Technical field
[0001] The present invention relates to a method for producing synthetic gas from hemp.
Technical background
[0002] Many current approaches to energy are unsustainable and non-renewable. Today, the
world's energy supply is largely based on fossil fuels. These sources of energy will
not last forever and have proven to be contributors to our environmental problems
and the world cannot indefinitely continue to base its life on the consumption of
finite energy resources.
[0003] Renewable energy and the use of biomass in energy production promotes sustainable
development and decreases the use of fossil fuels. Among renewable energy sources,
biomass has the lowest risk and capital required to be used in energy generation because
of its abundance, renewability, and significant environmental benefits since it is
considered as CO
2-neutral fuel which also contributes to the reduction of SO
x and NO
x emissions. Biomass such as wood chips can be used in the production of heat and electricity,
and as a biofuel component and novel product for the chemical industry.
[0004] Nowadays hemp has become very important as a crop for biomass production, which can
be used for example in energy production. More particularly, hemp is considered as
promising energy crop mainly owing to its rapid growth rate and high biomass and energy
yields. Hemp biomass may be used for energy purposes in different ways: by burning
(co-fired with coal to reduce emissions and offset a fraction of coal use; burned
to produce electricity; pelletized to heat structures; made or cut into logs for heating;
gasification), as oils (vegetable, seed and plant oil used "as-is" in diesel engines;
biodiesel - vegetable oil converted by chemical reaction; converted into high-quality
nontoxic lubricants), by conversion of cellulose to alcohol.
[0005] Among other applications, biomass has also been used to produce synthetic gas.
[0006] However, the presence of minerals and other components in the biomass, lead to different
by-products in the final product (synthetic gas for example) such as tar, biochar
and hydrogen sulfide, which could thus lead to products with low purity and low yield.
[0007] Among different types of biomass, hemp crops have also been used to produce synthetic
gas.
[0010] Document
WO 2020/198477 relates to methods for processing cannabis and hemp so as to improve the recovery
of high-value cannabis components and methods for utilizing residual biomass components
after the cannabis plant has been fully processed.
[0011] Document
WO 2013/056269 relates to different uses of cannabis sativa plant such as creation of bio-fuel,
paper, food, consumer textiles, building materials, personal hygiene products and
others.
[0013] There is still a need for a method that makes it possible to efficiently produce
highly pure synthetic gas with a high yield.
Summary of the invention
[0014] It is an object of the invention to provide a method for producing synthetic gas
from hemp material, the hemp material being obtained from hemp harvested at or after
full bloom, and the method comprising subjecting at least part of the hemp material
to a pyro-gasification step.
[0015] In some variations, the hemp is harvested at a sunshine duration of at least 700
hours, preferably at least 750 hours and more preferably at least 800 hours.
[0016] In some variations, the hemp material comprises or is hemp stalk.
[0017] In some variations, the hemp material has a cellulose content of at least 40 % dry
matter by weight relative to the weight of the hemp.
[0018] In some variations, the hemp material has a content in lignin equal to or lower than
15 % dry matter by weight relative to the weight of the hemp.
[0019] In some variations, the pyro-gasification step is carried out at a temperature equal
to or higher than 850°C, preferably equal to or higher than 900°C, and preferably
equal to or higher than 1000°C, more preferably equal to or higher than 1100°C, and
even more preferably equal to or higher than 1200°C.
[0020] In some variations, the pyro-gasification step is carried out in the presence of
a carrier gas, preferably selected from nitrogen and/or carbon dioxide.
[0021] In some variations, the hemp material is subjected to from one to three grinding
steps, and more preferably three grinding steps, prior to the pyro-gasification step.
[0022] In some variations, the hemp material undergoing the pyro-gasification step is in
the form of particles having a size from 100 to 400 µm, and preferably from 150 to
250 µm.
[0023] In some variations, the method further comprises subjecting the synthetic gas to
a filtration step after the pyro-gasification step.
[0024] In some variations, the synthetic gas comprises carbon monoxide in a content from
10 to 60 %, and preferably from 20 to 40 % by volume relative to the volume of the
synthetic gas.
[0025] In some variations, the synthetic gas comprises hydrogen in a content from 30 to
80 %, and preferably from 35 to 60 % by volume relative to the volume of the synthetic
gas.
