U.S. patent application number 16/791859 was filed with the patent office on 2020-06-11 for use of cooling media in biomass conversion process.
The applicant listed for this patent is INAERIS TECHNOLOGIES, LLC. Invention is credited to Bruce ADKINS, Lorenz J. BAUER, Ronald CORDLE, Richard A. ENGELMAN, J. Christopher LEWIS.
Application Number | 20200181500 16/791859 |
Document ID | / |
Family ID | 58387470 |
Filed Date | 2020-06-11 |
United States Patent
Application |
20200181500 |
Kind Code |
A1 |
ADKINS; Bruce ; et
al. |
June 11, 2020 |
USE OF COOLING MEDIA IN BIOMASS CONVERSION PROCESS
Abstract
Biomass is converted into a bio-oil containing stream in a riser
reactor containing a cooling media. The cooling media quenches the
rapid heat transfer to the biomass during cracking of the biomass
in the mixing zone of the riser. By lowering the temperature to
which the mixing zone effluent is exposed, production of carbon
monoxide and light gases is decreased during thermolysis of the
biomass.
Inventors: |
ADKINS; Bruce; (League City,
TX) ; BAUER; Lorenz J.; (Pasadena, TX) ;
CORDLE; Ronald; (League City, TX) ; ENGELMAN; Richard
A.; (Houston, TX) ; LEWIS; J. Christopher;
(Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INAERIS TECHNOLOGIES, LLC |
Pasadena |
TX |
US |
|
|
Family ID: |
58387470 |
Appl. No.: |
16/791859 |
Filed: |
February 14, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15763043 |
Mar 23, 2018 |
10563129 |
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PCT/US2016/053440 |
Sep 23, 2016 |
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16791859 |
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62233096 |
Sep 25, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C10G 1/002 20130101;
Y02E 50/30 20130101; C10G 2300/1014 20130101; C10G 2300/4081
20130101; C10G 1/02 20130101; Y02E 50/10 20130101; C10B 57/06
20130101; C10G 1/08 20130101; Y02P 30/20 20151101; C10G 2300/701
20130101; C10B 49/22 20130101; C10B 53/02 20130101; C10G 2300/4006
20130101; C10G 11/18 20130101 |
International
Class: |
C10G 1/08 20060101
C10G001/08; C10G 1/00 20060101 C10G001/00; C10B 57/06 20060101
C10B057/06; C10B 53/02 20060101 C10B053/02; C10B 49/22 20060101
C10B049/22; C10G 1/02 20060101 C10G001/02; C10G 11/18 20060101
C10G011/18 |
Claims
1. A process of subjecting solid biomass to thermolysis in a riser
reactor having a mixing zone and a zone upstream from the mixing
zone, the process comprising: (i) introducing a first solid
particulate heated to a temperature of T.sub.1 into the mixing zone
of the riser reactor; (ii) introducing solid biomass into the
mixing zone downstream from the first solid particulate; (iii)
mixing the solid biomass and the first solid particulate in the
mixing zone and reacting the solid biomass in the mixing zone to
render a mixing zone effluent; (iv) introducing the mixing zone
effluent into the zone upstream from the mixing zone, wherein the
temperature in the upstream zone is cooled by the addition of a
cooling media into the upstream zone, the cooling media comprising
a second solid particulate and/or a vaporizable liquid and the
cooling media having a temperature, T.sub.2, wherein T.sub.2 is
less than T.sub.1; and (v) subjecting the solid biomass to
fluidized catalytic thermolysis in the upstream zone.
2. The process of claim 1, wherein the first solid particulate is
sand.
3. The process of claim 1, wherein at least one of the following
conditions prevail: (a) the temperature in the mixing zone during
mixing is between from about 900.degree. F. to about 1350.degree.
F.; (b) T.sub.1 is from about 1100.degree. F. to about 1400.degree.
F. and T.sub.2 is from about 500.degree. F. to about 1100.degree.
F.; (c) the first solid particulate and the second solid
particulate are catalysts; (d) the first solid particulate and the
second solid particulate are of different sizes and/or density; (e)
the difference between T.sub.2 and T.sub.1 is about 50.degree. F.
to about 500.degree. F.; (f) the temperature in the mixing zone at
the time of introduction of biomass into the mixing zone is between
from about 900.degree. F. to about 1400.degree. F.; (g) the weight
ratio of the first solid particulate to second solid particulate in
the cooling media introduced into the riser reactor is between from
about 85:15 to about 15:85; and (h) the temperature in the mixing
zone is controlled by adjusting the ratio of first solid
particulate to biomass introduced into the mixing zone;
4. The process of claim 3, wherein T.sub.1 is from about
1100.degree. F. to about 1400.degree. F. and T.sub.2 is from about
500.degree. F. to about 1100.degree. F.
5. The process of claim 4, wherein the difference between T.sub.2
and T.sub.1 is about 50.degree. F. to about 500.degree. F.
6. The process of claim 3, wherein the weight ratio of the first
solid particulate to second solid particulate in the cooling media
introduced into the riser reactor is between from about 85:15 to
about 15:85.
7. The process of claim 1, wherein the cooling media comprises a
vaporizable liquid.
8. The process of claim 7, wherein the vaporizable liquid is a
distillate from a treated bio-oil stream hydrogenated in a
hydrotreater.
9. The process of claim 7, wherein the vaporizable liquid is
ethanol, methanol, butanol, a glycol or a combination thereof.
10. The process of claim 7, wherein the vaporizable material is a
liquid stream from a fractionator.
11. The process of claim 1, wherein the first solid particulate and
the second solid particulate are catalysts and wherein (i) the
first solid particulate and the second solid particulate are the
same; or (ii) the first solid particulate and the second solid
particulate are different catalysts and the first solid particulate
and the second solid particulate are separable from each other.
12. The process of claim 1, further comprising removing the first
solid particulate and the second solid particulate from the riser
reactor and regenerating at least a portion of the first solid
particulate and/or second solid particulate.
13. The process of claim 12, wherein the first solid particulate
and the second solid particulate removed from the riser reactor are
separated and regenerated in different regenerators.
14. The process of claim 12, wherein at least a portion of the
first solid particulate and/or second solid particulate material
are regenerated upstream from the cooling media.
15. The process of claim 12, further comprising regenerating the
first solid particulate and/or second solid particulate and
introducing the regenerated first solid particulate and/or
regenerated second solid particulate into the upstream zone as the
cooling media.
