Process for converting carbon-based energy carrier material

• US 7,901,568 B2
• Filed: 05/04/2007
• Issued: 03/08/2011
• Est. Priority Date: 05/05/2006
• Status: Expired due to Fees

• Current Assignee: MARD Incorporated
• Original Assignee: Kior Inc.
• Inventors: Moulijn, Jacob Adriaan, Stamires, Dennis, O'Connor, Paul
• Primary Examiner(s): Griffin; Walter D
• Assistant Examiner(s): McCaig; Brian
• Application Number:
  US12/299,319
• Publication Number:
  US 20090308787A1
• Time in Patent Office: 1,404 Days
• Field of Search: 208/44, 208125-126, 208/400, 208407-411, 443/07, 44605-606
• US Class Current: 208/411
• CPC Class Codes: C10B 49/20 in dispersed form
• CPC Class Codes: C10G 1/08 with moving catalysts
• CPC Class Codes: C10G 1/086 Characterised by the catalyst used
• CPC Class Codes: C10G 11/18 according to the "fluidised-bed" technique
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed; In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.

Claims

1. A process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of:

a) contacting said carbon-based energy carrier material with a particulate catalyst material;

b) converting said carbon-based energy carrier material at a reaction temperature between 200°

C. and 450°

C., thereby forming reaction products in the vapor phase;

c) separating at least a portion of said reaction products from said particulate catalyst material within 10 seconds after said reaction products are formed, wherein following said separating said particulate catalyst material further comprises coke and at least a portion of said reaction products;

d) optionally quenching said reaction products to a temperature below 200°

C.;

e) stripping at least a portion of said reaction products from said particulate catalyst material; and

f) burning off said coke formed on said particulate catalyst material.

2. The process of claim 1 comprising the further step of recycling said particulate catalyst material resulting from step f) to step a) or b) or both step a) and step b).

3. The process of claim 2 comprising the further step of cooling said particulate catalyst material after said coke has been burned off in step f) and prior to recycling said particulate catalyst.

4. The process of claim 3 whereby heat recovered from said particulate catalyst material is used for generating steam, hot water, or electricity.

5. The process of claim 1 wherein a reductive gas is present during step b) and said reductive gas comprises hydrogen, hydrogen sulfide iso-butane, naphthene, a volatile organic acid, or thereof.

6. The process of claim 1 wherein a reductive gas is present during step b) and said reductive gas comprises iso-butane, naphthene, a volatile organic acid, or mixtures thereof.

7. The process of claim 1, wherein said catalytic material comprises cationic clays, anionic clays, natural clays, hydrotalcite-like materials, layered materials, ores, minerals, metal oxides, hydroxides and carbonates of the alkaline and alkaline earth metals, or mixtures thereof.

8. The process of claim 1 wherein said carbon-based energy carrier material is of mineral origin.

9. The process of claim 1 wherein said carbon-based energy carrier material is selected from the group consisting of tar, heavy crude, bitumen, synthetic polymer or combinations thereof.

10. The process of claim 1 wherein said carbon based energy carrier material is a solid biomass.

11. The process of claim 10 wherein said solid biomass comprises cellulose, lignin, lignocellulose, or mixtures thereof.

12. The process of claim 10 wherein said solid biomass is of aquatic origin.

13. The process of claim 1 whereby CO₂ resulting from step f) is utilized in the production of biomass.

14. The process of claim 1 wherein step a) comprises contacting said carbon-based energy carrier material with an inorganic particulate material and a gas prior to step b) such that the particle size of the energy carrier material is reduced to less than 3 mm.

15. The process of claim 1 wherein step b) is carried out in a fluidized bed, a riser reactor, or a downer reactor.

16. The process of claim 1 wherein the reaction temperature in step b) is less than 350°

C.

17. The process of claim 1, wherein said reaction products comprise steam, hydrocarbons, or a mixture thereof.