[0026] In some variations, the synthetic gas comprises methane in a content from 0.5 to
20 %, and preferably from 2 to 10 % by volume relative to the volume of the synthetic
gas.
[0027] In some variations, the synthetic gas comprises hydrogen sulfide in a content equal
to or lower than 180 mg/m
3, preferably in a content equal to or lower than 100 mg/m
3, more preferably is substantially devoid of hydrogen sulfide.
[0028] The present invention addresses the need mentioned above. In particular the invention
provides a method that makes it possible to efficiently produce highly pure synthetic
gas with a high yield.
[0029] This is achieved by the method according to the present invention. More particularly,
this is achieved by a method wherein the hemp is harvested at or after full bloom.
In fact, it has been found that when the hemp is harvested at or after full bloom,
the performance of the pyro-gasification process is optimized. In particular, the
higher calorific value of the synthetic gas is high, and the amount of ash in the
hemp is low, which implies that a lesser content of impurities is generated in the
synthetic gas.
Detailed description
[0030] The invention will now be described in more detail without limitation in the following
description.
[0031] The method according to the invention makes it possible to produce synthetic gas
from hemp having a high yield and high purity.
[0032] By
"synthetic gas" or
"syngas" is meant a fuel gas mixture comprising, and preferably consisting essentially of
hydrogen, carbon monoxide, carbon dioxide and methane.
[0033] The term
"industrial hemp" or
"hemp" refers to varieties of
Cannabis sativa. Preferably, said hemp is characterized by low levels of tetrahydrocannabinol (THC),
grown for specific industrial, health, and food outcomes.
[0034] The hemp used in the method according to the present invention is harvested at or
after full bloom.
"Full bloom" should be distinguished from bloom and end of bloom:
- Bloom: this is the point in time when the stigma appears.
- Full bloom: this is the point in time when the last female flowers open on the apex.
- End of bloom: this is the point in time when the last female flowers are fertilized.
At this point, the plant ceases to grow.
[0035] The end of bloom generally occurs approximately one week after full bloom. In some
embodiments, the hemp used in the method according to the invention is harvested at
or after the end of bloom.
[0036] This determination is made on individual plants. Each of the above stages is considered
as reached by the crop when 85% of the plants in the crop are at or past this stage.
Male flowers and male plants if present are not taken into account.
[0037] The date of full bloom depends on a number of factors, among which the date of seeding
of the crop, the crop variety, the photoperiod, and the weather conditions to which
the crop is subjected, and in particular temperature and sunshine duration.
[0038] The
"sunshine duration" is defined as the sum of the periods for which the direct solar irradiance on the
crops exceeds 120 W.m
-2. The starting point for measuring the sunshine duration is seeding. The sunshine
duration is measured according to the standard ISO 9488 : 1999.
[0039] In some embodiments, the hemp used in the method according to the invention is harvested
at a sunshine duration of at least 700 hours, preferably at least 750 hours, more
preferably at least 800 hours. In some variations, it may be harvested at a sunshine
duration from 700 to 1300 hours. For example, the sunshine duration may be from 700
to 750 hours, or from 750 to 800 hours, or from 800 to 850 hours, or from 850 to 900
hours, or from 900 to 950 hours, or from 950 to 1000 hours, or from 1000 to 1050 hours,
or from 1050 to 1100 hours, or from 1100 to 1150 hours, or from 1150 to 1200 hours,
or from 1250 to 1300 hours.
[0040] Preferably, the hemp is harvested when the moisture content of the hemp is 15% by
weight or lower. It is conventional in hemp culture to ret the hemp on the field,
after cutting, in order to facilitate the obtention of high quality fibers. However,
retting is not necessary for the present method, and is thus preferably not carried
out.
[0041] More generally, in the present method, the hemp may be collected sooner than in conventional
hemp culture. This is advantageous in terms of soil management.
[0042] According to some embodiments, the entire harvested hemp is used to produce synthetic
gas. In other words, the stalk, the flowers and the leaves are used to produce synthetic
gas.
[0043] According to other preferred embodiments, the flowers and leaves are separated from
the stalk prior to carrying out the method according to the invention. Thus, in this
case, only the stalk is used to produce the synthetic gas. This is advantageous, as
the majority of the cellulose in the hemp is found in the stalk. Besides, hemp flowers
and leaves may be used for other industrial purposes. The term
"hemp material" designates herein the part of the hemp used for carrying out the method.
