Process for converting carbon-based energy carrier material

• US 8,460,541 B2
• Filed: 01/18/2011
• Issued: 06/11/2013
• Est. Priority Date: 05/05/2006
• Status: Active Grant

• Current Assignee: MARD Incorporated
• Original Assignee: Kior Inc.
• Inventors: O'Connor, Paul, Stamires, Dennis, Moulijn, Jacob Adriaan
• Primary Examiner(s): MCCAIG, BRIAN A
• Application Number:
  US13/008,430
• Publication Number:
  US 20110197511A1
• Time in Patent Office: 875 Days
• Field of Search: 208125-126, 208407-411, 208400-405, 443/07, 44605-606, 585/469, 585/638, 585/733
• 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 biomass to reaction products, comprising:

(a) mixing biomass and an inorganic material having catalytic properties, wherein the inorganic material comprises a zeolite or zirconia, and optionally one or more of silica, silica-alumina, and titania, at a temperature below 200°

C. to produce a biomass material susceptible to conversion in step b); and

(b) heating the biomass material to a reaction temperature ranging from 200°

C. to 450°

C. to at least partially convert the biomass material to reaction products, wherein the reaction products are liquid, gas, or liquid and gas, and include bio-oil; and

(c) recovering said reaction products.

2. The process of claim 1, wherein the reaction products include gaseous reaction products, the process further including separating at least a portion of the gaseous reaction products from the inorganic material within 10 seconds after formation of the reaction products.

3. The process of claim 2, further including separating at least a portion of the gaseous reaction products from the inorganic material within 5 seconds after formation of the reaction products.

4. The process of claim 3, further including separating at least a portion of the gaseous reaction products from the inorganic material within 3 seconds after formation of the reaction products.

5. The process of claim 1, wherein the reaction products include gaseous reaction products, the process further including cooling the gaseous reaction products below a temperature of 200°

C.

6. The process of claim 5, further including cooling the gaseous reaction products below a temperature of 200°

C. within 10 seconds after being separated from the inorganic material.

7. The process of claim 5, further including cooling the gaseous reaction products below a temperature of 200°

C. within 3 seconds after being separated from the inorganic material.

8. The process of claim 5, further including cooling the gaseous reaction products below a temperature of 150°

C. within 10 seconds after being separated from the inorganic material.

9. The process of claim 5, further including cooling the gaseous reaction products below a temperature of 150°

C. within 3 seconds after being separated from the inorganic material.

10. The process of claim 1, wherein the reaction products include gaseous reaction products, the process further including cooling the gaseous reaction products below a temperature of 150°

C.

11. The process of claim 1, wherein the inorganic material includes a mixture of zeolite and silica.

12. The process of claim 1, wherein the inorganic material includes a mixture of a zeolite and a silica-alumina.

13. The process of claim 1, wherein the inorganic material further comprises titania.

14. The process of claim 1, wherein the inorganic material comprises zirconia.

15. The process of claim 1, wherein the biomass includes biomass particulate material, the process further including milling the biomass particulate material to a mean particle size of less than 3 mm.

16. The process of claim 15, wherein the biomass includes biomass particulate material, the process further including milling the biomass particulate material to a mean particle size ranging from 0.1 mm to 3 mm.

17. The process of claim 1, further including drying the biomass at a drying temperature ranging from about 50°

C. to about 150°

C. before step (a).

18. The process of claim 1, further including recycling the inorganic material for use in a subsequent process for converting biomass to reaction products.

19. The process of claim 1, wherein coke is deposited on the inorganic material during step (b) and the reaction products include gaseous reaction products, the process further including:

separating at least a portion of the gaseous reaction products from the coked inorganic material;

combusting the coke deposited on the inorganic material to heat the inorganic material forming heated inorganic material; and

recycling the heated inorganic material for use in a subsequent process for converting biomass to bio-oil.

20. The process of claim 1, wherein the inorganic material comprises a zeolite and zirconia.