Integrated gas fermentation
Inventors
Holmgren, Jennifer Rosa • Rollag, Sean Alex • Rosin, Richard Russell • Schulz, Taylor Craig
Assignees
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Publication Number
US-12281344-B2
Publication Date
2025-04-22
Expiration Date
Abstract
Integrated process for providing multiple raw materials to a downstream operation to generate an article of manufacture. Pyrolysis, torrefaction, reforming, partial oxidation, and/or gasification is integrated with gas fermentation. Integrated process converts carbon sources that would otherwise be vented to the atmosphere or discarded as waste to a fermentation product and one or more byproducts, which in turn are provided to a downstream operation to generate an article of manufacture. In certain aspects, the fermentation product may be ethanol, isoprene, butane diol, ethylene. In certain aspects, the byproduct may be metal, metal oxide, char, silica, and or steel. The downstream operation to generate an article of manufacture may be an operation to generate plastic products, rubber products, textiles, clothes, and the like.
Core Innovation
The integrated process converts at least one of the listed feedstocks in a gasification process to produce a raw syngas steam comprising at least carbon monoxide and carbon dioxide and to produce a char byproduct. The feedstocks include coal, refinery residues, petroleum coke, biomass, lignocellulosic material, black liquor, municipal solid waste, municipal liquid waste, industrial solid waste, industrial liquid waste, refuse derived fuel, sewerage, sewerage sludge, sludge from wastewater treatment, landfill gas, biogas, tires including end of life tires, unsorted landfill waste, sorted landfill waste, plastics, fibers, microbial biomass, waste wood, agriculture waste, forest waste, or any combination thereof.
A portion of the syngas stream is passed to a gas fermentation process comprising a bioreactor containing a C1-fixing microorganism in a liquid nutrient medium. The fermentation produces at least one alcohol fermentation product, including embodiments grounded in a C1-fixing microorganism selected from specified microorganisms and including embodiments characterized by an acetogenic carboxydotrophic microorganism.
The at least one char byproduct and the at least one fermentation product are provided to a downstream operation to produce a tire. The disclosed integration further includes byproduct-specific handling in which gasification byproducts and fermentation products are delivered to downstream manufacturing, including embodiments that refine byproduct preparation for tire production, with additional refinements directed to zinc/zinc oxide byproducts and processing char to carbon black.
Claims Coverage
The document provides one independent claim with a three-part integrated workflow: gasification to generate raw syngas steam with carbon monoxide and carbon dioxide and a char byproduct from specified feedstocks, gas fermentation in a bioreactor with a C1-fixing microorganism in a liquid nutrient medium to produce at least one alcohol fermentation product, and providing the char byproduct and fermentation product to a downstream operation to produce a tire. Dependent claims refine the microorganism selection, byproduct characteristics, and additional byproduct and char processing before tire production.
Integrated gasification-to-gas fermentation workflow for tire production
processing at least one of the listed feedstocks in a gasification process to produce a raw syngas steam comprising at least carbon monoxide and carbon dioxide, and to produce char byproduct; passing at least a portion of the syngas stream to a gas fermentation process comprising a bioreactor containing a C1-fixing microorganism in a liquid nutrient medium to produce at least one alcohol fermentation product; and providing the at least one byproduct and the at least one fermentation product to a downstream operation to produce a tire.
C1-fixing microorganism selection in the fermentation bioreactor
the microorganism is selected from the specified C1-fixing microorganism set.
Acetogenic carboxydotrophic C1-fixing microorganism
the C1-fixing microorganism is an acetogenic carboxydotrophic microorganism.
Char byproduct processed to carbon black before tire production
processing the char byproduct to generate carbon black prior to being provided for use in the downstream operation to produce a tire.
Zinc-containing metal or metal oxide byproduct from gasification
the gasification process produces a second byproduct that is a metal or metal oxide comprising zinc.
Multiple gasification byproducts delivered to same or different downstream steps
the gasification process produces two or more byproducts and supplying the two or more byproducts to the same or different steps of a downstream operation to produce a tire.
Overall claim coverage centers on integrating gasification of diverse waste and carbon-containing feedstocks into raw syngas steam plus a char byproduct, fermenting at least a portion of the syngas using a C1-fixing microorganism in a liquid nutrient medium to form at least one alcohol fermentation product, and delivering both the char byproduct and fermentation product to a downstream operation to produce a tire, with dependent claims narrowing microorganism type, specifying zinc-containing byproducts, and optionally refining char to carbon black and routing multiple byproducts to downstream steps.
Stated Advantages
Documented Applications
Producing a tire using at least one char byproduct and at least one alcohol fermentation product from the integrated gasification and gas fermentation workflow.
Producing a tire with feedstocks including tires including end of life tires and other waste-derived materials, including municipal solid waste, municipal liquid waste, industrial solid waste, industrial liquid waste, refuse derived fuel, landfill gas, biogas, unsorted landfill waste, sorted landfill waste, and plastics.
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