16. A process of subjecting solid biomass to thermolysis in a riser
reactor having a mixing zone and an upper zone, the process
comprising: (a) introducing a first solid particulate heated to a
temperature T.sub.1 into the mixing zone of the riser reactor, (b)
introducing solid biomass into the mixing zone downstream from the
first solid particulate; (c) mixing the solid biomass and the first
solid particulate in the mixing zone and treating the mixture to
pyrolysis wherein at least a portion of the solid biomass is
pyrolyzed; (d) introducing into the upper zone a second solid
particulate heated to a temperature T.sub.2, wherein T.sub.2 is
less than T.sub.1, and further wherein the second solid particulate
is a catalyst; (e) subjecting the treated mixture to fluidized
catalytic thermolysis in the upper zone; (f) removing at least a
portion of the first solid particulate and the second solid
particulate from the riser reactor; (g) separating the removed
first solid particulate and the second solid particulate; (h)
regenerating at least a portion of the separated first solid
particulate and the separated second solid particulate; (i) feeding
at least a portion of the regenerated first solid particulate into
the riser reactor upstream from the mixing zone; (j) cooling at
least a portion of the regenerated second solid particulate to the
temperature T.sub.2; and (k) feeding at least a portion of the
cooled regenerated second solid particulate into the upper
zone.
17. The process of claim 16, wherein the first solid particulate is
an inorganic particulate.
18. The process of claim 17, wherein the inorganic particulate is
sand.
19. The process of claim 16, wherein at least one of the following
conditions prevail: (a) the temperature in the mixing zone during
mixing is between from about 900.degree. F. to about 1350.degree.
F.; (b) T.sub.1 is from about 1100.degree. F. to about 1400.degree.
F. and T.sub.2 is from about 500.degree. F. to about 1100.degree.
F.; or (c) the difference between T.sub.2 and T.sub.1 is about
50.degree. F. to about 500.degree. F.; (d) the temperature in the
mixing zone at the time of introduction of biomass into the mixing
zone is between from about 950.degree. F. to about 1400.degree.
F.
20. The process of claim 16, wherein the weight ratio of first
solid particulate to the second solid particulate introduced into
the riser reactor is between from about 85:15.
Description
SPECIFICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/763,043, filed on Mar. 23, 2018.
FIELD OF THE DISCLOSURE
[0002] The disclosure relates to a process of converting biomass
into bio-oil using a cooling media downstream from the mixing zone
in a riser reactor.
BACKGROUND OF THE DISCLOSURE
[0003] Renewable energy sources, such as biofuels, provide a
substitute for fossil fuels and a means of reducing dependence on
petroleum oil. In light of its low cost and wide availability,
solid biomass is often used as a feedstock to produce bio-oil
which, in turn, is used to produce biofuel.
[0004] Many different conversion processes have been developed for
converting solid biomass to bio-oil in a biomass conversion unit.
Existing biomass conversion processes include, for example,
thermolysis, such as slow pyrolysis and fast pyrolysis, and
catalytic thermolysis. Thermolysis is characterized by the thermal
decomposition of materials in an oxygen-poor or oxygen-free
atmosphere (i.e., significantly less oxygen than required for
complete combustion). The liquid product resulting from thermolysis
of biomass includes organic materials. In some instances, the
liquid product may be separated into an aqueous phase and an
organic phase. The organic phase is commonly referred to as
bio-oil. Bio-oil may be processed into transportation fuels as well
as into hydrocarbon chemicals and/or specialty chemicals.
[0005] In addition to liquid reaction products, pyrolysis produces
gaseous reaction products and solid reaction products. Gaseous
reaction products include carbon dioxide, carbon monoxide, and
relatively minor amounts of hydrogen, methane, and ethylene. Solid
reaction products include carbonaceous deposits, such as coke and
char. Such solids reduce the yield of bio-oil and are largely
removed after the converted biomass exits the biomass conversion
unit.
[0006] In order to maximize the liquid yield, while minimizing the
solid and non-condensable gaseous reaction products, thermolysis is
conducted at a relatively fast heating rate of the biomass
feedstock. For example, the biomass may be rapidly heated between
150 and 600.degree. C. and the reaction time kept short, i.e. on
the order of milli-seconds to seconds. Such fast thermolysis
results in high yields of primary, non-equilibrium liquids and
gases (including valuable chemicals, chemical intermediates,
petrochemicals and fuels).
[0007] There is a significant incentive to increase the yield of
organic liquid products obtained by pyrolysis. To do so, it is
necessary to enhance the yield of volatile condensable oily
products (e.g., organic liquids) and reduce the levels of coke,
char, gases (such as carbon monoxide and carbon dioxide).
[0008] It should be understood that the above-described discussion
is provided for illustrative purposes only and is not intended to
limit the scope or subject matter of the appended claims or those
of any related patent application or patent. Thus, none of the
appended claims or claims of any related application or patent
should be limited by the above discussion or construed to address,
include or exclude each or any of the above-cited features or
disadvantages.
SUMMARY OF THE DISCLOSURE
[0009] In an embodiment of the disclosure, a process of subjecting
solid biomass to thermolysis in a riser reactor is provided wherein
the temperature in the reactor is controlled by a downstream
cooling media. In this embodiment, a first catalyst is introduced
into a riser reactor. The riser reactor has a mixing zone and an
upper zone above the mixing zone. When introduced into the riser
reactor, the first catalyst has a temperature T.sub.1. A solid
biomass is then introduced into the mixing zone of the riser
reactor downstream from the entry of the first catalyst. The solid
biomass and the first catalyst are mixed in the mixing zone. At
least a portion of the solid biomass is reacted in the mixing zone.
A second catalyst is then introduced into the upper zone of the
riser reactor. The temperature of the second catalyst, T.sub.2, is
less than T.sub.1. The entire effluent from the mixing zone is
subjected to fluidized catalytic thermolysis in the upper zone of
the riser reactor. At least a portion of the catalyst is recovered
from the riser reactor and at least a portion of the recovered
catalyst is regenerated. A first portion of the regenerated
catalyst is then fed to a catalyst cooling chamber and a second
portion of the regenerated catalyst is fed to the reactor riser
upstream from the mixing zone. The first portion of the regenerated
catalyst is then cooled in the catalyst cooling chamber to
temperature T.sub.2. The cooled regenerated catalyst is then
introduced into the upper zone of the riser reactor.
[0010] In another embodiment of the disclosure, a process of
subjecting solid biomass to thermolysis in a riser reactor is
provided. The riser reactor has a mixing zone and an upper zone
above the mixing zone. In this embodiment, a first catalyst having
a temperature T.sub.1 is introduced into the riser reactor. Solid
biomass is also introduced into the mixing zone downstream from the
point of entry of the first catalyst. The solid biomass and the
first catalyst are mixed and the solid biomass is subjected to
pyrolysis in the mixing zone. The resulting product, the mixing
zone effluent, is then subjected to thermocatalysis in the upper
zone. The temperature in the upper zone of the riser reactor is
reduced by introducing into the upper zone a second catalyst. The
temperature, T.sub.2, of the second catalyst is less than T.sub.1.
