Abstract

The following describes a reconfigurable set of industrial processing techniques which, when appropriately combined, enable zero-emissions reforming, utilizing a wide range of conventional and unconventional feedstocks. Hydrocarbons, harvested or refuse biomass, as well as assorted byproducts and wastes are reformed through tightly integrated processing. The system is designed to incorporate alternative energy sources such as renewables or nuclear for high-density energy utilization and storage. Central to the processing methodology is a novel molten salt electrochemical reactor designed as a modular system for high-throughput carbochlorination and resource recovery. Such a configuration drastically reduces or eliminates waste while improving efficiency and realizing vast new economic incentives.

IPC Classes  ?

• C25B 15/08 - Supplying or removing reactants or electrolytesRegeneration of electrolytes
• C25B 11/036 - Bipolar electrodes
• B09B 3/00 - Destroying solid waste or transforming solid waste into something useful or harmless
• C01B 3/34 - Production of hydrogen or of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
• C25B 1/26 - ChlorineCompounds thereof
• C25B 11/02 - ElectrodesManufacture thereof not otherwise provided for characterised by shape or form
• C25C 3/34 - Electrolytic production, recovery or refining of metals by electrolysis of melts of metals not provided for in groups
• C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
• C25C 7/02 - ElectrodesConnections thereof
• C25B 11/043 - Carbon, e.g. diamond or graphene
• C25B 11/061 - Metal or alloy

Abstract

Disclosed are systems and methods having inherent carbon capture and conversion capabilities offering maximum flexibility, efficiency, and economics while simultaneously enabling environmentally and sustainably sound practices. A hybrid thermochemical cycle couples staged reforming with hydrogen production and residue chlorination. The residues of the upgrading are chlorinated, metals of interest are removed and bulk material is re-mineralized. Through the residue chlorination process, various metals including rare earths are concentrated and extracted. Energy is retained through chemical synthesis such as hydrocarbon and metal and non-metal chloride production. Produced chemicals are later exploited by redox reactions in the operation of an integrated gasification flow battery.

IPC Classes  ?

• C01B 3/34 - Production of hydrogen or of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
• H01M 8/0612 - Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants from carbon-containing material
• B01D 47/00 - Separating dispersed particles from gases, air or vapours by liquid as separating agent
• C01B 3/00 - HydrogenGaseous mixtures containing hydrogenSeparation of hydrogen from mixtures containing itPurification of hydrogen
• C10G 1/00 - Production of liquid hydrocarbon mixtures from oil shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
• C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
• C10J 3/86 - Other features combined with waste-heat boilers
• C10L 3/08 - Production of synthetic natural gas
• C22B 1/08 - Chloridising roasting
• C22B 59/00 - Obtaining rare earth metals
• B01D 53/32 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by electrical effects other than those provided for in group
• C01B 3/02 - Production of hydrogen or of gaseous mixtures containing hydrogen
• H01M 8/0662 - Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• H01M 8/14 - Fuel cells with fused electrolytes
• H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
• H01M 8/20 - Indirect fuel cells, e.g. fuel cells with redox couple being irreversible

Abstract

Method of combining industrial processes having inherent carbon capture and conversion capabilities offering maximum flexibility, efficiency, and economics while enabling environmentally and sustainably sound practices. Maximum chemical energy is retained throughout feedstock processing. A hybrid thermochemical cycle couples staged reforming with hydrogen production and chlorination. Hydrogen generated is used to upgrade feedstocks including bitumen, shale, coal, and biomass. Residues of upgrading are chlorinated, metals of interest are removed, and the remainder is reacted with ammonia solution and carbon dioxide to form carbonate minerals. The combination provides emissions free production of synthetic crude oil and derivatives, as well as various metals and fertilizers. Sand and carbonate minerals are potentially the only waste streams. Through this novel processing, major carbon dioxide reduction is afforded by minimizing direct oxidation. Supplemental heat to run the reactions is obtained through external means such as concentrated solar, geothermal, or nuclear.

IPC Classes  ?

• H01M 8/0612 - Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants from carbon-containing material
• C22B 1/08 - Chloridising roasting
• B01D 53/32 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by electrical effects other than those provided for in group
• C22B 59/00 - Obtaining rare earth metals
• H01M 8/0662 - Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• C01B 3/00 - HydrogenGaseous mixtures containing hydrogenSeparation of hydrogen from mixtures containing itPurification of hydrogen
• C01B 3/02 - Production of hydrogen or of gaseous mixtures containing hydrogen
• C01B 3/34 - Production of hydrogen or of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
• C10G 1/00 - Production of liquid hydrocarbon mixtures from oil shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
• C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
• C10J 3/86 - Other features combined with waste-heat boilers
• C10L 3/08 - Production of synthetic natural gas
• H01M 8/14 - Fuel cells with fused electrolytes
• H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
• H01M 8/20 - Indirect fuel cells, e.g. fuel cells with redox couple being irreversible
• B01D 47/00 - Separating dispersed particles from gases, air or vapours by liquid as separating agent

Abstract

Method of combining industrial processes having inherent carbon capture and conversion capabilities offering maximum flexibility, efficiency, and economics while enabling environmentally and sustainably sound practices. Maximum chemical energy is retained throughout feedstock processing. A hybrid thermochemical cycle couples staged reforming with hydrogen production and chlorination. Hydrogen generated is used to upgrade feedstocks including bitumen, shale, coal, and biomass. Residues of upgrading are chlorinated, metals of interest are removed, and the remainder is reacted with ammonia solution and carbon dioxide to form carbonate minerals. The combination provides emissions free production of synthetic crude oil and derivatives, as well as various metals and fertilizers. Sand and carbonate minerals are potentially the only waste streams. Through this novel processing, major carbon dioxide reduction is afforded byminimizing direct oxidation. Supplemental heat to run the reactions is obtained through external means such as concentrated solar, geothermal, or nuclear.

IPC Classes  ?

• C22B 1/08 - Chloridising roasting
• C22B 59/00 - Obtaining rare earth metals
• B01D 47/00 - Separating dispersed particles from gases, air or vapours by liquid as separating agent
• C10G 1/00 - Production of liquid hydrocarbon mixtures from oil shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
• C10J 3/84 - Gas withdrawal means with means for removing dust or tar from the gas
• C10L 3/08 - Production of synthetic natural gas
• C01B 3/00 - HydrogenGaseous mixtures containing hydrogenSeparation of hydrogen from mixtures containing itPurification of hydrogen
• C10J 3/86 - Other features combined with waste-heat boilers