Autonomous Modular Flare Gas Conversion Systems and Methods

1 . A system for converting flare gas into an end product, the system comprising:

a. a reformer stage and a synthesis stage;

b. the reformer stage comprising:

i. an intake for receiving a flow of a flare gas;

ii. an intake for receiving a flow of air;

iii. a mixer for combining the flow of air and the flow of the flare gas; wherein the mixer is configured to provide a mixture having a rich fuel/air equivalence ratio;

iv. an air breathing reformer, configured to operate under rich fuel/air conditions; wherein the reformer is configured to operate in a partial oxidation combustion window; whereby the reformer is configured to convert the mixture into a syngas;

v. a line for flowing the syngas to the synthesis stage;

c. the synthesis stage comprising:

i. a line for receiving a flow of syngas from the reformer stage;

ii. a synthesis unit configured to receive the syngas and convert the syngas into an end product;

d. a control system configured to operate the reformer stage at a predetermined partial oxidation temperature and a predetermined partial oxidation pressure; and the synthesis stage at a predetermined synthesis temperature and a predetermined synthesis pressure.

2 . The system of claim 1 , wherein the reformer stage and the synthesis stage are integral or wherein the reformer stage and the synthesis stage are separate connectable modular units.

3 . (canceled)

4 . The system of claim 1 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine.

5 . The system of claim 1 , wherein the air breathing reformer comprises a reciprocating engine having a variable compression ratio; and, further comprising:

a. a sensor system to detect ignition/combustion behavior over a range from pre-ignition to misfire; and configured to send detected ignition/combustion behavior information;

b. wherein the control system is in control communication with the sensor system and the engine;

c. wherein the control system is configured to adjust the engine compression ratio based on the detected ignition/combustion behavior information; and,

d. thereby the control system is configured to adjust the compression ratio in response to a variability in a composition of the flare gas.

6 . The system of claim 4 , wherein the engine is a compression ignition engine.

7 . The system of claim 4 , wherein the engine is a spark ignition engine.

8 . The system of claim 4 , wherein the engine is an opposed-piston free-piston linear internal combustion engine.

9 . The system of claim 4 , further comprising one or more of: (a) wherein the engine is a crankshaft-driven opposed-piston internal combustion engine with a crankshaft phaser to rotate a phasing of one piston relative to the other thereby modifying overall compression ratio; (b) wherein the engine is a conventional spark-ignited reciprocating engine, wherein the engine is configured for a variable effective compression ratio utilizing camshaft phasers to rotate intake and exhaust camshafts to thereby affect a valve opening and closing; (c) wherein the engine is configured for a variable effective compression ratio utilizing a variable lift, a duration valvetrain, or both to affect a valve opening and closing; and (d) wherein the engine comprises a multi-link system configured to rotate a crankshaft, and comprising an actuator motor configured to change an endpoint of the multi-link system.

10 . (canceled)

11 . (canceled)

12 . (canceled)

13 . The system of claim 4 , wherein the engine comprises a 2-stroke engine, or a 4-stroke engine.

14 . (canceled)

15 . The system of claim 1 , wherein the controller is configured to maintain a ratio of H 2 to CO in the syngas from about 2 to about 3.

16 . (canceled)

17 . The system of claim 4 , wherein the controller is configured to maintain a ratio of H 2 to CO in the syngas from about 1.1 to about 2.5.

18 . (canceled)

19 . The system of claim 1 , wherein the predetermined temperatures and pressures comprises one, more than one, or all of: (i) the predetermined partial oxidation temperature is from about 700° C. to about 1,200° C.; (ii) the predetermined partial oxidation pressure is from about 1 bar to about 70 bar; (iii) the predetermined synthesis temperature is from about 200° C. to about 300° C.; and, (iv) the predetermined synthesis pressure is from about 30 bar to about 100 bar.

20 . The system of claim 1 , wherein the reformer comprises one or more of a gas turbine engine, a combustion box, an internal combustion engine, an otto cycle reciprocating engine, and a diesel cycle reciprocating engine.

21 . The system of claim 1 , wherein the controller is configured to maintain a fuel/air equivalence ratio of from about 1.5 to about 2.5; and wherein the controller is configured such that a variation in a composition of the flare gas does not change a composition of the end product.

22 . (canceled)

23 . The system of claim 1 , wherein the control system is further configured such that a variation in a composition of the flare gas does not change a composition of the end product; and wherein the variation in the composition of the flare gas does not require a change in one or more than one, of the predetermined synthesis temperature, the predetermined synthesis pressure, and the predetermined reformer temperature, and the predetermined reformer temperature.

24 . The system of claim 1 , comprising a water, a steam or both inlet for introducing the water, the steam, or both into the reformer.