[0044] The hemp material used in the method for producing synthetic gas may have a content
in cellulose of at least 40 % dry matter by weight relative to the weight of the hemp.
[0045] For example, this cellulose content may be from 40 to 45 %; or from 45 to 50 %; or
from 50 to 55 %; or from 55 to 60 %; or from 60 to 65 %; or from 65 to 70 %; or from
70 to 75 %; or from 75 to 80 %; or higher than 80 % by weight relative to the weight
of the hemp material. The cellulose content may be measured by using the standard
NF V18-122.
[0046] The hemp material used in the method for producing synthetic gas may have a content
in lignin equal to or lower than 15 % dry matter by weight relative to the weight
of the hemp.
[0047] The hemp material may have a content in hemi-cellulose equal to or lower than 20
% by weight relative to the weight of the hemp.
[0048] The cellulose content in the hemp material is desirably as high as possible. After
a certain point, the transformation of a significant part of the cellulose in jemp
into hemicellulose then lignin occurs. Lignin is responsible for the production of
by-products such as different aromatic compounds and tar. Thus, harvesting the hemp
before allows to maximize the cellulose content and thus minimize the lignin content,
which makes it possible to provide high-yield synthetic gas and to reduce or even
avoid the formation of by-products such as tar, soot and biochar. Harvesting the hemp
at the above specific moment also allows to obtain high-yield synthetic gas with reduced
amounts (or even devoid) of sulfur compounds such as hydrogen sulfide.
[0049] According to some embodiments, the hemp material may have a content in minerals (ashes)
from 1 to 15 %, and preferably from 1.5 to 10 % by weight relative to the weight of
the hemp material. This content is measured by calcining the hemp material and by
measuring the resulting weight (as all carbon components have been transformed to
gas). Examples of minerals may include calcium, potassium, iron, silicon and heavy
metals (in trace amounts) such as lead.
[0050] After the harvest, the hemp material may be dried in order to achieve at least 80
% of dry matter, and preferably at least 85 % of dry matter. Drying may be carried
out by leaving the hemp material under sunlight for a suitable duration. This step
makes it possible to avoid fermentation and self-combustion of the hemp.
[0051] According to some embodiments, after the harvest and optionally the drying, the hemp
material may be pressed and stored for further use.
[0052] Alternatively or additionally, one or more grinding steps may be carried out in order
to reduce the size of the hemp material. Preferably, the method according to the invention
may comprise from one to three grinding steps, and more preferably three grinding
steps. The purpose of such steps is to reduce the size of the hemp material, preferably
in order to form hemp particles prior to subjecting said hemp particles to pyro-gasification.
[0053] For example, a first step of grinding may be carried out in order to reduce the size,
notably the length, of the hemp material from a few dozen centimeters to a few millimeters.
[0054] At the end of this step, the (number) average length of the hemp material may be
from 5 to 60 mm, preferably from 10 to 40 mm, and more preferably from 15 to 30 mm.
This step may be carried out in a shredder with a cooled rotor.
[0055] The hemp material may then be dried in order to achieve at least 90 % of dry matter,
and preferably at least 95 % of dry matter. Drying may be carried out in a rotative
furnace with air flow.
[0056] According to some embodiments, during this drying step, different undesired elements
(such as minerals, rock fragments, metallic elements) may be removed.
[0057] According to some embodiments, a second step of grinding may be carried out in order
to further reduce the size, notably the length, of the hemp material from the above
size range to few millimeters. At the end of this step, the (number) average length
of the hemp particles may be from 1 mm to 2 cm, preferably from 1 to 1 cm, and more
preferably from 2 to 7 mm. The grinding can be carried out either with a knife / counter-knife
mill or by a hammer mill. These apparatuses may preferably be equipped with a sieve
screen which can be of different shape but calibrated to the desired size (for example
less than 4 mm, or less than 1 mm, etc.)
[0058] According to some embodiments, the method according to the invention may further
comprise a step comprising passing the hemp particles through an inert atmosphere.
Such inert atmosphere may be for example a gas chosen from air, nitrogen, and carbon
dioxide.
