NukeEthanol, I believe the process may be simular to this...
Biomass Gasification Overview
Biomass to Ethanol Process
EXECUTIVE OVERVIEW:
Technology Overview Gasification
Gasification is a technology that has been widely used in commercial applications for more than 50 years in the production of fuels and chemicals. Current trends in the chemical manufacturing and petroleum refinery industries indicate that use of gasification facilities to produce synthesis gas ("syngas") will continue to increase. Attractive features of the technology include:
the ability to produce a consistent, high-quality syngas product that can be used for energy production or as a building block for other chemical manufacturing processes; and
the ability to accommodate a wide variety of gaseous, liquid, and solid feedstock’s. Conventional fuels such as coal and oil, as well as low- or negative-value materials and wastes such as petroleum coke, heavy refinery residuals, secondary oil-bearing refinery materials, municipal sewage sludge, hydrocarbon contaminated soils, and chlorinated hydrocarbon byproducts have all been used successfully in gasification operations.
The gasification process converts any carbon-containing material into a synthesis gas composed primarily of carbon monoxide and hydrogen, which can be used as a fuel to generate electricity or steam or used as a basic chemical building block for a large number of uses in the petrochemical and refining industries. Gasification adds value to low- or negative-value feedstock by converting them to marketable fuels and products.
Gasification technologies differ in many aspects but share certain general production characteristics. Typical raw materials used in gasification are coal, petroleum based materials (crude oil, high sulfur fuel oil, petroleum coke, and other refinery residuals), gases, or materials that would otherwise be disposed of as waste. The feedstock is prepared and fed to the gasifier in either dry or slurried form. The feedstock reacts in the gasifier with steam at high temperature and pressure in a reducing (oxygen starved) atmosphere. This produces the synthesis gas, or syngas, made up primarily of carbon monoxide and hydrogen (more than 85% by volume) and smaller quantities of carbon dioxide and methane.
Gas treatment facilities refine the raw gas using proven commercial technologies that are an integral part of the gasification plant. Trace elements
or other impurities are removed from the syngas and are either recirculated to the gasifier or are recovered.
If the syngas is to be used to produce electricity, it is typically used as a fuel in reciprocating engine generator set. The syngas can also be used to fire a boiler to create steam to drive a turbine.
The syngas can also be processed using commercially available technologies to produce a wide range of products, fuels, chemicals, fertilizer or industrial gases. Some facilities have the capability to produce both power and products from the syngas, depending on the plant's configuration as well as site specific technical and market conditions.
The Ecology Energy Biomass Conversion System
We believe the proprietary Ecology Energy Biomass Conversion System ("BCS") represents the next major step in this evolutionary march. The BCS mates an advanced, patent pending pyrolytic steam reforming gasifier to a catalytic ethanol reactor which features a proprietary catalyst, and other trade secret elements.
It can be easily configured to generate ethanol from ANY organic biomass or petroleum feedstock, while reducing it's volume by as much as 95% or more. Moreover, the character of the residue left over from the process is drastically changed. In almost all cases the resultant 5% to 10% residue is a benign clay-like solid or ash; non toxic, non hazardous, non leachable and odor free. The materials which can be easily handled by the BK` Process include (but is not limited to):
centrifuged digested sewer sludge (biosolids);
municipal solid waste, etc.;
Any cellulose based feed stock;
Agricultural waste
Pecan shells
Peanut shells
rice straw and hulls;
grass clippings and landscape waste;
tree and vine waste;
wood waste, forest waste, and residue; • etc.
Plastics,
fossil fuels including,
waste or flared natural gas;
crude oil;
coal;
coal seam gas;
oil shale;
land fill gas;
raw animal waste;
waste tires & rubber,
carpet waste.
"Fluff' from auto salvage, etc.;
Rapid adoption and application of our process is an answer to the need to reduce drastically the amount of waste taxing city, county, state and federal disposal resources as well as develop a much more efficient alternative to fermentation based ethanol production capability while nt the same time recovering something of immediate value from what is considered to be waste and a nuisance, and, extending and enhancing societies ability to manage its future increase.
