In principle, syngas (primarily consisting of CO and H2) can be produced from any hydrocarbon feedstock, including: natural gas, naphtha, residual oil, petroleum coke, coal, and biomass. The lowest cost routes for syngas production, however, are based on natural gas, the cheapest option being remote or stranded reserves. Economic considerations dictate that the current production of liquid fuels from syngas translates into the use of natural gas as the hydrocarbon source. Nevertheless, the syngas production operation in a gas-to-liquids plant amounts to greater than half of the capital cost of the plant. The choice of technology for syngas production also depends on the scale of the synthesis operation. Syngas production from solid fuels can require an even greater capital investment with the addition of feedstock handling and more complex syngas purification operations. The greatest impact on improving the economics of gas-to liquids plants is through (1) decreasing capital costs associated with syngas production and (2) improving the thermal efficiency with better heat integration and utilization. Improved thermal efficiency can be obtained by combining the gas-to-liquids plant with a power generation plant to take advantage of the availability of low-pressure steam. The extensive research and development efforts devoted to syngas conversion more » to fuels and chemicals are documented in a vast amount of literature that tracks the scientific and technological advancements in syngas chemistry. The purpose of this report is to review the many syngas to products processes and summarize the salient points regarding the technology status and description, chemistry, catalysts, reactors, gas cleanliness requirements, process and environmental performances, and economics. Table 1 lists the products examined in this study and gives some facts about the technology as well as advantages and disadvantages. Table 2 summarizes the catalysts, process conditions, conversions, and selectivities for the various syngas to products processes. Table 3 presents catalyst poisons for the various products. « less

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Preliminary screening: Technical and economic assessment of synthesis gas to fuels and chemicals with emphasis on the potential for biomass-derived syngas

The use of gas fermentation for the production of low carbon biofuels such as ethanol or butanol from lignocellulosic biomass is an area currently undergoing intensive research and development, with the first commercial units expected to commence operation in the near future. In this process, biomass is first converted into carbon monoxide (CO) and hydrogen (H2)-rich synthesis gas (syngas) via gasification, and subsequently fermented to hydrocarbons by acetogenic bacteria. Several studies have been performed over the last few years to optimise both biomass gasification and syngas fermentation with significant progress being reported in both areas. While challenges associated with the scale-up and operation of this novel process remain, this strategy offers numerous advantages compared with established fermentation and purely thermochemical approaches to biofuel production in terms of feedstock flexibility and production cost. In recent times, metabolic engineering and synthetic biology techniques have been applied to gas fermenting organisms, paving the way for gases to be used as the feedstock for the commercial production of increasingly energy dense fuels and more valuable chemicals.

Commercial Biomass Syngas Fermentation

A process for producing ethanol including a combination of biochemical and synthetic conversions results in high yield ethanol production with concurrent production of high value coproducts. An acetic acid intermediate is produced from carbohydrates, such as corn, using enzymatic milling and fermentation steps, followed by conversion of the acetic acid into ethanol using esterification and hydrogenation reactions. Coproducts can include corn oil, and high protein animal feed containing the biomass produced in the fermentation.

Process for producing ethanol

Biomass pretreatment aims at separating and providing easier access to the main biomass components (cellulose, hemicellulose and lignin), eventually removing lignin, preserving the hemicellulose, reducing the cellulose crystallinity and increasing the porosity of the material. Pretreatment is an essential step towards the development and industrialization of efficient 2nd generation lignocellulosic ethanol processes. The present work reviewed the main options available in pretreatment. Autohydrolysis and steam explosion were then selected for further investigation. Experimental work was carried out on batch scale reactors, using Miscanthus as biomass feedstock: the effects on sugar solubilization and degradation products generation have been examined for each of these two pretreatment systems. A new process using only water and steam as reacting media was then developed, experimentally tested, and results compared to those achieved by the autohydrolysis and steam explosion processes. Products obtained with the new pretreatment contained a lower amount of usual fermentation inhibitor compounds compared to that typically obtained in steam explosion. This result was achieved under operating conditions that at the same time allowed a good xylan yield, preventing degradation of hemicelluloses. The new pretreatment process was also able to act as an equalization step, as the solid material from the pretreatment phase had a similar composition even under different operating conditions. As regards the effect of pretreatment on enzymatic hydrolysis, the new process achieved yields similar to steam explosion on glucans: however, this was obtained reducing the formation of degradation products from sugars, mainly from C5 sugars. These results made the proposed pretreatment system suitable for further development and industrialization on pilot and industrial scale.