[0059] According to some embodiments, a third grinding step (or micronization step) may
be carried out. This makes it possible to obtain an ideal size of the hemp particles
prior to transforming hemp into synthetic gas. In fact, an ideal size makes it possible
to maximize the reaction kinetics of the generation of synthetic gas. Thus, at the
end of this step the size of the hemp particles may be from 100 to 400 µm, and preferably
from 150 to 250 µm. For example, this size may be from 100 to 150 µm; or from 150
to 200 µm; or from 200 to 250 µm; or from 250 to 300 µm or from 300 to 350 µm; or
from 350 to 400 µm. In this case, by
"size" is meant the median diameter (Dv50) of the hemp particles according to a volume-based
particle distribution.
[0060] The hemp particles are then subjected to a pyro-gasification step.
[0061] By
"pyro-gasification step" is meant a step which combines pyrolysis at a very high temperature and gasification,
i.e. the transformation of the organic material in the hemp material into one or more
gases. Such step may be carried out in a chamber, such as an oven.
[0062] The pyro-gasification step may be carried out at a temperature equal to or higher
than 850°C, preferably equal to or higher than 900°C, preferably equal to or higher
than 1000°C, more preferably equal to or higher than 1100°C, and even more preferably
equal to or higher than 1200°C. A particularly preferred range of temperature is from
950 to 1080°C.
[0063] During this step, a carrier gas may be used to transfer the hemp material into the
heated chamber. Such carrier gas may be for example nitrogen or carbon dioxide or
a mixture comprising nitrogen and carbon dioxide (for example comprising from 10 mol.%
nitrogen and 90 mol.% carbon dioxide to 90 mol.% nitrogen and 10 mol.% carbon dioxide).
Alternatively, water vapor can also be employed (optionally in combination with nitrogen
and/or carbon dioxide).
[0064] The residence time of the hemp particles in the heated chamber may be from 0.5 seconds
to 2 hours depending on the type of the pyro-gasification step.
[0065] The desired humidity may be achieved by injecting steam water into the heating chamber.
In some variations, the relative humidity may be at least 80 %, preferably of at least
85 %, more preferably of at least 90 %; and even more preferably of at least 95 %.
[0066] According to some preferred embodiments, the pyro-gasification step is a continuous
step. In other words, the hemp material is continuously introduced at an inlet of
the heated chamber and thus gas is continuously produced at the outlet of the heated
chamber. In this case, the chamber may be heated for example at a temperature equal
to or higher than 950°C such as from 950 to 1200°C.
[0067] According to some embodiments, during a continuous pyro-gasification step, the residence
time of the hemp material in the heated chamber may be from 0.5 to 10 seconds, and
preferably from 1 to 5 seconds.
[0068] According to other embodiments, during a continuous pyro-gasification step, the residence
time of the hemp material in the heated chamber may be from 30 to 120 minutes, and
preferably from 60 to 90 minutes.
[0069] In this case, water may be injected in a continuous manner in a hemp/water weight
ratio from 2/1 to 1/2, preferably of approximately 1/1.
[0070] At the end of the pyro-gasification step, the produced synthetic gas may exit the
heated chamber at atmospheric pressure and at a temperature from 300 to 800°C, and
at a temperature from 300 to 400°C, and more preferably from 350 to 380°C.
[0071] The synthetic gas obtained by the method according to the invention may comprise
carbon monoxide in a content from 10 to 60 %, preferably from 20 to 40 % and more
preferably from 12 to 24 % by volume relative to the volume of the synthetic gas.
[0072] Furthermore, this gas may comprise hydrogen in a content from 30 to 80 %, and preferably
from 33 to 60 % by volume relative to the volume of the synthetic gas.
[0073] In addition, the synthetic gas may comprise methane in a content from 0.5 to 20 %,
and preferably from 2 to 10 % by volume relative to the volume of the synthetic gas.
[0074] In addition, the synthetic gas may comprise water in a content from 0.5 to 35 %,
and preferably from 5 to 30 % by volume relative to the volume of the synthetic gas.
[0075] In addition, the synthetic gas may comprise carbon dioxide in a content from 0.5
to 20 %, and preferably from 5 to 20 % by volume relative to the volume of the synthetic
gas.
