Production of synthetic fuels using syngas from a steam hydrogasification and reforming process

This thesis is aimed at the research, optimization and development of a thermo-chemical process aimed at the production of synthesis gas (mixture of H2 and CO) with a flexible H2 to CO ratio using coupled steam hydrogasification and steam reforming processes. The steam hydrogasification step generates a product gas containing significant amounts of methane by gasifying a carbonaceous feed material with steam and internally generated H2. This product gas is converted to synthesis gas with an excess H2 to CO using the steam reformer. Research involving experimental and simulation work has been conducted on steam hydrogasification, steam reforming and the Fischer-Tropsch reaction. The Aspen Plus simulation tool has been used to develop a process model that can perform heat and mass balance calculations of the whole process using built-in reactor modules and an empirical FT model available in the literature. This model has been used to estimate optimum feed ratios and process conditions for specific feedstocks and products. Steam hydrogasification of coal and wood mixtures of varying coal to wood ratios has been performed in a stirred batch reactor. The carbon conversion of the feedstocks to gaseous products is around 60% at 700°C and 80% at 800°C. The coal to wood ratio of the feedstock does not exert a significant influence on the carbon conversion. The rates of formation of CO, CO 2 and CH4 during gasification have been calculated based on the experimental results using a simple kinetic model. Experimental research on steam reforming has been performed. It has been shown that temperature and the feed CO2/CH4 ratio play a dominant role in determining the product gas H2/CO ratio. Reforming of typical steam hydrogasification product-gas stream has been investigated over a commercial steam reforming catalyst. The results demonstrate that the combined use of steam hydrogasification process with a reformer can generate a synthesis gas with a predetermined H2/CO ratio from carbonaceous feedstocks. Experimental work on the Fischer-Tropsch synthesis has also been performed. A life cycle analysis has been performed with the objective of comparing the life cycle energy consumption and emissions of synthetic diesel fuel produced through the CE-CERT process with other fuel/vehicle combinations. The experimental and simulation results presented here demonstrate that the CE-CERT process is versatile and can potentially handle a number of different feedstocks. CE-CERT process appears to be suitable for commercialization in very large scales with a coal feedstock and also in a distributed network of smaller scale reactors utilizing localized renewable feedstocks.