At least a portion of the first catalyst and the second catalyst
are recovered from the riser reactor and at least a portion of the
recovered catalyst is regenerated. A first portion of the
regenerated catalyst is fed to a catalyst cooling chamber and a
second portion of the regenerated catalyst is fed to the reactor
riser upstream from the mixing zone. The first portion of the
regenerated catalyst is cooled in the catalyst cooling chamber to
temperature T.sub.2. The cooled regenerated catalyst is then
introduced into the upper zone.
[0011] In another embodiment, a process of subjecting solid biomass
to thermolysis in a riser reactor using a first solid particulate
and a second solid particulate is provided. In this embodiment, the
riser reactor has a mixing zone and an upper zone. A first solid
particulate heated to a temperature T.sub.1 is introduced into the
riser reactor. Solid biomass is also introduced into the mixing
zone downstream from the entry of the first solid particulate. The
solid biomass and the first solid particulate are mixed in the
mixing zone and the mixture is then subjected to pyrolysis where at
least a portion of the solid biomass is pyrolyzed. A second solid
particulate is then introduced into the upper zone of the riser
reactor. The second solid particulate having been heated to a
temperature T.sub.2, wherein T.sub.2 is less than T.sub.1. The
second solid particulate is a catalyst. The treated mixture is then
subjected to fluidized catalytic thermolysis in the upper zone. At
least a portion of the first solid particulate and the second solid
particulate is removed from the riser reactor and the first solid
particulate and the second solid particulate are separated. At
least a portion of the separated first solid particulate and the
separated second solid particulate are regenerated. At least a
portion of the regenerated first solid particulate is fed into the
riser reactor upstream from the mixing zone, the regenerated first
solid particulate heated to the temperature T.sub.1. At least a
portion of the regenerated second solid particulate is cooled to
the temperature T.sub.2. At least a portion of the cooled
regenerated second solid particulate is then fed into the upper
zone as a cooling media and to cool the effluent from the mixing
zone.
[0012] In another embodiment, a process of subjecting solid biomass
to thermolysis in a riser reactor is provided wherein the
temperature in the reactor is controlled by a cooling media which
may, optionally, include a vaporizable liquid. The riser reactor
has a mixing zone and an upper zone above the mixing zone. A first
solid particulate heated to a temperature of T.sub.1 is introduced
into the riser reactor. Solid biomass is also introduced into the
mixing zone downstream from the entry point of the first solid
particulate. The solid biomass and the first solid particulate are
mixed in the mixing zone and the solid biomass reacted. The
resulting effluent from the mixing zone is then introduced into the
upper zone; the temperature in the upper zone cooled by the
addition of a cooling media into the upper zone. The cooling media
comprises a second solid particulate comprising a solid catalyst
and, optionally, the vaporizable liquid; the cooling media having a
temperature, T.sub.2, wherein T.sub.2 is less than T.sub.1. The
mixing zone effluent is subjected to fluidized catalytic
thermolysis in the upper zone.
[0013] In another embodiment of the disclosure, a process for
converting solid biomass to hydrocarbons in a riser reactor using a
vaporizable material as cooling media is provided. In this
embodiment, a first solid particulate heated to a temperature of
T.sub.1 is introduced into the riser reactor. The riser reactor has
an upper zone above a mixing zone. The solid biomass is introduced
into the mixing zone downstream from the point of entry of the
first solid particulate. The solid biomass and the first solid
particulate are agitated in the mixing zone and the agitated
mixture is reacted. The resulting pyrolyzed product is introduced
to the upper zone of the riser reactor and the cooling media is
introduced into the upper zone. The cooling media comprises the
vaporizable material, the vaporizable material having a
temperature, T.sub.2, wherein T.sub.2 is less than T.sub.1. The
pyrolyzed product is subjected to fluidized catalytic thermolysis
in the upper zone. A fluid stream is then separated from effluent
from the riser reactor. An organic-enriched stream and an aqueous
stream are separated from the fluid stream. The vaporizable
material may be bio-naphtha separated from the organic-enriched
stream and/or light hydrocarbons having a boiling point between
from about 150.degree. F. to about 180.degree. F. originating from
a topped bio-oil fraction from the organic-enriched stream.
[0014] In another embodiment of the disclosure, a process of
subjecting solid biomass to thermolysis in a riser reactor is
provided. The riser reactor has a mixing zone and an upper zone
above the mixing zone. A first solid particulate, heated to a
temperature of T.sub.1, is introduced into the mixing zone of the
riser reactor. The solid biomass is then introduced into the mixing
zone downstream from the point of entry of the first solid
particulate. The solid biomass and the first solid particulate are
mixed in the mixing zone and the mixture treated such that at least
a portion of the solid biomass is pyrolyzed. A vaporizable material
having a temperature, T.sub.2 (wherein T.sub.2 is less than
T.sub.1), is introduced into the upper zone of the riser reactor as
a cooling media and the treated mixture is subjected to fluidized
catalytic thermolysis in the upper zone. The effluent from the
catalytic thermolysis is removed from the riser reactor. The
effluent is separated into a fluid phase and a solid phase. An
organic-enriched phase is separated from the fluid phase and the
organic-enriched phase is then separated into a bio-oil containing
stream and a distillate stream. The vaporizable material is
separated from the bio-oil containing stream or distillate stream.
The separated vaporizable material is then introduced into the
upper zone of the riser reactor as the cooling media.
[0015] Accordingly, the present disclosure includes features and
advantages which are believed to enable it more efficiently produce
bio-oil from solid biomass using a cooling media to control the
temperature in the reactor. Characteristics and advantages of the
present disclosure described above and additional features and
benefits will be readily apparent to those skilled in the art upon
consideration of the following detailed description of various
embodiments and referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The following figures are part of the present specification,
included to demonstrate certain aspects of various embodiments of
this disclosure and referenced in the detailed description
herein:
[0017] FIG. 1 is a flow diagram illustrating a process of
converting a biomass into bio-oil by thermocatalysis using a
cooling media comprising a catalyst.
[0018] FIG. 2 is a flow diagram illustrating an alternative process
of converting a biomass into bio-oil using a cooling media
comprising regenerated catalyst.
[0019] FIG. 3 is a flow diagram illustrating a process of
converting a biomass into bio-oil by use of a cooling media and
dissimilar solid particulates.
[0020] FIG. 4 is a flow diagram illustrating a process of
converting a biomass into bio-oil by use of a cooling media and
regenerated dissimilar solid particulates.
[0021] FIG. 5 is a flow diagram illustrating a process of
converting a biomass into bio-oil by use of a cooling media
comprising vaporizable material.
[0022] FIG. 6 is a flow diagram illustrating an alternative process
of converting a biomass into bio-oil by use of a cooling media and
regenerated dissimilar solid particulates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Characteristics and advantages of the present disclosure and
additional features and benefits will be readily apparent to those
skilled in the art upon consideration of the following detailed
description of exemplary embodiments of the present disclosure and
referring to the accompanying figures. It should be understood that
the description herein and appended drawings, being of example
embodiments, are not intended to limit the claims of this patent or
any patent or patent application claiming priority hereto. On the
contrary, the intention is to cover all modifications, equivalents
and alternatives falling within the spirit and scope of the claims.
