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(12) United States Patent (10) Patent No.: US 9,388,345 B2 Mcneff Et Al

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(12) United States Patent (10) Patent No.: US 9,388,345 B2 Mcneff Et Al USOO9388345B2 (12) United States Patent (10) Patent No.: US 9,388,345 B2 McNeff et al. (45) Date of Patent: *Jul. 12, 2016 (54) HYDROCARBON SYNTHESIS METHODS, (58) Field of Classification Search APPARATUS, AND SYSTEMS USPC ............. 585/240; 44/306, 307, 308,385,605 See application file for complete search history. (71) Applicant: SarTec Corporation, Anoka, MN (US) (56) References Cited (72) Inventors: Clayton V. McNeff, Andover, MN (US); U.S. PATENT DOCUMENTS Larry C. McNeff. Anoka, MN (US); Daniel Thomas Nowlan, Hugo, MN 2,154,835 A 4, 1939 Eisenlohr (US); Bingwen Yan, Shoreview, MN 4,138,336 A 2f1979 Mendel et al. (US); Peter G. Greuel, Anoka, MN (US) (Continued) (73) Assignee: SarTec Corporation, Anoka, MN (US) FOREIGN PATENT DOCUMENTS (*) Notice: Subject to any disclaimer, the term of this AU 2011 200090 2, 2011 patent is extended or adjusted under 35 BR 060016O2 10/2007 U.S.C. 154(b) by 0 days. (Continued) OTHER PUBLICATIONS This patent is Subject to a terminal dis claimer. Adebanjo, Adenike O. et al., “Production of Diesel-Like Fuel and Other Value-Added Chemicals from Pyrolysis of Animal Fat'. (21) Appl. No.: 13/934,713 Energy & Fuels, vol. 19, 2005, pp. 1735-1741. (Continued) (22) Filed: Jul. 3, 2013 Primary Examiner — In Suk Bullock (65) Prior Publication Data Assistant Examiner — YoungSul Jeong (74) Attorney, Agent, or Firm — Pauly, DeVries Smith & US 2014/0046104A1 Feb. 13, 2014 Deffner, L.L.C. Related U.S. Application Data (57) ABSTRACT Embodiments of the invention include apparatus and systems (60) Provisional application No. 61/667,813, filed on Jul. 3, for hydrocarbon synthesis and methods regarding the same. 2012, provisional application No. 61/680,360, filed on In an embodiment, the invention includes a process for cre Aug. 7, 2012, provisional application No. 61/702,582, ating a hydrocarbon product stream comprising reacting a reaction mixture in the presence of a catalyst inside of a filed on Sep. 18, 2012. reaction vessel to form a product mixture, the reaction mix ture comprising a carbon Source and water. The temperature (51) Int. C. inside the reaction vessel can be between 450 degrees Celsius CIOG 3/00 (2006.01) and 600 degrees Celsius and the pressure inside the reaction CIOL L/04 (2006.01) vessel can be above Supercritical pressure for water. In an (Continued) embodiment, the invention includes an extrusion reactor sys tem for creating a hydrocarbon product stream. The tempera (52) U.S. C. ture inside the extrusion reactor housing between 450 degrees CPC ................. CI0G 3/44 (2013.01); B01J 21/063 Celsius and 600 degrees Celsius. Pressure inside the reaction (2013.01); B01J 21/066 (2013.01); B01J 23/30 vessel can be above supercritical pressure for water. Other (2013.01); embodiments are also included herein. (Continued) 23 Claims, 63 Drawing Sheets 2 Biomass Feedstock High Pressure Pumps w S! 8 Backpressure Regulator US 9,388,345 B2 Page 2 (51) Int. Cl. 2010/0324310 A1 12/2010 Dumesic et al. 2011 OOO95O1 A1 1/2011 Ernst CIOL 9/08 (2006.01) 2011/0035993 A1 2/2011 Loescher BOI 2/06 (2006.01) 2011/0105814 A1 5/2011 Koivusalmi et al. BOI. 23/30 (2006.01) 2011/0213040 Al 9, 2011 Hassan et al. BOI. 23/34 (2006.01) 2011/0287991 A1 11, 2011 Dubois BOII 2.3/755 (2006.01) 3: E. A 3: OlliaSFE et al. BOI 35/02 (2006.01) 2012/0055077 A1 3/2012 Savage et al. BOI 35/10 (2006.01) 2014/O115955 A1 5, 2014 McNeff et al. (52) U.S. Cl. CPC ................ B01J 23/34 (2013.01); B01J 23/755 FOREIGN PATENT DOCUMENTS (2013.01); B01J 35/023 (2013.01); B01.J 35/1014 (2013.01); B01J 35/1038 (2013.01); A : !: 38. B01J 35/1061 (2013.01); CIOL I/04 (2013.01); CN 10187O989 10, 2010 CI0L 9/086 (2013.01); Y02P 30/20 (2015.11) DE 1962O378 2, 1999 EP 1642560 4/2006 (56) References Cited EP 1869.173 12/2007 EP 2290035 3, 2011 U.S. PATENT DOCUMENTS EP 2290045 3, 2011 FR 293.8536 5, 2010 4,911,941 A 3, 1990 Katz et al. FR 294,7564 1, 2011 5,108,597 A 4, 1992 Funkenbusch et al. JP O2289692 11, 1990 5, 182,016 A 1/1993 Funkenbusch et al. WO 9108677 6, 1991 5,254,262 A 10/1993 Funkenbusch et al. WO 9627632 9, 1996 5,271,833. A 12/1993 Funkenbusch et al. WO 97O7187 2, 1997 5,346,619 A 9, 1994 Funkenbusch et al. WO 02102337 12/2002 5,540,834 A 7, 1996 Carr et al. 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