[0076] According to some embodiments, the synthetic gas may comprise hydrogen sulfide (H
2S) in a content equal to or lower than 180 mg/m
3. The H
2S content may be 100 mg/m
3 or lower, or 50 mg/m
3 or lower, or 10 mg/m
3 or lower. In some embodiments, the synthetic gas is substantially (or completely)
devoid of H
2S. In some embodiments, the amount of H
2S may be at least 1 mg/m
3 or at least 10 mg/m
3.
[0077] The synthetic gas may also have a content in other sulfur compounds in a content
equal to or lower than 300 mg/m
3
[0078] According to some embodiments, the synthetic gas may comprise tar in a content equal
to or lower than 400 mg/m
3.
[0079] According to some embodiments, the synthetic gas may comprise dust (particles having
an average diameter from 0.5 to 10 µm) in a content equal to or lower than 6500 mg/m
3.
[0080] According to some embodiments, the synthetic gas may comprise ammonia (NH
3) in a content equal to or lower than 1030 mg/m
3.
[0081] According to some embodiments, the synthetic gas may comprise hydrogen chloride (HCI)
in a content equal to or lower than 8 mg/m
3.
[0082] According to some embodiments, the synthetic gas may comprise hydrogen cyanide (HCN)
in a content equal to or lower than 200 mg/m
3.
[0083] According to some embodiments, the synthetic gas may comprise volatile organic compounds
(COV) in a content equal to or lower than 45 g/m
3.
[0084] According to some embodiments, the synthetic gas may comprise nitrogen oxides (NOx)
in a content equal to or lower than 5 mg/m
3.
[0085] According to some embodiments, the synthetic gas may comprise nitrous oxides (N
2O) in a content equal to or lower than 600 mg/m
3.
[0086] The above concentration ranges of carbon monoxide, hydrogen, methane, water, carbon
dioxide and various impurities (H
2S, etc.) relate to the synthetic gas obtained from the pyro-gasification step, before
any optional purification (e.g. filtration) step as described below. Besides, these
ranges are calculated by deducting the contribution from the carrier gas (which can
be for example nitrogen or a combination of nitrogen and carbon dioxide) in the synthetic
gas.
[0087] According to some embodiments, the process may create ashes in a content equal to
or lower than 5% in weight. These ashes may have a content in carbon (biochar) equal
to or lower than 3% in weight.
[0088] The method according to the present invention makes it possible to obtain a high-purity
synthetic gas comprising reduced amounts of by-products, or even being devoid of such
by-products. This makes it possible to reduce significantly the number of additional
purification steps and as a result to reduce the costs related to any purification
process.
[0089] The method according to the present invention may further comprise a filtration step
after the pyro-gasification step. The filtration may be carried out for example in
a cyclone filter, a bag filter or an electrostatic filter.
[0090] The purpose of this step is to remove certain by-products present in the synthetic
gas. Such by-products may be sulfur oxides (SO
x) such as sulfur dioxide (SO
2), nitrogen oxides (NO
x) such as nitrogen monoxide (NO) and nitrogen dioxide (NO
2), nitrous oxide (N
2O), hydrogen sulfide (H
2S) soot, biochar, tar (EPA-PAH), ammonia (NH
3), hydrogen cyanide (HCN), hydrogen chloride (HCI), volatile organic compounds (VOC),
mercury (Hg), and dust.
[0091] Depending on the desired use, the method according to the invention may further comprise
one or more steps in order to treat and/or separate the different components of the
synthetic gas.
[0092] The synthetic gas may for example be treated with a catalyst in order to transform
carbon monoxide to carbon dioxide.
[0093] According to some embodiments, the method comprises a step for separating hydrogen
from the rest of the components of the synthetic gas. The separated hydrogen may then
be used e.g. as a fuel.
[0094] According to some embodiments, the method comprises a step for separating methane
from the rest of the components of the synthetic gas.
[0095] According to some embodiments, the method comprises a step for separating carbon
monoxide from the rest of the components of the synthetic gas.
[0096] The method according to the present invention may further comprise a step of separating
the carbon dioxide formed after treatment of the synthetic gas with a catalyst (as
mentioned above) from the rest of the components of the treated synthetic gas.
Example
[0097] The following example illustrates the invention without limiting it.