Many changes may be made to the particular embodiments and details
disclosed herein without departing from such spirit and scope.
[0024] In showing and describing preferred embodiments in the
appended figures, common or similar elements are referenced with
like reference numerals or are apparent from the figures and/or the
description herein. The figures are not necessarily to scale and
certain features and certain views of the figures may be shown
exaggerated in scale or in schematic in the interest of clarity and
conciseness.
[0025] As used herein and throughout various portions (and
headings) of this patent application, the terms "disclosure",
"present disclosure" and variations thereof are not intended to
mean every possible embodiment encompassed by this disclosure or
any particular claim(s). Thus, the subject matter of each such
reference should not be considered as necessary for, or part of,
every embodiment hereof or of any particular claim(s) merely
because of such reference.
[0026] Certain terms are used herein and in the appended claims to
refer to particular components. As one skilled in the art will
appreciate, different persons may refer to a component by different
names. This document does not intend to distinguish between
components that differ in name but not function. Also, the terms
"including" and "comprising" are used herein and in the appended
claims in an open-ended fashion, and thus should be interpreted to
mean "including, but not limited to . . . " Further, reference
herein and in the appended claims to components and aspects in a
singular tense does not necessarily limit the present disclosure or
appended claims to only one such component or aspect, but should be
interpreted generally to mean one or more, as may be suitable and
desirable in each particular instance.
[0027] In the process disclosed, a solid biomass feedstock is first
agitated in the mixing zone of a biomass conversion unit in the
presence of a solid particulate. Since the process may employ
multiple solid particulates, the solid particulate introduced into
the mixing zone shall be referred to as the "first solid
particulate".
[0028] The biomass conversion unit is preferably a riser reactor.
In addition to the mixing zone, the riser reactor has an upper zone
into which effluent from the mixing zone ("the mixing zone
effluent") advances. One or more zones ("uppermost zones") in the
riser reactor may be located downstream from the upper zone. The
upper zone and uppermost zones are thermal zones and are not
necessarily physically separate zones or separated zones.
[0029] The first solid particulate may be any suitable heat
exchange material. Heat exchange materials may be inorganic, such
as sand. Exemplary heat exchange materials may further include a
biomass conversion catalyst (BCC).
[0030] Suitable biomass conversion catalysts include those known in
the art, such as (i) a solid acid, such as a zeolite, super acid,
clay, etc., (ii) a solid base, such as metal oxides, metal
hydroxides, metal carbonates, basic clays, etc., (iii) a metal or a
compound containing a metal functionality, such as Fe, Cu, Ni (like
NiW or NiMo), transition metal sulfides such as sulfided NiMo,
sulfided CoMo, etc., reduced metals, such as reduced Ni; noble
metal catalysts, such as Ru, Pt, and Pd., transition metal
carbides, etc., (iv) an amphoteric oxide, such as alumina, silica,
titania, etc. and (v) a metal loaded onto a support such as
alumina, silica, zirconia, carbon, etc. Catalysts with an acid
functionality such as a silica-alumina, sulfated oxides, and
support phosphoric acids are also exemplary BCCs.
[0031] The biomass may be in the form of solid particles of finely
divided particles. The biomass may be introduced into the mixing
zone of the reactor in a slurry. The biomass is rarely pre-heated
prior to being introduced into the mixing zone. In an embodiment,
the biomass may include fibrous materials comprising cellulose.
Examples of suitable cellulose-containing materials include algae,
paper waste, and/or cotton linters. In one embodiment, the biomass
comprises a lignocellulosic material. Examples of suitable
lignocellulosic materials include forestry waste such as wood
chips, saw dust, pulping waste, and tree branches; agricultural
waste such as corn stover, wheat straw, and bagasse; and/or energy
crops such as eucalyptus, switch grass, and coppice.
[0032] The first solid particulate is added to the riser reactor
upstream from the point of entry of the biomass into the mixing
zone. The first solid particulate acts as a heat source and enables
the cracking of the biomass into smaller molecules. Bio-oil is
produced from the cracking of the biomass. Agitation of the biomass
and the first solid particulate in the mixing zone is very brief,
typically no more than 20 seconds and, in many instances, less than
20 milliseconds.
[0033] In the mixing zone, the biomass and the first solid
particulate are combined with an upwardly flowing gas from a lift
gas source. The solid biomass and first solid particulates are
entrained by the lift gas and rise upwardly into the upper zone of
the reactor. The lift gas introduced into the mixing zone may be
any of a variety of substantially oxygen-free gases including inert
gases (such as nitrogen, steam or carbon dioxide), reducing gases
(such as hydrogen or carbon monoxide, etc.
[0034] In the mixing zone, the biomass and the first solid
particulate may be subjected to shearing action sufficient to mix
the biomass and particulates to facilitate the conversion of the
biomass into bio-oil. This may include turbulent gas flow within
the reactor. For instances, in some cases, the design of the
catalyst bed within the reactor may provide eddies and vortices for
turbulent gas flow. Mechanical action may further provide the
requisite shear for conversion of the biomass into bio-oil. Such
mechanical action may be provided by kneading, milling, crushing,
extruding, chopping, mixing or a combination thereof.
[0035] Typically, the temperature in the mixing zone in the riser
reactor during agitation of the biomass and the first solid
particulate is between from about 900.degree. F. to about
1350.degree. F. The temperature in the mixing zone may be
controlled by adjusting the ratio of the first solid particulate to
the solid biomass introduced into the mixing zone.
[0036] The temperature, T.sub.1, of the first solid particulate
introduced into the mixing zone is typically from about
1100.degree. F. to about 1400.degree. F. The temperature in the
mixing zone at the time of introduction of the solid biomass into
the mixing zone is between from about 950.degree. F. to about
1400.degree. F.
[0037] The mixing zone effluent (which includes the bio-oil
converted from the biomass) ascends into the upper zone of the
riser reactor. The mixing zone effluent contains solids, bio-oil,
gases as well as minerals. While coke and char may be left as
residue in the mixing zone, the mixing zone effluent advancing into
the upper zone of the riser reactor contains most of the coke and
char produced during conversion of the biomass. In addition, while
minerals may remain in the inventory of the first solid particulate
in the mixing zone, they may also be contained in the mixing zone
effluent.
[0038] The mixing zone effluent is subjected to thermolysis in the
upper zone of the riser reactor. A cooling media is introduced into
the upper zone of the riser reactor. The cooling media contacts the
mixing fluid effluent as it ascends into the upper zone of the
riser. The cooling media most desirably does not condense in the
reactor riser during thermolysis.