25 . The system of claim 1 , wherein the reformer is a reciprocating engine; and the reciprocating engine has one, more than one, or all of:

a) a compression ratio in the range of about 8:1 to about 17:1;

b) an inlet manifold air temperature of ambient temperature to about 300° C.;

c) an inlet manifold air pressure of ambient to about 5 bar;

d) a spark timing between TDC and 50 degrees before TDC; and,

e) an engine speed for from about 8,000 rpm to about 1,500 rpm;

26 . The system of claim 1 , wherein the reformer comprises a gas turbine assembly; and the gas turbine assembly has one, more than one, or all of:

a) a first partial oxidation combustor;

b) a two-stage combustion process;

c) a gas turbine combustor; and,

d) a combustion cycle time of from 5 to 50 milliseconds.

27 . The system of claim 1 , comprising a hydrogen separation unit to provide a stream of a recovered hydrogen to the system.

28 . (canceled)

29 . The system of claim 1 , comprising a hydrogen separation unit to provide a stream of a recovered hydrogen for mixing with the syngas; and wherein the control system is configured to control the mixing of the recovered hydrogen with the syngas to provide a predetermined H 2 to CO ratio.

30 . The system of claim 1 , wherein the end product comprises a compound selected from the group consisting of methanol, ethanol, mixed alcohols, ammonia, dimethyl-ether, and F-T liquids.

31 . A system for converting a flare gas to an end product, the system comprises:

a) a flare gas source, defining a starting specific entropy;

b) an oxygen source, wherein the oxygen source comprises air;

c) a fuel/air mixture defining a starting specific entropy;

d) a control system;

e) an air-breathing reformer;

f) the reform in conjunction with the control system, configured to partially oxidize a mixture of the oxygen source and the flare gas; thereby providing a reprocessed gas flow comprises a syngas;

g) a synthesis unit in conjunction with the control system configured to provide a first product stream comprising an end product; wherein the end product stream and an exhaust product stream define a final specific entropy;

h) the control system configured to operate the system wherein the starting specific entropy and the final specific entropy are less than about 1 kJ/kg ° C. of each other; and,

i) wherein during operation the system is configured to produces less than 2.0 kg of CO 2 per kg of flare gas received.

32 . A system for converting a flare gas to an end product, the system comprises:

a) a flare gas source, defining a starting specific entropy;

b) an air source;

c) a fuel/air mixture defining a starting specific entropy;

d) a control system;

e) an air-breathing reformer;

f) the reform in conjunction with the control system, configured to partially oxidize a mixture of the air and the flare gas; thereby providing a reprocessed gas flow comprises a syngas;

g) a synthesis unit in conjunction with the control system configured to provide a first product stream comprising an end product; wherein the end product stream and an exhaust product stream define a final specific entropy;

h) the control system configured to operate the system wherein the starting specific entropy and the final specific entropy are less than about 1 kJ/kg ° C. of each other; and,

i) wherein during operation, the system is configured to be net carbon-negative, whereby during operation the system produces less than about −20 kg CO 2 e per kg of end product provided.

33 . A system for converting a flare gas to an end product, the system comprises:

a) a flare gas source, defining a starting specific entropy;

b) an air source,

c) a fuel/air mixture defining a starting specific entropy;

d) a control system;

e) an air-breathing reformer;

f) the reform in conjunction with the control system, configured to partially oxidize a mixture of the air and the flare gas; thereby providing a reprocessed gas flow comprises a syngas;

g) a synthesis unit in conjunction with the control system configured to provide a first product stream comprising an end product; wherein the end product stream and an exhaust product stream define a final specific entropy;

h) the control system configured to operate the system wherein the starting specific entropy and the final specific entropy are less than about 1 kJ/kg ° C. of each other;

i) wherein during operation, the system is configured to be net carbon-negative, whereby during operation the system produces less than about −20 kg CO 2 e per kg of end product provided; and,

j) wherein during operation the system is configured to produces less than 2.0 kg of CO 2 per kg of flare gas received.

34 . (canceled)

35 . The system of claim 31 , comprising a reformer stage and a synthesis stage; and wherein the reformer stage and the synthesis stage are separate connectable modular units.

36 . The system of claim 32 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine.

37 . The system of claim 31 , wherein the air breathing reformer comprises a reciprocating engine having a variable compression ratio; and, further comprising:

a. a sensor system to detect ignition/combustion behavior over a range from pre-ignition to misfire; and configured to send a detected ignition/combustion behavior information;

b. wherein the control system is in control communication with the sensor system and the engine;

c. wherein the control system is configured to adjust the engine compression ratio based on the detected ignition/combustion behavior information; and,

d. thereby the control system is configured to adjust the compression ratio in response to a variability in a composition of the flare gas.

38 . The system of claim 31 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine comprising an engine selected from the group consisting of (i) a compression ignition engine, (ii) a spark ignition engine, (iii) an opposed-piston free-piston linear internal combustion engine, (iv) a crankshaft-driven opposed-piston internal combustion engine with a crankshaft phaser to rotate a phasing of one piston relative to the other thereby modifying overall compression ratio, (v) a conventional spark-ignited reciprocating engine, wherein the engine is configured for a variable effective compression ratio utilizing camshaft phasers to rotate intake and exhaust camshafts to thereby affect a valve opening and closing, and (vi) wherein the engine configured for a variable effective compression ratio utilizing a variable lift, a duration valvetrain, or both to affect a valve opening and closing.