Overview of Competing Technologies
Fermentation
Most biomass conversion processes utilize two or three technologies, sometimes in combination. Additionally they may also require pretreatment to make the cellulosic components of the biomass more accessible to hydrolysis by acids, or by enzymes called "cellulases", that convert sugar polymers into sugars. The sugars then undergo fermentation by microbes to convert the five and six carbon sugars to ethanol and other oxygenated chemicals
The latter two steps of pretreatment and fermentation may be combined into "Simultaneous Saccharification and Fermentation" (SSF). If cellulases are produced in the same reactor vessel, the approach is called Consolidated Bioprocessing or Direct Microbial Conversion (DMC). There is a further distillation process which produces the characteristics necessary for the intended use of the ethanol, e.g. transportation fuel.
Incineration
It is an unfortunate fact of life that incineration is often confused with gasification. Incineration is defined as complete combustion and reduction to ash of a fuel where the fuel to air ratio is high enough (typically 15:1) to completely oxidize the feedstock fuel. By way of contrast, the gasification of carbon based feed stocks without the introduction of air or oxygen is at the technological heart of the Biomass Conversion System. The absence of air in the thermal conversion of the BCS system makes all the difference in the world. The following chart summarizes the differences between the 2 processes.
Biomass Conversion System Incineration
Decomposes oxygen free; converts feedstock to gas and benign ash Thermal destruction with direct flame and high oxygen
Low air flow (low NOX) High air flow (high NOX)
No toxic emissions (no Furans or Dioxins) Generates Furans and Dioxins
90-95% reduction in volume and weight Maximum 80% reduction
Creates highly available and usable energy (up to 450 to 900 BTU SynGas) Energy is much less available and usable
Secondary control device rarely required (Scrubber of Dust Collector) Scrubbers and secondary control device always required
The Biomass Conversion System v. Competing Technologies
None of the technologies described above as "competing" are comparable to our process. By way of contrast, The BCS features a patent pending pyrolytic steam reforming gasifier mated to a catalytic ethanol reactor which features a proprietary catalyst, and other trade secret elements. It is distinctly different from competing technologies in that it:
The BCS Technology process utilizes the various feedstocks much more efficiently. Although it varies according to the feedstock our process results 5 % to 15% of benign, solid residue compared to 70% to 80% residue for other processes1;
The BCS Technology does not involve fermentation or hydrolysis;
The BCS Technology does not need or create sugar although it can easily accommodate agricultural feedstock’s used in sugar production;
The BCS Process Description
The gasification of carbon based feed stocks without the introduction of air or oxygen is at the technological heart of the Biomass Conversion System. The ability to provide gasification of carbon based feedstock's without the introduction of air or oxygen represents a major step in providing clean non diluted product gas. Our patented process has features necessary to allow the conversion of the carbon components without the oxygen of composition and the oxygen entrained within the feed to generate excessive carbon dioxide or runaway temperatures.
The Patented reactor consists of a multi stage system that stage reacts the feed to allow the conditioning of the carbon based material to a react able state within. the various stages of the system. These steps include:
feed preheat with waste heat from the process heater.
Gradual carbonation and devolitization of the feed to allow the oxygen of composition and entrained oxygen to react near or below the combustion point of the feed. This is also accomplished using waste reactor heat.
The devolitized feed material is induced to the entrained flow reactor/heater by way of a patented cyclonic inducer. This allows the material entering the reactor to do so within the vortex of the cyclone. This increases the residence time within the reactor and prevents the solid feed material from coming in contact with the reactor wall, thus preventing fouling of the reactor with tars, phenols etc. The process reaches the final stages of temperature within this section of the reactor. Unreacted material or unreactable components of the feed are carried through this section of the reactor and are eliminated from the process loop by a cyclone separator located at the discharge of the main reactor coil. This material may be reintroduced at the inlet of the reactor, or enter the reactor heaters fluidized bed for use as fuel.
A second stage cyclone is located further down the process to remove any ash or entrained catalysts from the hot process gas. The quench circuit the system employs is a critical component of the overall process. The formation of boudouard carbon will occur when the product gas, SynGas, is allowed to cool to slowly. The quench circuit quickly drops the product gas from the reactor process temperature down below the carbon formation zone. Tars and phenols condense at these temperatures and are removed in the process filtration system. This filter utilizes sock type filters for ease of service and removal. Additional stages of filtration are employed prior to the gas compression stage of the process.
