting of coal, hydrocarbon oil, natural gas, petroleum coke, oil shale, carbonaceous-containing waste oil, carbonaceous-containing hazardous waste, carbonaceous-containing medical waste, and mixtures thereof and a greenhouse gas stream, a catalyst for converting the combined feedstock into synthesis gas comprising carbon monoxide and hydrogen, and an outlet for the synthesis gas; (b) a fuel cell for the production of electrical energy comprising a first half-cell having an inlet in fluid communication with the synthesis gas and an anode for electrochemically oxidizing synthesis gas into a first half-cell exit gas of carbon dioxide and water, a second half-cell having a cathode for electrochemically reducing an oxygen-containing gas, and a membrane separating said first and second half cells that will not allow passage of components from the respective half-cells; and (c) a passage means for passing the carbon dioxide from said first half-cell to serve as at least a portion of the greenhouse gas stream for said gasification unit.
Claim 20
Dependent Claim
13 words
The system of claim 17 wherein the greenhouse gas stream is carbon dioxide.
Claim 21
Dependent Claim
28 words
The system of claim 17 wherein said gasification unit contains a fluidized catalytic bed and operates at temperatures in the range of about 400° to about 700° C.
Claim 22
Dependent Claim
33 words
The system of claim 17 wherein a chemical reactor is in fluid communication with said gasification unit to convert a portion of said synthesis gas from said gasification unit into useful hydrocarbon products.
Claim 23
Dependent Claim
13 words
The system of claim 20 wherein said chemical reactor is a Fischer-Tropsch reactor.
Claim 24
Dependent Claim
24 words
The system of claim 21 wherein a condenser is used to condense a major portion of the water from said first half-cell exit gas.
Claim 25
Dependent Claim
58 words
The system of claim 22 wherein the hydrogen and at least a portion of the condensed water is passed to said gasification unit in an amount to adjust the hydrogen to carbon ratio of the combined carbonaceous feedstock and greenhouse gas stream is sufficient to result in a synthesis gas having an optimum ratio for the Fischer-Tropsch reactor.
Claim 26
Dependent Claim
24 words
The system of claim 23 wherein said synthesis gas has a hydrogen to carbon ratio in the range of about 1.75 to about 2.25.
Claim 27
Dependent Claim
47 words
The system of claim 21 wherein the amount of greenhouse gas stream is adjusted in step (a) so that the combined carbonaceous feedstock and greenhouse gas stream to said gasification unit has a hydrogen to carbon monoxide ratio in the range of about 1.75 to about 2.25.
Claim 28
Dependent Claim
25 words
The system of claim 17 wherein the oxygen-containing gas is air and the nitrogen that remains after the ionic reduction is exited into the atmosphere.
Claim 29
Dependent Claim
22 words
The system of claim 17 wherein said first half-cell of said fuel cell contains an electrolyte surrounding a porous catytic anode electrode.
Claim 30
Dependent Claim
22 words
The system of claim 27 wherein said second half-cell of said fuel cell contains an air electrolyte surrounding a catalytic cathode electrode.
Claim 31
Dependent Claim
149 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous-containing organic waste feedstock and a carbon dioxide gas stream in said reactor to synthesis gas comprising carbon monoxide and hydrogen in a high temperature steam reforming reactor operating at temperatures in the range of about 400° and about 700° C.; (b) converting at least a portion of said synthesis gas from said reactor to methanol; (c) electrochemically oxidizing said methanol directly in a first half-cell of a fuel cell to a fist half-cell exit gas comprising carbon dioxide and water; (d) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas stream in step (a); and (e) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 32
Dependent Claim
149 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous-containing organic waste feedstock and a carbon dioxide gas stream in said reactor to synthesis gas comprising carbon monoxide and hydrogen in a high temperature steam reforming reactor operating at temperatures in the range of about 400° and about 700° C.; (b) converting at least a portion of said synthesis gas from said reactor to methanol; (c) electrochemically oxidizing said methanol directly in a first half-cell of a fuel cell to a fist half-cell exit gas comprising carbon dioxide and water; (d) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas stream in step (a); and (e) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 33
Dependent Claim
33 words
The process of claim 29 wherein said fuel cell utilizes a pre-conversion means to convert methanol to hydrogen and carbon dioxide to permit hydrogen to feed said first half-cell of said fuel cell.
Claim 34
Dependent Claim
63 words
The process of claim 30 wherein said conversion means comprises a low temperature stream reformer operating at temperatures less than about 400° C. and a selective oxidizer and wherein the carbon dioxide from said selective oxidizer serves as a portion of said carbon dioxide gas stream in step (a) and the hydrogen from said selective oxidizer is electrochemically oxidized in said first half-cell.
Claim 35
Dependent Claim
25 words
The process of claim 29 wherein said electrical energy is used to service buildings equipped with solar panels during the night and cloudy daytime conditions.
Claim 36
Dependent Claim
29 words
The process of claim 32 wherein hydrogen is produced in an electrolyzer to produce a balanced gas for the production of methanol, said electrolyzer energized by said electrical energy.
