Process for converting carbon-based energy carrier material

• US 8,709,239 B2
• Filed: 05/13/2013
• Issued: 04/29/2014
• 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:
  US13/892,728
• Publication Number:
  US 20130245346A1
• Time in Patent Office: 351 Days
• Field of Search: 585240-242, 585/469, 585638-640, 585/733, 443/07, 44605-606, 446/20, 208/390, 208/400, 208/404, 208/405, 208409-411, 208/415, 208/417
• 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) sensitizing the carbon-based energy carrier material to produce a sensitized material, wherein the carbon-based energy carrier material is a solid biomass;

b) contacting the sensitized material with a particulate catalyst material, wherein the step of contacting is carried out in a fluidized bed;

c) converting the sensitized material at a reaction temperature between 200°

C. and 450°

C., thereby forming reaction products in the vapor phase, in the presence of a reductive gas and wherein the reductive gas comprises iso-butane, naphthene, a volatile organic acid, or combination thereof;

d) separating at least a portion of the reaction products from the particulate catalyst material within 10 seconds after the reaction products are formed; and

e), optionally quenching the reaction products to a temperature below 200°

C.

2. The process of claim 1 wherein said sensitizing in step a) comprises contacting the carbon-based energy carrier material with a portion of the reaction products from step c).

3. The process of claim 1 further comprising intimately contacting the carbon-based energy carrier material with a portion of the particulate catalyst material by milling.

4. The process of claim 1 wherein the sensitizing in step a) is carried out below 200°

C.

5. The process of claim 1 wherein the sensitizing in step a) is carried out at ambient temperature.

6. The process of claim 1, wherein the 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.

7. The process of claim 1 further comprising contacting the carbon-based energy carrier material with an inorganic particulate material and a gas such that the particle size of the energy carrier material is reduced to less than 3 mm.

8. The process of claim 7 further comprising forming a mixture of carbon-based energy carrier material and inorganic particulate material and subjecting the mixture to agitation such as to form a fluid bed, an ebullient bed, a spouting bed or a pneumatic conveyance.

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

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

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