[0039] The temperature of the cooling media, T.sub.2, is lower than
T.sub.1. While T.sub.2 may be as low as ambient, T.sub.2 more
typically from about 500.degree. F. to about 1100.degree. F. In an
embodiment, the difference between T.sub.2 of the cooling media
entering the upper zone of the riser reactor and T.sub.1 of the
first solid particulate is between from about 50.degree. F. to
about 500.degree. F.
[0040] The temperature of the mixing zone effluent is reduced by
the cooling media. Thus, thermolysis in the upper zone of the riser
reactor proceeds at a lower temperature than the mixing zone
effluent. Typically, a high rate of heat transfer to the biomass
occurs during reaction of the solid biomass and the first solid
particulate in the mixing zone of the riser reactor. Without the
use of the cooling media disclosed herein excessive overcracking of
the biomass occurs in the riser reactor as the outlet temperature
from the reactor is near the inlet temperature of the solid
particulate in the mixing zone. The addition of the cooling media
in the upper zone reduces the production of carbon monoxide and
light gases during thermolysis. This, in turn, reduces the
efficiency of deoxygenation downstream from the riser reactor.
Thus, the cooling media decreases the temperature in the riser
reactor in a controlled manner that suppresses the thermal
reactions relative to the catalytic reactions.
[0041] The cooling media may be a solid particulate or a
vaporizable material. Where a solid particulate is introduced into
the upper zone of the riser reactor, it shall be referred to herein
as the "second solid particulate".
[0042] Catalytic thermolysis may be conducted in the upper zone by
use of a catalyst as the cooling media. Exemplary catalysts for use
as cooling media include any of the biomass conversion catalysts
set forth in the paragraphs above.
[0043] Where the first solid particulate and the second solid
particulate are both catalysts, the catalyst introduced into the
mixing zone and the upper zone, respectively, may be the same
catalyst or different catalysts.
[0044] Where the first solid particulate and the second solid
particulate are different materials, they preferably are separable
from each other in order that they may be regenerated as separate
streams in different regenerators. Alternatively, the first and
second solid particulates may be first regenerated in a single
regenerator and the regenerated products separated downstream from
the regenerator, yet upstream from the cooling media.
[0045] The first solid particulate and second solid particulate may
differ from each other by a physical property, such as particle
size, density, etc.
[0046] Typically, the weight ratio of first solid particulate to
second solid particulate introduced into the mixing zone and the
upper zone of the riser reactor, respectively, is between from
about 85:15 to about 15:85.
[0047] The riser reactor may have more than one zone downstream
from the mixing zone. For instance, the riser reactor may have an
uppermost zone downstream from the upper zone. A heat exchange
material, defined herein, may be fed into the uppermost zone to
enhance thermolysis efficiency. The heat exchange material ("the
third solid particulate") may also serve as a cooling media. The
heat exchange material introduced into the uppermost zone may
differ from the second solid particulate and/or first solid
particulate.
[0048] Where a solid particulate is used in the uppermost zone, the
weight ratio of the first solid particulate to the third solid
particulate is preferably between from about 85:15 to about
15:85.
[0049] The temperature of the third solid particulate, T3,
introduced into the uppermost zone of the reactor is different from
T.sub.1 and T.sub.2 and typically is less than T2.
[0050] The riser effluent may include solids and fluid (e.g. gas
and vapors) as well as spent and/or used solid particulate(s).
Typically, the amount of coke and char produced in the riser during
thermolysis is between from about 9 to about 25% by weight based on
the weight of the solid biomass. The majority of the coke and char
exits the riser reactor as part of the riser effluent.
[0051] The solids and gases in the riser effluent are separated in
a gas solid separator. Suitable separators may include any
conventional device capable of separating solids from gas and
vapors such as, for example, a cyclone separator, gas filter,
coalescer, gravity phase separator, etc. Typically, from about 95
to essentially 100% percent of the solids are removed from the
mixture in the separator. Optionally and preferably, remaining
solids in the mixture may further be removed, such as by polishing
filtration.
[0052] The separated gas stream containing volatile components may
be processed downstream. In addition to the removal of heavy
materials and solids, water may be removed during the
separation.
[0053] The separated solids may then be sent into a regeneration
unit. In the regeneration unit, char and coke are combusted and
activity is restored to at least some of the first solid
particulates and/or the second solid particulates and/or (where
applicable) the third solid particulates.
[0054] Where the first solid particulates and second solid
particulates (and optional third solid particulates) do not differ
from each other then the solid particulates may be regenerated in a
single regeneration unit. A portion of the regenerated solid
particulates may then be fed into the mixing zone upstream from the
point of entry of the biomass into the mixing zone. A portion of
the regenerated solid particulates may be fed into the cooling
chamber and cooled to a temperature, T.sub.2, and then introduced
into the upper zone as cooling media. Where the riser reactor has
an uppermost zone, a portion of the regenerated solid particulates
may be fed into the uppermost zone.
[0055] Where the first solid particulates, second solid
particulates and/or third solid particulates are distinct and
separable from each other, streams containing the first solid
particulates, second solid particulates and/or third solid
particulates may be introduced into a solids separator capable of
separating the streams.
[0056] Once separated, each of the streams may be alternatively
introduced into separate regeneration units where char and coke are
combusted and activity is restored to each of the particulates. The
separated first solid particulates may then be introduced into the
reactor riser upstream from the mixing zone, the separated second
solid particulates, after being cooled to a temperature of T.sub.2,
may be introduced into the upper zone of the riser reactor as
cooling media and, where applicable, the separated third solid
particulates may be introduced into the uppermost zone of the riser
reactor.
[0057] As an alternative, in those instance where the first solid
particulates, second solid particulates and/or third solid
particulates are distinct and separable from each other, the stream
containing the first solid particulates, second solid particulates
and/or third solid particulates may be introduced into a
regenerator where char and coke are combusted and activity is
restored to the particulates. The particulates may then be
separated in a solids separator upstream from the cooling media.
The separated first solid particulates may then be introduced into
the riser reactor upstream from the mixing zone, the second solid
particulates, after being cooled to a temperature of T.sub.2, may
be introduced into the upper zone of the reactor as cooling media
and, where applicable, the separated third solid particulates may
be introduced into the uppermost zone of the riser reactor.
[0058] Instead of the cooling media being a solid particulate, the
cooling media may comprise a vaporizable material. The vaporizable
material, cooled to a temperature of T.sub.2, may originate
downstream. In an embodiment, for instance, the vaporizable
material may constitute a distillate from fractionation. In another
embodiment, the vaporizable material may constitute a distillate
from a hydrotreatment process. Vaporizable materials may include,
for example, ethanol, methanol, butanol, a glycol or a combination
thereof.
[0059] The processes referred to herein may be continuous.