Review of pretreatment processes for lignocellulosic ethanol production, and development of an innovative method

Bioconversion of syngas/waste gas components to produce ethanol appears to be a promising alternative compared to the existing chemical techniques. Recently, several laboratory-scale studies have demonstrated the use of acetogens that have the ability to convert various syngas components (CO, CO2, and H2) to multicarbon com- pounds, such as acetate, butyrate, butanol, lactate, and ethanol, in which ethanol is often produced as a minor end- product. This bioconversion process has several advantages, such as its high specifi city, the fact that it does not require a highly specifi c H2/CO ratio, and that biocatalysts are less susceptible to metal poisoning. Furthermore, this process occurs under mild temperature and pressure and does not require any costly pre-treatment of the feed gas or costly metal catalysts, making the process superior over the conventional chemical catalytic conversion process. The main challenge faced for commercializing this technology is the poor aqueous solubility of the gaseous sub- strates (mainly CO and H2). In this paper, a critical review of CO-rich gas fermentation to produce ethanol has been analyzed systematically and published results have been compared. Special emphasis has been given to under- stand the microbial aspects of the conversion process, by highlighting the role of different micro-organisms used, pathways, and parameters affecting the bioconversion. An analysis of the process fundamentals of various bioreac- tors used for the biological conversion of CO-rich gases, mainly syngas to ethanol, has been made and reported in this paper. Various challenges faced by the syngas fermentation process for commercialization and future research requirements are also discussed. © 2011 Society of Chemical Industry and John Wiley & Sons, Ltd

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Biological conversion of carbon monoxide: rich syngas or waste gases to bioethanol

A stable continuous method for producing ethanol from the anaerobic bacterial fermentation of a gaseous substrate containing at least one reducing gas involves culturing in a fermentation bioreactor anaerobic, acetogenic bacteria in a liquid nutrient medium; supplying the gaseous substrate to the bioreactor; and manipulating the bacteria in the bioreactor by reducing the redox potential, or increasing the NAD(P)H TO NAD(P) ratio, in the fermentation broth after the bacteria achieves a steady state and stable cell concentration in the bioreactor. The free acetic acid concentration in the bioreactor is maintained at less than 5 g/L free acid. This method allows ethanol to be produced in the fermentation broth in the bioreactor at a productivity of greater than 10 g/L per day. Both ethanol and acetate are produced in a ratio of ethanol to acetate ranging from 1:1 to 20:1.

Methods for increasing the production of ethanol from microbial fermentation

A modified water-immiscible solvent useful in the extraction of acetic acid from aqueous streams is a substantially pure mixture of isomers of highly branched di-alkyl amines. This solvent is substantially devoid of mono-alkyl amines and alcohols. Solvent mixtures formed of such a modified solvent with a desired cosolvent, preferably a low boiling hydrocarbon which forms an azeotrope with water are useful in the extraction of acetic acid from aqueous gaseous streams. An anaerobic microbial fermentation process for the production of acetic acid employs such solvents, under conditions which limit amide formation by the solvent and thus increase the efficiency of acetic acid recovery. Methods for the direct extraction of acetic acid and the extractive fermentation of acetic acid also employ the modified solvents and increase efficiency of acetic acid production. Such increases in efficiency are also obtained where the energy source for the microbial fermentation contains carbon dioxide and the method includes a carbon dioxide stripping step prior to extraction of acetic acid in solvent.

Microbial process for the preparation of acetic acid as well as solvent for its extraction from the fermentation broth

The present invention is directed to improvements in gasification for use with synthesis gas fermentation. Further, the present invention is directed to improvements in gasification for the production of alcohols from a gaseous substrate containing at least one reducing gas containing at least one microorganism.

Methods for sequestering carbon dioxide into alcohols via gasification fermentation

A bioreactor is provided that includes a main reactor having a configuration selected from the group consisting of stirred and unstirred tank reactor, trickle bed reactor (TBR), cocurrent contactor (CCC), moving bed bioreactor (MBBR), and a bubble column reactor. The bioreactor also includes a growth reactor continuous with the main reactor and having a configuration selected from the group consisting of stirred and unstirred tank reactor, trickle bed reactor (TBR), cocurrent contactor (CCC), moving bed bioreactor (MBBR), and a bubble column reactor. A method is also provided where acetogenic bacteria are contacted with syngas in a growth fermentor section of a reactor vessel that is continuous with a main fermentor section of a reactor vessel.

Bioreactor for syngas fermentation

A process and apparatus is provided which are effective for improving CO mass transfer. The process includes introducing syngas into a reactor vessel through a gas sparger located below a liquid level in the reactor vessel. The syngas being introduced at a flow rate effective for maintaining a pressure inside of the reactor vessel of at least about 1 psig. An agitation energy of about 0.01 to about 12 kWatts/m3 medium is provided. The process is effective for providing a volumetric CO mass transfer coefficient of about 100 to about 1500 per hour.

Ching-Whan Ko

Papers

Methods for increasing the production of ethanol from microbial fermentation

Microbial process for the preparation of acetic acid as well as solvent for its extraction from the fermentation broth

Methods for sequestering carbon dioxide into alcohols via gasification fermentation

Bioreactor for syngas fermentation

Method and apparatus for syngas fermentation with high co mass transfer coefficient