[0098] Hemp was seeded at two growing sites A and B. Plant samples were harvested at various
dates and subjected to pyro-gasification. In most cases, and unless indicated otherwise,
the full plants were used. In one case, only the stalks were used.
[0099] The hemp material was ground to particles having a size ranging from 40 to 400 µm,
and a mode (size with highest frequency in a volume-based distribution) of approximately
150 µm. The pyro-gasification was carried out in a tubular oven heated at 1050°C.
The hemp material was fed to the oven with nitrogen as a carrier gas. The residence
time of the hemp material in the oven was approximately 1 second.
[0100] The cellulose content, lignin content and ash content were determined on the hemp
material. The Van Soest method was used for determining the cellulose and lignin content.
[0101] The produced synthetic gas was analyzed for its content in carbon monoxide, carbon
dioxide, methane and hydrogen by gas phase chromatography. No H
2S was detected in the produced synthetic gas (the limit of detection being 0.1 ppm).
The higher calorific value (HCV) of the synthetic gas was also determined using a
calorimeter.
[0102] The results are presented in the tables below. For both tested crops, the full bloom
took place at approximately 800 hours of sunshine duration. The lines of the tables
shaded in gray thus correspond to samples harvested before full bloom.
Characterization of the hemp material:
[0103]

Characterization of the synthetic gas:
[0104]

[0105] It can readily be seen that the synthetic gas produced from hemp harvested at or
after full bloom has a reliably high calorific value. Besides, the ash content in
the hemp material is reliably low, ensuring a relatively low level of impurities in
the synthetic gas.
[0106] It should be noted that the contribution of the carrier gas N
2 has not been deducted from the composition of the synthetic gas in the above table.
1. A method for producing synthetic gas from hemp material, the hemp material being obtained
from hemp harvested at or after full bloom, and the method comprising subjecting at
least part of the hemp material to a pyro-gasification step.
2. The method according to claim 1, wherein the hemp is harvested at a sunshine duration
of at least 700 hours, preferably at least 750 hours and more preferably at least
800 hours.
3. The method according to claim 1 or 2, wherein the hemp material comprises or is hemp
stalk.
4. The method according to claim 3, wherein the hemp material has a cellulose content
of at least 40 % dry matter by weight relative to the weight of the hemp.
5. The method according to claim 3 or 4, wherein the hemp material has a content in lignin
equal to or lower than 15 % dry matter by weight relative to the weight of the hemp.
6. The method according to any one of claims 1 to 5, wherein the pyro-gasification step
is carried out at a temperature equal to or higher than 850°C, preferably equal to
or higher than 900°C, and preferably equal to or higher than 1000°C, more preferably
equal to or higher than 1100°C, and even more preferably equal to or higher than 1200°C.
7. The method according to any one of claims 1 to 6, wherein the pyro-gasification step
is carried out in the presence of a carrier gas, preferably selected from nitrogen
and/or carbon dioxide.
8. The method according to any one of claims 1 to 7, wherein the hemp material is subjected
to from one to three grinding steps, and more preferably three grinding steps, prior
to the pyro-gasification step.
9. The method according to any one of claims 1 to 8, wherein the hemp material undergoing
the pyro-gasification step is in the form of particles having a size from 100 to 400
µm, and preferably from 150 to 250 µm.
10. The method according to any one of claims 1 to 9, further comprising subjecting the
synthetic gas to a filtration step after the pyro-gasification step.
11. The method according to any one of claims 1 to 10, wherein the synthetic gas comprises
carbon monoxide in a content from 10 to 60 %, and preferably from 20 to 40 % by volume
relative to the volume of the synthetic gas.
12. The method according to any one of claims 1 to 11, wherein the synthetic gas comprises
hydrogen in a content from 30 to 80 %, and preferably from 35 to 60 % by volume relative
to the volume of the synthetic gas.
13. The method according to any one of claims 1 to 12, wherein the synthetic gas comprises
methane in a content from 0.5 to 20 %, and preferably from 2 to 10 % by volume relative
to the volume of the synthetic gas.
14. The method according to any one of claims 1 to 13, wherein the synthetic gas comprises
hydrogen sulfide in a content equal to or lower than 180 mg/m3, preferably in a content equal to or lower than 100 mg/m3, more preferably is substantially devoid of hydrogen sulfide.