Single loop multistage fuel production

Abstract

Synthetic fuels are produced from synthesis gas in a four-stage reactor system with a single recycle loop providing the requisite thermal capacity to moderate the high heat release of the reactions and to provide the reactants and reaction environments for the efficient operation of the process. The first reactor converts a portion of the synthesis gas to methanol; the second reactor converts the methanol to dimethylether; the third reactor converts the methanol and dimethylether to fuel; and the fourth reactor converts the high melting point component, durene, and other low volatility aromatic components such as tri- and tetra-methylbenzenes to high octane branched paraffins. A large part of the gas stream of the fourth reactor is recycled to the inlet of the first stage and mixed with the fresh synthesis gas stream. Alternatively, the fresh synthetic gas stream is mixed with the product of the second stage.