Process for producing hydrocarbon derivative products from feedstock containing hydrocarbons
The process for producing a predetermined C X H Y O Z product from a primary feedstock containing hydrocarbons and a secondary feedstock is disclosed, wherein X, Y and Z are integers. The process includes the steps of: providing primary feedstock; indirectly heating it generally in the absence of oxygen; cleaning the gas stream produced therefrom by removing CO 2 and solids; determining the amount of CO and H 2 therein; comparing the percentage of CO and H 2 in the cleaned gas stream with the required CO and H 2 to produce the predetermined C X H Y O Z product; determining the additional of CO and H 2 required; determining the secondary feedstock; calculating the amount of CO, H 2 and heat produced from the secondary feedstock; partially oxidizing the secondary feedstock to produce heat and a secondary gas stream; combining the CO and H 2 from both feedstocks to produce a mixed gas stream; adding a catalyst; and distilling to produce the predetermined C X H Y O Z product.
1. A process for producing an ethanol product from a primary feedstock containing hydrocarbons comprising the steps of:
subjecting the primary feedstock with a water content of not greater than 25% to indirect heating, substantially in the absence of oxygen, by a secondary feedstock to create a primary synthesis gas stream comprising CO and H 2 and solids;
cleaning the gas stream by removing CO 2 and solids to produce a cleaned gas stream;
determining the amount of CO and H 2 in the cleaned gas stream;
comparing the percentage of CO and H 2 in the cleaned gas stream with the required CO and H 2 ratio to form the ethanol product;
calculating the amount of the secondary feedstock required for indirect heating of the primary feedstock;
depending on additional components required to produce the ethanol product, determining an additional quantity of CO and H 2 which may be required as a secondary gas stream from the secondary feedstock;
partially oxidizing the calculated amount of secondary feedstock to produce heat required for the indirect heating of the primary feedstock;
combining the determined additional quantity of CO and H 2 which may be required from the secondary gas stream with the cleaned gas stream to produce a mixed gas stream;
adding a catalyst to the mixed cleaned gas stream and reacting the CO and H 2 with the catalyst in a methanol reactor to produce methanol;
converting the methanol into methyl acetate;
converting the methyl acetate into ethanol and methanol; and
distilling the ethanol and methanol to produce the ethanol product.
2. A process as claimed in claim 1 further including the steps of determining whether the quantity of H 2 in the secondary gas stream meets the additional quantity of H 2 required for the ethanol product, and if the quantity of H 2 is not enough, passing CO through a water/gas shift wherein the CO is mixed with water to produce H 2 and CO 2 and adding H 2 so obtained and then passing the remaining CO and H 2 to the combining step.
3. A process as claimed in claim 2 further including the step of cleaning the secondary gas stream and removing CO 2 and solids to produce a cleaned secondary gas stream.
4. A process as claimed in claim 3 wherein steam is used for the indirect heating step.
5. A process as claimed in claim 3 wherein a raw primary feedstock has a water content of higher than 25% and further including the step of drying the raw primary feedstock to produce the primary feedstock.
6. A process as claimed in claim 3 wherein the CO 2 is removed using an amine separator.
7. A process as claimed in claim 3 wherein the catalyst is a nickel and copper catalyst.
8. A process as claimed in claim 3 further comprising recycling the methanol.
9. A process as claimed in claim 8 further comprising purifying the ethanol.
10. A process as claimed in claim 3 wherein the primary feedstock is chosen from a group consisting of waste biomass and organic material.
11. A process as claimed in claim 10 wherein the waste biomass is chosen from a group consisting of crop residues, wood residues from harvesting, milling and municipal activities, pulp and paper bar and sawdust.
12. A process as claimed in claim 10 wherein the organic material is chosen from a group consisting of human and animal sewage, and high protein residues from the fermentation of alcohols from grains, called dry distiller's grains or dry distiller's grains and solubles.
13. A process as claimed in claim 3 wherein the secondary feedstock is chosen from a group consisting of hydrocarbon fuels in gas, liquid and solid form, biomass containing cellulose and organic material.
14. A process as claimed in claim 1 wherein the primary feedstock is chosen from the group consisting of waste biomass and organic material.
15. A process as claimed in claim 14 wherein the waste biomass is chosen from a group consisting of crop residues, wood residues from harvesting, milling and municipal activities, pulp and paper bar and sawdust.
16. A process as claimed in claim 14 wherein the organic material is chosen from a group consisting of human and animal sewage, and high protein residues from the fermentation of alcohols from grains, called dry distiller's grains or dry distiller's grains and solubles.
17. A process as claimed in claim 1 wherein the secondary feedstock is chosen from the group consisting of hydrocarbon fuels in gas, liquid and solid form, biomass containing cellulose and organic material.
18. A process as claimed in claim 1 wherein steam is used for the indirect heating step.
19. A process as claimed in claim 1 wherein a raw primary feedstock has a water content of higher than 25% and further including the step of drying the raw primary feedstock to produce the primary feedstock.