[0060] Various alternative embodiments of the process are set forth
in the Figures. It should be understood that all of the apparatus
and processes mentioned below may have any suitable number and type
of components, configuration and operation, as is and may become
further known. Further, all embodiments of the present disclosure
are neither limited to, nor require, each component, process and
the particular details mentioned below.
[0061] Referring to FIG. 1, in accordance with an embodiment of the
present disclosure, a method of producing renewable fuels from
biomass material is provided wherein the first solid particulates
and the second solid particulates are the same and are catalysts.
As depicted, a solid biomass feedstream 120 is fed from one or more
external sources into a biomass conversion unit, shown as riser
reactor 122. The biomass is heated and mixed with first catalyst
124 in mixing zone 126. The temperature in the mixing zone during
mixing is between from about 900.degree. F. to about 1350.degree.
F. As shown, first catalyst 124 and lift gas 128 are added upstream
from the point of entry of biomass 120 into riser reactor 122.
First catalyst 124 acts as a heat source enabling the cracking of
the biomass in mixing zone 126. The residence time of mixing solid
biomass 120 and first catalyst 124 in mixing zone 126 is very
brief, typically no more than 20 seconds, and in some cases less
than 20 milli-seconds.
[0062] FIG. 1 shows first catalyst 124 being fed into riser reactor
122 as regenerated catalyst from regenerator 130. The temperature,
T.sub.1, of first catalyst 124 introduced into mixing zone 126 is
typically from about 1100.degree. F. to about 1400.degree. F.
[0063] The mixing zone effluent containing bio-oil ascends into
upper zone 132 of riser reactor 122. The mixing zone effluent is
subjected to catalytic thermolysis in upper zone 132. The second
catalyst 134 (the cooling media) of temperature T.sub.2 (where
T.sub.2 is lower than T.sub.1) is introduced into upper zone 132.
The temperature of the mixing zone effluent is reduced by second
catalyst 134 such that catalytic thermolysis occurs in upper zone
132 at a cooler temperature than the reaction in mixing zone
126.
[0064] After exiting riser reactor 122, the riser effluent is
introduced into solids separator 136. In solids separator 136,
solids and fluids 139 in the riser effluent are separated. The
solids which include char, coke and spent and/or used catalyst, are
introduced into regenerator 130. In regenerator 130, char and coke
are combusted and catalytic activity is restored to at least some
of the catalyst.
[0065] After regeneration, at least a portion of the hot
regenerated catalyst 129 may be fed back into mixing zone 126 of
riser reactor 122 as stream 124. A portion of hot regenerated
catalyst 129 from regenerator 130 may be fed into cooling chamber
138 (shown as stream 125) and cooled to T.sub.2. The resulting
cooled catalyst 134 then enters into the upper zone 132 of riser
reactor 122.
[0066] FIG. 2 illustrates a modification of the process depicted in
FIG. 1 wherein solid catalyst 224 and lift gas 228 are introduced
into mixing zone 226 upstream from entry of biomass feed 220. In
FIG. 2, the riser effluent stream from riser reactor 222 is
introduced into solid/gas separator 236 to produce gas stream 252
and fluid stream 254. Separated gas stream 252 containing volatile
components may be further processed downstream.
[0067] Separated fluid stream 254 is then treated in stripper 260
with stripping media 262. Suitable stripping media include steam,
natural gas, nitrogen as well as other inert gases. In a preferred
embodiment, the stripping media is steam.
[0068] Stripped stream 264 containing catalyst, volatiles and,
predominately, hard coke is then fed into second separator 256. The
volatiles in stream 264 are removed as stream 268 in second
separator 256 and may be processed downstream with stream 252.
Solid stream 266 from second separator 256 contains hard coke,
characterized by low hydrogen content, and spent catalyst. The
residual coke is removed from the spent catalyst in regenerator
230, principally by combustion.
[0069] Regenerated catalyst 229 may be fed back into mixing zone
226 as stream 224 or into catalyst cooling chamber 238 as stream
225 and cooled to T.sub.2. Cooled regenerated catalyst 234 may then
be fed into upper zone 232.
[0070] The riser reactor used in the conversion of biomass may
consist of more than two zones. Depicted in FIG. 3 is riser reactor
322 having mixing zone 326, upper zone 332 and uppermost zone 340.
The temperature in uppermost zone 340 is less than the temperature
in upper zone 332. As in FIG. 1, solid biomass 320 is fed from one
or more external sources into mixing zone 326 of riser reactor 322
and is heated and mixed with first catalyst 324 and lift gas 328.
First catalyst 324 and lift gas 328 are added to mixing zone 326
upstream from the point of entry of the biomass into the mixing
zone. First catalyst 324 is fed into mixing zone 326 as regenerated
catalyst stream 324 from regenerator 330.
[0071] The mixing zone effluent is subjected to catalytic
thermolysis in upper zone 332. A portion of hot regenerated
catalyst 329 from regenerator 330 is fed as stream 325 into cooling
chamber 338. The second catalyst 334 (the cooling media) of
temperature, T.sub.2, cooled in cooling chamber 338, is introduced
into upper zone 332, wherein T.sub.2 is lower than T.sub.1.
[0072] As illustrated in FIG. 3, a third catalyst 342 may be
introduced into uppermost zone 340 and catalytic thermolysis is
then advanced from upper zone 332 to uppermost zone 340. In this
depiction, the first catalyst 324, second catalyst 334 and third
catalyst 342 are the same. The riser effluent may be treated as
discussed in the processes depicted in FIG. 1 and FIG. 2 and the
catalyst separated from gaseous fluid 339 in separator 336 may then
be regenerated in regenerator 330. The temperature of the third
catalyst, T.sub.3, introduced into uppermost zone 340 is lower than
T.sub.2 which, in turn, is lower than T.sub.1.
[0073] FIG. 3 illustrates two exemplary embodiments for the cooling
of third catalyst 342 prior to introducing the third catalyst into
uppermost zone 340. In one embodiment, a portion of regenerated
catalyst of stream 325 may be diverted into catalyst cooling
chamber 341 and the cooled catalyst 342A then introduced into
uppermost zone 340. In another embodiment, a portion of regenerated
catalyst stream 325 may be diverted into catalyst cooling chamber
338. In catalyst cooling chamber 338, the regenerated catalyst is
cooled to the temperature T.sub.2 for introducing second catalyst
334 into upper zone 332. A portion of the second catalyst from
catalyst cooling chamber 338 may be further diverted to a second
catalyst cooling chamber 344 to render the third catalyst 342B
having a temperature of T.sub.3. Either or both of these
alternative embodiments may be used to render the third catalyst of
temperature T.sub.3.
[0074] FIG. 4 illustrates another embodiment of the disclosure,
where two different catalysts are used in the conversion of biomass
and wherein both catalysts are regenerated during the conversion
process. The two catalysts may differ in particle size, density or
by other properties which permit the two catalysts to be separated.
