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Anoka, MN, United States

Patent
SarTec Corporation | Date: 2013-07-03

Embodiments of the invention include apparatus and systems for hydrocarbon synthesis and methods regarding the same. In an embodiment, the invention includes a process for creating a hydrocarbon product stream comprising reacting a reaction mixture in the presence of a catalyst inside of a reaction vessel to form a product mixture, the reaction mixture comprising a carbon source and water. The temperature inside the reaction vessel can be between 450 degrees Celsius and 600 degrees Celsius and the pressure inside the reaction vessel can be above supercritical pressure for water. In an embodiment, the invention includes an extrusion reactor system for creating a hydrocarbon product stream. The temperature inside the extrusion reactor housing between 450 degrees Celsius and 600 degrees Celsius. Pressure inside the reaction vessel can be above supercritical pressure for water. Other embodiments are also included herein.


Grant
Agency: Department of Agriculture | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 80.00K | Year: 2008

Biodiesel is a renewable petroleum diesel substitute whose use can improve air quality and help combat global warming. We propose to test the feasibility of using a novel and innovative process to synthesize biodiesel that could change the economics and commercial practices of the biodiesel industry. Our research will evaluate the feasibility of using a novel, highly efficient heterogeneous zirconia-based catalyst in a continuous flow packed-bed reactor for synthesizing biodiesel from a variety of feedstocks. The surface chemistry of zirconia is dominated by Lewis acid-base chemistry, which will allow for the controlled adsorption of acid or base moieties that can be used for catalysis of both esterification and transesterification reactions. In this research, both base, acid and unmodified forms of zirconium dioxide will be evaluated at elevated temperature and pressure for efficient, continuous transesterification of triglycerides (TGs) and esterification of free fatty acids. Phase I research will test the capability of this catalyst to produce biodiesel using a variety of feedstocks (i.e. soybean oil, algae oil, yellow grease, beef tallow and acidulated soapstock) without significant catalyst deterioration over extended periods of use. Furthermore, we will purposefully foul the catalyst with dirty feedstocks and evaluate if the catalyst can be regenerated by pyrolysis of adsorbed organic matter in order to restore its original catalytic activity. If successful, we believe this research will overcome the most significant limitations currently experienced by the biodiesel industry, namely the difficulty in using inexpensive feedstocks that contain high levels of free fatty acids, the necessity to continuously add catalyst to the reaction (in either batch or semi-continuous production modes), resulting in the need to dispose of waste products harmful to the environment and eliminating the need for extensive washing of the biodiesel with water. If successful the proposed fixed bed catalysts should stimulate use of inexpensive feedstocks, thereby lowering the cost of biodiesel production significantly. In summary, a successful phase I project will demonstrate the feasibility of using zirconia at elevated temperature and pressure to change the economics of biodiesel production and expand its role as a renewable, environmentally friendly energy source.


Grant
Agency: Department of Energy | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 100.00K | Year: 2009

The combustion of fossil fuels is believed to have caused a rapid increase in the amount of carbon dioxide present in the atmosphere. Carbon dioxide is considered a key ¿greenhouse¿ gas and its accumulation in the atmosphere is believed to be a primary cause of the global energy imbalance that is driving climate change. This project will develop a method for capturing and converting carbon dioxide into valuable and useful chemicals. The approach will involve the use of stable metal oxides, in particular zirconia, as catalysts for the conversion of CO2 and alkyl alcohols into carbonate reaction products. These metal oxides are extremely durable at high temperature and pressures, thus allowing their use to be continuous and cost effective. In Phase I, methanol and CO2 will be combined in a zirconia reactor operating at supercritical conditions to produce useful chemicals including dimethyl carbonate, which is considered a green chemical. In Phase II, the technology will be scaled up for the production of industrial quantities. Commercial Applications and other Benefits as described by the awardee: The zirconia catalyst technology should represent an exciting new opportunity for the energy and chemical industry. In addition to helping solve the CO2 problem, the production of useful chemicals from this gas should provide a multimillion dollar opportunity in the production of products with applications in plastics, fuel oxygenates, specialty solvents, and downstream chemical syntheses


Grant
Agency: Department of Agriculture | Branch: | Program: SBIR | Phase: Phase II | Award Amount: 350.00K | Year: 2009

Biodiesel is a renewable substitute and additive for petroleum diesel and its use can improve air quality, combat climate change and increase national energy security. The current biodiesel production methods are not well suited for efficient, large-scale continuous production and improved technology is needed. Recent Phase I research findings from SarTec Corporation demonstrate that biodiesel can be rapidly produced from a variety of feedstocks using heterogeneous zirconia catalysts in continuous-flow, fixed-bed reactors (The Mcgyan process). At elevated temperatures and pressures, efficient conversion of triglycerides and fatty acids to biodiesel (which met ASTM D 6751 quality standards) was achieved. Furthermore there was minimal pressure drop across the reactor bed and purposely-fouled catalyst was easily regenerated to its original activity. During Phase II work, we propose to further advance the development of this biodiesel production technology. Emphasis will be placed upon expanding the Mcgyan process so it can be used to process large quantities of high free fatty acid containing lipid feedstocks especially those that are solid or semi-solid at room temperature. We also wish to conduct a more complete mass and energy balance of a pilot scale production system as a prologue to full scale design, production and commercialization. When fully developed, The Mcgyan process will overcome the most significant limitations currently encountered by the biodiesel industry, namely the difficulty in using inexpensive feedstocks that contain high levels of free fatty acids, the necessity of continually adding catalyst to a batch mode process, and eliminating the need for extensive washing of the biodiesel with water. Therefore in addition to the advantage of converting high free fatty acid feedstocks to biodiesel, another major advantage of the Mcgyan process is water conservation. The proposed production technology will stimulate use of inexpensive feedstocks and lower the cost of biodiesel production. Successful development of this technology will change the economics of biodiesel production and expand its role as a renewable, environmentally friendly biofuel.


Patent
SarTec Corporation | Date: 2014-01-02

Embodiments of the invention include apparatus and systems for hydrocarbon synthesis and methods regarding the same. In an embodiment, the invention includes a method for creating a hydrocarbon product stream comprising reacting a reaction mixture in the presence of a catalyst inside of a reaction vessel to form a product mixture, the reaction mixture comprising a carbon source and water. The temperature inside the reaction vessel can be between 450 degrees Celsius and 600 degrees Celsius and the pressure inside the reaction vessel can be above supercritical pressure for water. In an embodiment, the invention includes an extrusion reactor system for creating a hydrocarbon product stream. The temperature inside the extrusion reactor housing between 450 degrees Celsius and 600 degrees Celsius. Pressure inside the reaction vessel can be above supercritical pressure for water. Other embodiments are also included herein.

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