The energy required to propel the feed material throughout the reactor is supplied through an eductor, employing the cooled and filtered process gas. A compressor is used to boost a small side stream of the product gas to a pressure that will allow the use of an eductor. This enables the process material within the cyclone reactor coil to maintain sufficient velocity to maintain the cyclonic action and entrainment within the coil. This technique allows the reactor to avoid outside materials from entering the reactor or the requirement of introducing a large quantity of excess steam to the process. This allows us to closely control the components of reaction within our process. However, depending on the feedstock, it may involve pretreatment.
Other Features and Advantages
Although relative efficiency varies somewhat by feedstock, the BCS is more efficient than competing processes because it effects a greater reduction in the volume of residue. It is also more efficient than competing technologies in that it requires less energy per unit or gallon of ethanol produced. Additionally, some of the byproducts, e.g. hydrogen, certain hydrocarbons,
and excess heat can be used to generate power for the process, offsetting some of the power that may otherwise be required from the grid or co-production sources.
"Designer" Gas
In addition, The BCS enables relatively easy manipulation of the composition and characteristics of the syngas to match the specific chemical, BTU or other requirements of its end use.
High BTU content
The process also generates a high BTU gas that can also be custom tailored to the end use requirements. BTU content ranging between 450 and 900 BTU can be accomplished. The resultant high BTU gas can be compressed and stored, thus enabling time shifting of syngas utilization.
Energy Efficiency
In addition to efficient utilization of the feedstock, the BCS is also energy efficient; very nearly energy self sufficient. Except for a small amount of energy necessary to initiate the process, the BCS generates nearly all the energy necessary to power the process.
Size
It also features a small footprint. Not considering finished product storage requirements, an installed plant taking up space of 100' by 150', depending on the feedstock, can produce 20,000 gallons of ethanol in 24 hours. Because of the small footprint it can be skid mounted and is easily scalable. The small footprint also allows great flexibility in siting, depending on the relative economics and permitting requirements of the project. The unit can be sited close to either the ultimate end user or the source of the feedstock, eliminating many of the problems currently associated with transportation.
Environmental Impact
Perhaps the most powerful aspect of the Technology is that it is so environmentally friendly. It is a completely closed process except for the negligible emissions of the gasifier heat source; therefore it virtually eliminates any of the odorous discharges, noxious gases, or emissions which may be associated with competing processes. Moreover, the residue of the process is a relatively small volume of solids which is environmentally benign, easily compacted, with trace minerals and, in some cases, suitable for use as fertilizer or animal feed supplement.
The ability to take a large volume of waste material, e.g., biosolids, municipal solid waste, agricultural waste and landfill bound grass clippings, yard waste, etc., recover something valuable, and leave an absolutely and comparatively very small amount of benign material has far reaching implications. There is a natural synergy between the company's technology and those public agencies and private companies tasked with handling enormous volumes of society's waste products.
Landfills and other waste storage and handling facilities are always sources of contention and controversy. Our technology has the capability of drastically reducing in volume the amount of objectionable waste that must be handled. At the same time, the volume of residue we return to them, depending on the feedstock, is reduced to a very small fraction of it's original volume and weight. Moreover, it's character is changed drastically from the original feedstock to a benign clay-like solid or ash; odorless, nontoxic and non-hazardous.
Implementation Time
The BCS also has a comparatively short fabrication and deployment lead time. The Company can build and bring on line a modular facility capable of generating 20,000 gallons of ethanol a day from approximately 250 tons/day from any of the feedstock’s listed below within 6 months. Thereafter, the company can deliver and deploy an waste to ethanol generation facility of the same output capacity each 3 months.
Comparative Analysis of Various Feedstock’s
The table below shows the estimated ethanol yields and other performance parameters of the Technology per ton of various feedstock’s. The charted yield is based on gallons of ethanol per dry ton of feedstock. The actual yields achieved depend on a great variety of static and dynamic factors, too complex to be itemized here. Use these figures as a guideline only.
Biomass Ethanol Yield(Gal./Dry Ton) Primary Waste Product as a % of Original Feedstock
Biosolids 115-130 10-12% Benign Solids
MSW 90-112 5-7% Benign Solids
Grass Clippings 101-116 5-7% Benign Solids
Rice Straw 101-116 5-7% Benign Solids
Tree Wood, and Vine Waste 101-116 5-7% Benign Solids
Stranded or Land Fill Gas 4.0-6.5 (Gal/MMBTU) Trace ash residual
Plastics 115-130 5-7% Benign Solids
Current Status
The Technology has been widely field tested and demonstrated to work outside the laboratory and is working in production at multiple locations in the North American Continent.
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