It will be understood that FIG. 4 may be modified to include more
than two regenerators where the process involves one or more zones
downstream from the upper zone.
[0075] Referring now to FIG. 4, solid biomass 420 and lift gas 428
are fed into mixing zone 426 of riser reactor 422.
[0076] First solid particulates 424 (which may be a biomass
conversion catalyst) having a temperature of T.sub.1, are provided
to riser reactor 422 and are heated and mixed with the biomass
feedstream in mixing zone 426. As shown, first solid particulates
424 are added upstream from the point of entry of biomass 420 into
riser reactor 422. First solid particulates 424 may be fed into
riser reactor 422 as regenerated particulates from regenerator
431.
[0077] The mixing zone effluent ascends into upper zone 432 of
riser reactor 422. The mixing zone effluent is subjected to
catalytic thermolysis in upper zone 432. Second solid particulates
434 (which may also be a biomass conversion catalyst) having
temperature, T.sub.2, are introduced into upper zone 432, wherein
T.sub.2 is lower than T.sub.1. A portion of second solid
particulates 434 may be regenerated solid particulates from
regenerator 433.
[0078] First solid particulates 424 and second solid particulates
434B introduced into mixing zone 426 and upper zone 432,
respectively, are different solid particulates and may differ by a
physical property, such as particle size, density, etc.
[0079] Referring still to the embodiment of FIG. 4, the riser
effluent ascends and exits riser reactor 422 through a top port.
The riser effluent may include solids and fluid (e.g. gas and
vapors) as well as spent first solid particulates and spent second
solid particulates. After exiting riser reactor 422, the riser
effluent is introduced into solid/gas separator 436 to render gas
stream 452 and fluid stream 454. Separated gas stream 452
containing volatile components may be further processed
downstream.
[0080] Spent first solid particulates 424S (spent particulates of
solid particulates 424) and spent second solid particulates 434S in
fluid stream 454 are separated from each other in solids separator
440. Solids separator 440 may be a conventional separator known in
the art, such as a gravitational separator or magnetic separator,
provided it is capable of separating solid particulates of
different density, particle size, etc.
[0081] First solid particulates 424 are regenerated from spent
first solid particulates catalyst 424S in first regenerator 431
where char and coke are combusted and activity is restored to them.
Second solid particulates 434B are regenerated from spent second
solid particulates 434S in second regenerator 433, where char and
coke are combusted and activity is restored.
[0082] After regeneration, hot regenerated first solid particulates
424 may be fed back into mixing zone 426 of riser reactor 422. A
portion of the second solid particulates 434A regenerated in
regenerator 433 may further be fed into catalyst cooling chamber
438 and cooled to T.sub.2. The resulting cooled regenerated
catalyst 434B is then fed into upper zone 432 of riser reactor
422.
[0083] FIG. 6 illustrates another embodiment where two different
catalysts are used in the conversion of biomass and wherein both
catalysts are regenerated during the conversion process. The two
catalysts may differ in particle size, density or by other
properties which permit the two catalysts to be separated.
Referring to FIG. 6, solid biomass 620 is fed into mixing zone 626
of riser reactor 622.
[0084] First solid particulates 624 (which may be a biomass
conversion catalyst) having a temperature of T.sub.1, are provided
to riser reactor 622 and are heated and mixed with the biomass
feedstream in mixing zone 626. As shown, first solid particulates
624 as well as lift gas 628 are added upstream from the point of
entry of biomass 620 into riser reactor 622. First solid
particulates 624 may be fed into riser reactor 622 as regenerated
particulates from solid separator 646.
[0085] The mixing zone effluent ascends into upper zone 632 of
riser reactor 622. The mixing zone effluent is subjected to
catalytic thermolysis in upper zone 632. Second solid particulates
634B (which may also be a biomass conversion catalyst) having
temperature, T.sub.2, are introduced into upper zone 632, wherein
T.sub.2 is lower than T.sub.1. A portion of second solid
particulates 634B may be regenerated solid particulates separated
in separator 646.
[0086] First solid particulates 624 and second solid particulates
634B introduced into mixing zone 626 and upper zone 632,
respectively, are different solid particulates and may differ by a
physical property, such as particle size, density, etc.
[0087] Referring still to the embodiment of FIG. 6, the riser
effluent ascends and exits riser reactor 622 through a top port.
The riser effluent may include solids and fluid (e.g. gas and
vapors) as well as spent first solid particulates and spent second
solid particulates. After exiting riser reactor 622, the riser
effluent is introduced into solid/gas separator 636 to render gas
stream 652 and fluid stream 654. Separated gas stream 652
containing volatile components may be further processed
downstream.
[0088] Fluid stream 654 is then introduced into regenerator 645
where char and coke are combusted and where spent first solid
particulates and spent second solid particulates are regenerated
and their activity restored. The regenerated solid particulates 634
are then fed from regenerator 645 into separator 646 where
regenerated first solid particulates 624 and regenerated second
solid particulates 634A are separated. Solids separator 646 may be
a conventional separator known in the art, such as a gravitational
separator, provided it is capable of separating solid particulates
of different density, particle size, etc.
[0089] Hot regenerated first solid particulates 624 may be fed back
into mixing zone 626 of riser reactor 622. At least a portion of
the regenerated second solid particulates 634A separated in
separator 646 may further be fed into catalyst cooling chamber 638
and cooled to T.sub.2. The resulting cooled regenerated catalyst
634B is then fed into upper zone 632 of riser reactor 622.
[0090] FIG. 5 illustrates another embodiment of the disclosure
where the cooling media entering into the upper zone of the riser
reactor is a vaporizable material. As illustrated, solid biomass
feedstock 520 is fed into mixing zone 526 of reactor riser 522.
First solid particulates (which may be a catalyst) 524 and lift gas
528 are fed into mixing zone 526. Mixing zone 526 is downstream
from the point of entry of first solid particulates 524. First
solid particulates 524 may be fed into riser reactor 522 as
regenerated particulates from regenerator 530. The biomass and
first solid particulates are agitated in mixing zone 526.
[0091] The mixing zone effluent then enters into upper zone 532
where it is cooled by cooling media 534 having a temperature of
T.sub.2. The cooling media is a vaporizable material treated in
cooling chamber 538. Fluid stream 578 containing combustible solids
and gaseous stream 580 in the riser effluent are separated in solid
gas separation unit 536.
[0092] Fluid stream 578 containing spent first solid particulates
may then be fed into regeneration unit 530 where the stream
undergoes combustion and first solid particulates are regenerated.
Regenerated first solid particulates 524 may then be fed back into
mixing zone 526 of riser reactor 522 through a port upstream from
the entry port of the biomass.