Claim 37
Dependent Claim
28 words
The process of claim 33 wherein oxygen produced in said electrolyzer is recycled to said second half-cell to serve as at least a portion of said oxygen-containing gas.
Claim 38
Dependent Claim
15 words
The process of claim 32 wherein said organic waste feedstock is a carbonaceous-containing municipal garbage.
Claim 39
Dependent Claim
149 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous-containing organic waste feedstock and a carbon dioxide gas stream in said reactor to synthesis gas comprising carbon monoxide and hydrogen in a high temperature steam reforming reactor operating at temperatures in the range of about 400° and about 700° C.; (b) converting at least a portion of said synthesis gas from said reactor to methanol; (c) electrochemically oxidizing said methanol directly in a first half-cell of a fuel cell to a first half-cell exit gas comprising carbon dioxide and water; (d) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas stream in step (a); and (e) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 40
Dependent Claim
149 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous-containing organic waste feedstock and a carbon dioxide gas stream in said reactor to synthesis gas comprising carbon monoxide and hydrogen in a high temperature steam reforming reactor operating at temperatures in the range of about 400° and about 700° C.; (b) converting at least a portion of said synthesis gas from said reactor to methanol; (c) electrochemically oxidizing said methanol directly in a first half-cell of a fuel cell to a first half-cell exit gas comprising carbon dioxide and water; (d) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas stream in step (a); and (e) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 41
Dependent Claim
33 words
The process of claim 36 wherein said fuel cell utilizes a pre-conversion means to convert methanol to hydrogen and carbon dioxide to permit hydrogen to feed said first half-cell of said fuel cell.
Claim 42
Dependent Claim
63 words
The process of claim 37 wherein said conversion means comprises a low temperature steam reformer operating at temperatures less that about 400° C. and a selective oxidizer and wherein the carbon dioxide from said selective oxidizer serves as a portion of said carbon dioxide gas stream in step (a) and the hydrogen from said selective oxidizer is electrochemically oxidized in said first half-cell.
Claim 43
Dependent Claim
25 words
The process of claim 36 wherein said electrical energy is used to service buildings equipped with solar panels during the night and cloudy daytime conditions.
Claim 44
Dependent Claim
29 words
The process of claim 39 wherein hydrogen is produced in an electrolyzer to produce a balanced gas for the production of methanol, said electrolyzer energized by said electrical energy.
Claim 45
Dependent Claim
28 words
The process of claim 40 wherein oxygen produced in said electrolyzer is recycled to said second half-cell to serve as at least a portion of said oxygen-containing gas.
Claim 46
Dependent Claim
15 words
The process of claim 39 wherein said organic waste feedstock is a carbonaceous-containing municipal garbage.
Claim 47
Dependent Claim
170 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous feedstock and a carbon dioxide gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen; (b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a solid oxide fuel cell to a first half-cell exit gas comprising carbon dioxide and water; (c) condensing water from said half-cell exit gas in a condenser and separating out the major portion of water from the carbon dioxide; (d) passing the carbon dioxide from said condenser to serve as at least a portion of said greenhouse gas stream in step (b); (e) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas steam in step (a); and (f) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 48
Dependent Claim
170 words
A process for converting carbonaceous feedstocks into energy without the production of greenhouse gas emissions comprising: (a) converting a carbonaceous feedstock and a carbon dioxide gas stream in a gasification unit to synthesis gas comprising carbon monoxide and hydrogen; (b) electrochemically oxidizing at least a portion of said synthesis gas from said gasification unit in a first half-cell of a solid oxide fuel cell to a first half-cell exit gas comprising carbon dioxide and water; (c) condensing water from said half-cell exit gas in a condenser and separating out the major portion of water from the carbon dioxide; (d) passing the carbon dioxide from said condenser to serve as at least a portion of said greenhouse gas stream in step (b); (e) recovering the carbon dioxide from said first half-cell exit gas to serve as at least a portion of said carbon dioxide gas steam in step (a); and (f) electrochemically reducing an oxygen-containing gas in a second half-cell of said fuel cell resulting in the production of electrical energy.
Claim 49
Dependent Claim
31 words
The process of claim 43 wherein said feedstock is selected from the group consisting of coal, oil shale, carbonaceous-containing solid waste and mixtures thereof combined with water or carbonaceous-containing liquid waste.
Claim 50
Dependent Claim
19 words
The process of claim 43 wherein heat given off in said fuel cell is recovered in a heat recuperator.
Claim 51
Dependent Claim
44 words
The process of claim 45 wherein boiler feed water is converted to high pressure steam in said gasification unit operating at temperatures in the range of about 400° and about 900° C. and used to drive the third of a three stage steam turbine.
Claim 52
Dependent Claim
32 words
The process of claim 44 wherein the oxygen-containing gas is heated in said heat recuperator, expanded to drive the second stage of said three stage steam turbine, and used in step (f).
Claim 53
Dependent Claim
30 words
The process of claim 43 wherein sulfur is removed from said synthesis gas from said gasification unit in a sulfur removal unit before being electrochemically oxidized in said fuel cell.
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