39 . (canceled)

40 . (canceled)

41 . (canceled)

42 . (canceled)

43 . (canceled)

44 . The system of claim 32 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine comprising a multi-link system configured to rotate a crankshaft, and comprising an actuator motor configured to change an endpoint of the multi-link system.

45 . The system of any of claim 31 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine comprising an engine selected from the group comprising a 2-stroke engine and a 4-stroke engine.

46 . (canceled)

47 . The system of claim 31 , wherein the controller is configured to maintain a ratio of H 2 to CO in the syngas from about 2 to about 3.

48 . The system of claim 32 , wherein the controller is configured to maintain a ratio of H 2 to CO in the syngas from about 0.8 to about 2.5.

49 . The system of claim 33 , wherein the controller is configured to maintain a ratio of H 2 to CO in the syngas from about 1.1 to about 2.5.

50 . (canceled)

51 . (canceled)

52 . (canceled)

53 . The system of claim 31 , wherein the controller is configured to maintain a fuel/air equivalence ratio of from about 1.5 to about 2.5; and wherein the reformer comprises one or more of a gas turbine engine, a combustion box, an internal combustion engine, an otto cycle reciprocating engine, and a diesel cycle reciprocating engine.

54 . (canceled)

55 . The system of claim 33 , wherein the controller is configured such that a variation in a composition of the flare gas does not change a composition of the end product; and wherein the variation in the composition of the flare gas does not require a change in one or more than one, of the predetermined synthesis temperature, the predetermined synthesis pressure, and the predetermined reformer temperature, and the predetermined reformer temperature.

56 . The system of claim 31 , comprising a water, a steam or both inlet for introducing the water, the steam, or both into the reformer.

57 . (canceled)

58 . (canceled)

59 . The system of claim 33 , comprising a hydrogen separation unit to provide a stream of a recovered hydrogen to the system.

60 . The system of claim 31 , comprising a hydrogen separation unit to provide a stream of a recovered hydrogen for mixing with the syngas.

61 . The system of claim 32 , comprising a hydrogen separation unit to provide a stream of a recovered hydrogen for mixing with the syngas; and wherein the control system is configured to control the mixing of the recovered hydrogen with the syngas to provide a predetermined H 2 to CO ratio.

62 . (canceled)

63 . A system for converting flare gas into an end product, the system comprising:

a. a reformer stage and a synthesis stage;

b. the reformer stage comprising:

i. an intake for receiving a flow of a flare gas;

ii. an intake for receiving a flow of air;

iii. an air breathing reformer, configured to operate under rich fuel/air conditions; wherein the reformer is configured to operate in a partial oxidation combustion window; whereby the reformer is configured to convert mixture of flare gas and air into a syngas;

iv. a line for flowing the syngas to the synthesis stage;

c. the synthesis stage comprising:

i. a line for receiving a flow of syngas from the reformer stage;

ii. a synthesis unit configured to receive the syngas and convert the syngas into an end product;

d. a control system configured to operate the reformer stage at a predetermined partial oxidation temperature and a predetermined partial oxidation pressure; and the synthesis stage at a predetermined synthesis temperature and a predetermined synthesis pressure.

64 . The system of claim 63 , wherein the air breathing reformer comprises a rich-burn, air-breathing reciprocating engine with variable compression ratio to produce a syngas mixture with a predetermined H 2 /CO ratio.

65 . The system of claim 63 , wherein steam or hydrogen or both is added to the incoming air or fuel and the amount of addition is varied together with engine compression ratio to achieve desired combustion burn and desired exhaust gas composition.

66 . The system of claim 63 , comprising a fuel conditioning system to remove liquids and contaminants harmful to a downstream component, thereby providing a conditioned fuel source.

67 . The system of claim 1 , comprising a separation assembly associated with the synthesis unit, wherein a byproduct is selectively removed from the synthesis unit in situ.

68 . The system of claim 32 , comprising a separation assembly associated with the synthesis unit, wherein a byproduct is selectively removed from the synthesis unit by a liquid or gaseous sweep.

69 . The system of claim 67 , wherein the byproduct is water.

70 . The system of claim 68 , wherein the separation assembly comprises at least one of a device for membrane separation, a device for absorption, a device for adsorption, or a device for distillation.

71 . The system of claim 63 , comprising a separation assembly associated with the synthesis unit, wherein the end product is selectively removed from the synthesis unit in situ.

72 . The system of claim 63 , comprising a separation assembly associated with the synthesis unit, wherein the end product is selectively removed from the synthesis unit by a liquid or gaseous sweep.

73 . The system of claim 63 , wherein the end product is methanol.

74 . (canceled)