Integrated gas fermentation and carbon black processes
Inventors
Holmgren, Jennifer Rosa • Arakawa, Steven Tadashi • Rollag, Sean Alex • Rosin, Richard Russell • Schulz, Taylor Craig
Assignees
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Publication Number
US-12359224-B2
Publication Date
2025-07-15
Expiration Date
Abstract
Integrated process for providing raw materials to a downstream operation to generate an article of manufacture. A carbon black production process is integrated with a gas fermentation process, and a feedstock preparation process is integrated with gas fermentation process. Both carbon black and a gas fermentation product are provided to a downstream operation. Secondary products from the carbon black process may be used in the gas fermentation process. Byproducts from the feedstock preparation process may be provided to the downstream operation or may be passed to the carbon black process. In certain aspects, the fermentation product may be ethanol, isoprene, butane diol, and/or ethylene. In certain aspects, the byproduct may be metal, metal oxide, char, silica, and/or steel. In certain aspects, the secondary product may be hydrogen and/or carbon dioxide. The downstream operation may be to generate plastic products, rubber products, tires, textiles, clothes, and the like.
Core Innovation
The invention relates to an integrated process that combines a carbon black process with feedstock preparation and gas fermentation. A carbon black process feedstock is processed in a carbon black process to generate a carbon black stream and at least a first secondary product stream comprising carbon dioxide and/or hydrogen.
The process further includes processing at least one material comprising carbon atoms in a gasification process to produce a raw syngas steam comprising at least carbon monoxide and carbon dioxide and a first byproduct stream comprising a component selected from a metal, metal oxide, silica, steel, and/or char. At least a portion of the raw syngas stream and at least a portion of the first secondary product stream are passed to a gas fermentation process comprising a bioreactor containing a C1-fixing microorganism in a liquid nutrient medium.
The gas fermentation bioreactor produces at least one fermentation product. At least a portion of the carbon black stream and at least a portion of the at least one fermentation product are provided to a downstream operation to produce tires, and secondary products and byproducts are routed to the gas fermentation process and/or the downstream operation.
Claims Coverage
The claim set includes one independent claim that defines an integrated process with four main inventive elements: generating a carbon black stream and a carbon dioxide and/or hydrogen secondary product stream, gasifying carbon-atom material to form raw syngas and a selected byproduct stream, feeding the streams to a gas fermentation bioreactor containing a C1-fixing microorganism to produce fermentation products, and supplying the carbon black stream and fermentation products to a downstream operation to produce tires.
Integrated process for producing tires from carbon black, syngas, and C1 fermentation products
An integrated process comprising processing a carbon black process feedstock in a carbon black process to generate a carbon black stream and at least a first secondary product stream comprising carbon dioxide, hydrogen, or both; processing at least one material comprising carbon atoms in a gasification process to produce a raw syngas steam comprising at least carbon monoxide and carbon dioxide, and a first byproduct stream comprising a component selected from a metal, metal oxide, silica, steel, and/or char; passing at least a portion of the raw syngas stream and at least a portion of the first secondary product stream to a gas fermentation process comprising a bioreactor containing a C1-fixing microorganism in a liquid nutrient medium to produce at least one fermentation product; and providing the at least a portion of the carbon black stream and at least a portion of the at least one fermentation product to a downstream operation to produce tires.
Byproduct stream components provided to the downstream operation
The process where the byproduct streams comprise metal, metal oxide, silica, steel, and/or char, and at least a portion of any is provided to the downstream operation.
Sulfur or sulfur-containing component from secondary products
The process where the first secondary product stream further comprises sulfur or a sulfur containing component, and the process separates a sulfur or sulfur-containing component stream and provides it to the downstream operation.
Hydrogen-containing stream added with raw syngas
The process where the gas fermentation process receives and/or combines a hydrogen-containing stream with the raw syngas stream, where the hydrogen may be green.
Fermentation product selected as an alcohol
The process where the fermentation product is selected from an alcohol.
Acetogenic carboxydotrophic microorganism as the C1-fixing microorganism
The process where the C1-fixing microorganism is an acetogenic carboxydotrophic microorganism.
Overall, the claim coverage centers on an integrated workflow that links carbon black processing with gasification and gas fermentation to generate fermentation products that are supplied, together with the carbon black stream, to a downstream operation to produce tires. Dependent claims refine selected stream components, sulfur, hydrogen supply, fermentation product type, and microorganism type.
Stated Advantages
Documented Applications
Tire production using a downstream operation supplied with at least a portion of the carbon black stream and at least a portion of the fermentation product.
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