[0093] Gaseous stream 580 may then be cooled and quenched to
provide gaseous stream 581 and liquid stream 582. Liquid stream 582
may then be fed into separator 556 to render organic-enriched
stream 558 and aqueous stream 560. The organic-enriched stream 558
and aqueous stream 560 in separator 556. The organic-enriched phase
558 may further be separated in fractionator 562 into a full range
bio-naphtha ("Bio-FRN") 565 containing light oxygenates of C.sub.5
or less, a heavier bio-oil, or topped bio-oil fraction 567
containing C.sub.6 or greater oxygenates and water (not shown).
Bio-FRN 565 may be further separated in separator 561 and the
bio-naphtha distillate 559 passed into cooling chamber 538.
[0094] Topped bio-oil stream 567 may be fed into hydrotreater 568.
In the hydrotreater, the bio-oil containing stream is subjected to
deoxygenation and desulfurization by the introduction of
hydrogen.
[0095] Following deoxygenation in the hydrotreater, the
deoxygenated stream may then be introduced into fractionator 570 to
render renewable bio-oil (RBO). In fractionator 570, at least a
portion of the material may be separated into light fraction stream
572, intermediate fraction stream 574 and heavy fraction stream 576
for use in renewable bio-fuels. The light fraction stream may have
a boiling range below petroleum-derived gasoline and the
intermediate fraction may have a boiling range comparable to
petroleum-derived gasoline. The heavy fraction stream may have a
boiling range comparable to diesel fuel. For instance, in an
embodiment, the light fraction stream may have a boiling point
between from about 150.degree. F. to about 180.degree. F., the
intermediate fraction may have a boiling point between from about
180.degree. F. to about 420.degree. F. and the heavy fraction may
have a boiling point above 420.degree. F. Light fraction stream
572, intermediate fraction stream 574 and/or heavy fraction stream
576 may then be introduced as vaporizable material into catalyst
cooling chamber 538. Preferably, all or a portion of heavy fraction
stream 576 is fed into cooling chamber 538.
[0096] While not shown in FIGS. 3, 4, 5, and 6, it is understood
that effluent from the riser may be separated into a gas stream and
a fluid stream and the separated gas stream may then be treated in
a stripper with a stripping media (as illustrated in FIG. 2).
[0097] Preferred embodiments of the present disclosure thus offer
advantages over the prior art and are well adapted to carry out one
or more of the objects of this disclosure. However, the present
disclosure does not require each of the components and acts
described above and are in no way limited to the above-described
embodiments or process of operation. Any one or more of the above
components, features and processes may be employed in any suitable
configuration without inclusion of other such components, features
and processes. Moreover, the present disclosure includes additional
features, capabilities, functions, processs, uses and applications
that have not been specifically addressed herein but are, or will
become, apparent from the description herein, the appended drawings
and claims.
EXAMPLES
[0098] The Examples herein are provided to illustrate different
aspects of the disclosure. In the baseline case, hot catalyst and
nitrogen were introduced to the bottom of a reactor riser, at a
temperature of T.sub.1. The biomass was then added and mixed with
the hot catalyst, yielding a temperature of T.sub.h. In the
examples herein, cooler catalyst of temperature T.sub.2 was then
added further downstream, yielding a lower temperature of T.sub.c.
For these examples the biomass contained 35 pounds of water for
every 500 pounds of biomass on a dry basis. Nitrogen was added at
250 lb/hr while biomass was introduced at 500 lb/hr on a dry basis.
The biomass and the nitrogen were introduced at 70.degree. F. The
temperature of the regenerated catalyst was 1325.degree. F. In
these examples the portion of circulating catalyst introduced above
the feed point was cooled to 800.degree. F. The following physical
properties are assumed for these examples: [0099] Biomass and
pyrolysis products have a heat capacity of 0.406 BTU/lb .degree. F.
[0100] The heat of reaction for pyrolysis of the biomass is -85.5
BTU/lb [0101] The nitrogen has a heat capacity of 0.263 BTU/lb
.degree. F. [0102] The catalyst has a heat capacity of 0.265 BTU/lb
.degree. F. [0103] The moisture in the biomass has a heat capacity
of 0.454 BTU/lb .degree. F. [0104] The heat of vaporization for the
initial moisture in biomass is 970 BTU/lb
[0105] Base. Hot catalyst was circulated at 4000 lb/hr and all of
the catalyst was introduced into the riser reactor, below the
biomass feed point.
Example 1
[0106] In Example 1, the total catalyst circulation rate remained
at 4000 lb/hr, but 1000 lb/hr of the catalyst flow was passed
through a heat exchanger that reduced the temperature of the
catalyst from 1325.degree. F. to 800.degree. F. This cooler
catalyst was introduced to the riser at a point downstream from the
biomass feed.
Example 2
[0107] In Example 2, the total catalyst circulation rate was
increased to 6000 lb/hr. Of this amount, 4000 lb/hr was introduced
to the bottom of the riser (upstream from the biomass feed). The
remaining 2000 lb/hr was cooled from 1325.degree. F. to 800.degree.
F. and introduced at a point downstream from the biomass feed.
Example 3
[0108] In Example 3, the total catalyst circulation rate was 4000
lb/hr. Half of the catalyst was introduced to the bottom of the
riser at 1325.degree. F. while the other half was cooled to
800.degree. F. and then introduced to the riser at a point
downstream from the biomass feed.
[0109] The temperatures in the three zones (T.sub.1, T.sub.h and
T.sub.c) for each case are shown in Table I below.
TABLE-US-00001 TABLE I Ex. T.sub.1 (.degree. F.) T.sub.h (.degree.
F.) T.sub.c (.degree. F.) Base 1252 1066 1066 Example 1 1229 1002
963 Example 2 1252 1066 991 Example 3 1187 897 859
[0110] The process that may be described above or claimed herein
and any other process which may fall within the scope of the
appended claims can be performed in any desired suitable order and
are not necessarily limited to any sequence described herein or as
may be listed in the appended claims. Further, the process of the
present disclosure does not necessarily require use of the
particular embodiments shown and described herein, but are equally
applicable with any other suitable structure, form and
configuration of components.
[0111] The biomass to be pyrolyzed is generally ground to a small
particle size in order to optimize pyrolysis. The biomass may be
ground in a grinder or a mill until the desired particle size is
achieved.
[0112] While exemplary embodiments of the disclosure have been
shown and described, many variations, modifications and/or changes
of the system, apparatus and process of the present disclosure,
such as in the components, details of construction and operation,
arrangement of parts and/or process of use, are possible,
contemplated by the patent applicant(s), within the scope of the
appended claims, and may be made and used by one of ordinary skill
in the art without departing from the spirit or teachings of the
disclosure and scope of appended claims. Thus, all matter herein
set forth or shown in the accompanying drawings should be
interpreted as illustrative, and the scope of the disclosure and
the appended claims should not be limited to the embodiments
described and shown herein.
* * * * *