Technology & Process Description

The PEFI System converts synthesis gas into a mix of higher alcohols trade named Ecalene(tm). PEFI uses a syngas H2/CO input ratio of 0.9/1.0 (by volume) in producing the Ecalene(tm) composition shown in Table 1.

An Ecalene(tm) plant incorporates two primary technologies as shown in Figure 1. The first technology, gasification, converts carbon-based feedstock into syngas under high temperatures and pressure. The second technology is a catalytic conversion of syngas into Ecalene(tm). Figure 1 shows both processes for a typical Waste-to-Ecalene(tm) processing facility.

As shown in the diagram, the gasifier converts waste or other feedstocks into syngas. Heat is recovered from the hot syngas as steam and sent to a steam turbine which generates electricity, most of which is used internally. As an option, some of the syngas can be used to fire a gas turbine that generates additional electricity. The catalyst is located in the converter and Ecalene(tm) is produced.

Two patents have been issued to PECI (owner of the Ecalene(tm) patents issued to PEFI on an exclusive basis) covering seven claims of invention for the production of mixed alcohols from synthesis gas using nano-sized metal catalyst in slurry: US 6,248,796 B1 issued June 19, 2001 and US 6,753,353 B2 issued June 22, 2004.

The original discovery of this process was made and patented by Dow Chemical ("Dow") in the 1980's. Dow built and operated a demonstration plant for nine months but decided not to commercialize it due to low demand for ethanol in late eighties. The technology developed originally by Dow was called the "Sygmal Process."

PECI made significant improvements to the technology, and was awarded its own patents. Modeling and testing of the improved process was performed at bench scale at Brookhaven National Laboratory in Upton, NY and Western Research Institute in
Laramie, WY. The data from these tests confirmed the extreme selectivity to higher alcohols with an attractive product yield. The primary improvement is nano-sizing the catalyst during synthesis with a molybdenum sulfide material and operated
with the slurry bed reactor.

Key Benefits

The key differentiator for PECI's process is that it can use any feedstock containing carbon that can be gasified into syngas, including coal, coal fines, natural gas, petroleum coke (a byproduct of oil refining), used tires and any type of biomass including agricultural waste, sewage sludge and municipal solid waste ("MSW") or refuse derived fuel ("RDF"). The wide range of acceptable feedstock permit Ecalene(tm)plants to have local feedstock provided anywhere in the world.

Another key differentiator for the Ecalene(tm) process is the yields produced by various feedstock. The yield per/ton of feedstock used can range from between 100-130 gallons of fuel. Many competitive technologies produce less than half this quantity. Higher yields significantly reduce operating costs per unit of production.

Ecalene(tm)production requires no water, gas or electrical utilities for its production. Not only does the process not consume water, it actually produces water that can be provided for local consumption. While the plants do require electricity, they produce their own from processing the feedstock. Independence from water, gas and electrical utilities enable Ecalene(tm) plants to be profitably operated in remote locations with no utilities.

Better Than Fischer Tropsch

The long-standing Fischer-Tropsch (FT) process has been successfully producing diesel fuel for decades using a catalytic conversion process similar to PEFI's process. The Ecalene(tm) technology process however has several very significant advantages over the FT process:

The first major advantage is that the Ecalene(tm) uses a sulfided catalyst that is extremely tolerant of sulfur and H2S contaminants in the syngas stream. Sulfur poisoning is a major problem to catalysts in a number of other processes, particularly Fischer-Tropsch ("FT") syngas-to-diesel processes. FT processes require the removal of sulfur from the syngas prior to injection into the slurry reactor that adds considerable capital and operating cost.

The second major advantage is that the Ecalene(tm) catalyst is not prone to carbon buildup, which permits the use of synthesis gas with varied hydrogen to carbon monoxide ratios. The tolerance of the catalyst to sulfur and other impurities means that, for example, a plant could be designed to use raw coal and skip the "clean coal" steps that remove these impurities (and which generally add 33% to the cost). A mobile (sled, boat, offshore platform) plant could be designed to utilize stranded natural gas, including "sour natural gas" that contains too much corrosive sulfur to ship through pipelines.

Third, the FT process requires that the product leaving the catalytic conversion process must be further refined into various commercial products much like oil products are refined. The product leaving the Ecalene™ catalytic conversion process is finished product requiring only the removal of a small amount of water (if desired. Ecalene(tm) can be used as a stand-alone fuel (except for jet aircraft) with the trace amounts (less than 10%). Many engines actually perform better when the water is allowed to remain in the fuel.

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