Energy Integration, Inc.

Range Fuels, Inc.

William Bryan Schafer, Iii

Lynn Allen Crawford

Mitchell Mandich

Zachary Arthur Schafer

A method for starting up vapor-recompression units comprises: providing a vapor recompression sub-system comprising one or more vapor-recompression units, wherein the vapor recompression sub-system has a vapor inlet and a compressed-vapor outlet; providing a means of reducing vapor density through pressure reduction in vapor communication with the vapor recompression sub-system; reducing pressure within the vapor recompression sub-system to reach a sub-system pressure selected from 0.1 kPa to 1000 kPa; introducing a vapor mass flow to the vapor recompression sub-system at a restricted vapor mass flow rate; starting up the vapor recompression sub-system while maintaining the restricted vapor mass flow rate for a start-up time period; and then, following the start-up time period, introducing additional vapor mass flow to the vapor recompression sub-system to reach a full vapor mass flow rate. The restricted vapor mass flow rate is from 0.1% to 90% of the full vapor mass flow rate.

Methods and systems for starting up and operating one or more vapor-recompression units

The present invention utilizes mechanical vapor compression and/or thermal vapor compression integrating compression loops across multiple process stages. A sequential network of compressors is utilized to increase the pressure and condensing temperature of the vapors within each process stage, as intra-vapor flow, and branching between process stages, as inter-vapor flow. Because the vapors available are shared among and between compressor stages, the number of compressors can be reduced, improving economics. Balancing vapor mass flow through incremental compressor stages which traverse multiple process stages by splitting vapors between compressor stages enables the overall vapor-compression system to be tailored to individual process energy requirements and to accommodate dynamic fluctuations in process conditions.

Methods and systems for optimizing mechanical vapor compression and/or thermal vapor compression within multiple-stage processes

Processes and systems are provided to compress vapors produced in distillation and recover the heat of condensation through vapor compression and to derive mechanical, thermal, and electrical energy from a combined heat and power system, while maintaining the plant's original ability to operate. The plant's existing distillation system, steam generation, and electrical demand determine the design basis for the retrofit system that is targeted at an optimized combination of energy usage, energy cost, and environmental impact. Vapor compression (by mechanical vapor recompression and/or thermal vapor recompression) minimizes the total energy usage. Optionally, combined heat and power provides a means of converting energy between fuel, electricity, and thermal energy in a manner that best complements plant requirements and energy economics and minimizes inefficiencies and energy losses.

Enhancing a biorefinery with an optional vapor recompression unit while maintaining the ability to operate without the vapor recompression unit

Energy-efficient systems including vapor compression for biofuel or biochemical plants

This disclosure provides systems and methods that utilize integrated mechanical vapor or thermal vapor compression to upgrade process vapors and condense them to recover the heat of condensation across multiple processes, wherein the total process energy is reduced. Existing processes that are unable to recover the heat of condensation in vapors are integrated with mechanical or thermal compressors that raise vapor pressures and temperatures sufficient to permit reuse. Integrating multiple processes permits vapor upgrading that can selectively optimize energy efficiency, environmental sustainability, process economics, or a prioritized blend of such goals. Mechanical or thermal vapor compression also alters the type of energy required in industrial processes, favoring electro-mechanical energy which can be supplied from low-carbon, renewable sources rather than combustion of carbonaceous fuels.

Methods and systems for electrifying, decarbonizing, and reducing energy demand and process carbon intensity in industrial processes via integrated vapor compression

A method is disclosed for improving the energy efficiency of biorefinery drying operations through integration of a dryer that utilizes the heat of condensation of process vapors to dry material whose emissions are captured with energy recovery. The dryer separates clean process vapors (e.g., ethanol) and steam from vapors containing volatile organic compounds and entrained materials, to minimize the need for vapor cleanup. An indirect dryer condenses vapors in a tube dryer similar to a steam tube dryer, but utilizing compressed process vapors, transferring the heat to wet material undergoing drying. The resulting exhaust vapors are either directed to a process stage that requires heat (e.g., distillation) and minimizes the need for vapor cleanup or to an out-of-contact heat exchanger that produces vapors for process use, or to another dryer as an additional effect. Mechanical-vapor recompression or thermal-vapor recompression are employed to produce vapors that optimize overall energy recovery.

Methods and systems for energy-efficient drying of co-products in biorefineries

Systems and methods are disclosed for optimizing the process energy required for the conversion of carbon dioxide (CO) to biochemicals through vapor compression. Mechanical or thermal vapor compression are used to minimize both the process energy and the cooling in condensers, integrating the heat required by those processes and reusing heat that is typically lost. Some variations provide a process for producing biochemicals from biomass, comprising: cooking biomass to release saccharides; fermenting the saccharides to generate a biochemical in aqueous solution, and carbon dioxide; hydrogenating the carbon dioxide with a hydrogen source to generate an additional quantity of biochemical; feeding the fermentation-derived biochemical, as well as the CO-derived biochemical, to a distillation column for purification; and compressing vapors from the distillation column, using mechanical vapor recompression and/or thermal vapor recompression, to recover heat of distillation that is utilized elsewhere in the biorefinery to reduce overall process energy usage.

Systems and methods for integrated COreuse using vapor compression

Processes and systems are provided to compress vapors produced in distillation and recover the heat of condensation through mechanical vapor compression and to derive mechanical and electrical energy from a combined heat and power system, while maintaining the plant's original ability to operate. The plant's existing distillation system, steam generation, and electrical demand determine the design basis for the retrofit system that is targeted at an optimized combination of energy usage, energy cost, and environmental impact. Mechanical vapor compression minimizes the total energy usage. Combined heat and power provides a means of converting energy between fuel, electricity, and thermal energy in a manner that best complements plant requirements and energy economics and minimizes inefficiencies and energy losses.

Energy-efficient systems including combined heat and power and mechanical vapor compression for biofuel or biochemical plants

Energy-efficient systems including mechanical vapor compression for biofuel or biochemical plants

The present invention provides modular and distributed methods and systems to convert biomass feedstocks into synthesis gas (syngas). The syngas can then be turned into liquid chemicals and fuels such as ethanol. The modular units of the invention bring the conversion process to the biomass source, thereby minimizing feedstock transportation costs. The modules are capable of being connected to, and/or disconnected from, each other to easily adjust the overall feedstock capacity. The present invention also provides methods and systems to determine an optimal number and distribution of modular conversion units spatially located within a region of land. The disclosed methods and systems are flexible, efficient, scalable, and are capable of being cost-effective at any commercial scale of operation.

Growing community of inventors

Boulder, CO, United States of America

William Bryan Schafer, Iii