Bubbling bed catalytic hydropyrolysis process utilizing larger catalyst particles and smaller biomass particles featuring an anti-slugging reactor
First Claim
1. A method of hydropyrolysis comprising:
- a. introducing an oxygenated organic feedstock into a fluidized bed reactor, wherein said feedstock is rapidly heated from ambient temperature to the temperature of the fluidized bed, and is thereby devolatilized;
b. introducing a stream of fluidizing gas comprising mostly molecular hydrogen into the fluidized bed reactor, creating conditions under which rapid mixing and heat transfer occur throughout the fluidized bed;
c. maintaining a deep bed of solid particles of catalyst, the depth of which is significantly greater than 2 reactor diameters, in a state of vigorous motion, to promote reactions resulting in deoxygenation and chemical stabilization of vapors produced when the feedstock is devolatilized;
d. removing solid residues, remaining after devolatilization and hydropyrolysis of the feedstock, from the fluidized bed reactor via entrainment in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor;
e. removing attritted residues of catalyst, but not intact particles of catalyst, or particles of catalyst that have been minimally attritted, from the fluidized bed reactor via entrainment in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor;
f. separating the solid residues, entrained in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor, from the stream of fluidizing gas and product vapors exiting the fluidized bed reactor;
g. recovering a product stream of hydrocarbon vapors comprising hydrocarbon species with atmospheric-pressure boiling points, consistent with those of at least one of gasoline, kerosene and diesel fuel, from the hydropyrolysis process as condensed liquid;
h. releasing enough exothermic heat from the deoxygenation reactions occurring during hydropyrolysis of the feedstock to supply process heat required by endothermic processes occurring during hydropyrolysis of the feedstock, including chemical reactions, heating of feedstock, and evaporation of liquids; and
i. dispersing one or more modifications to an interior of the reactor vessel, in such a manner that slugging does not occur within the fluidized bed reactor.
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Abstract
This invention relates to a process for thermochemically transforming biomass or other oxygenated feedstocks into high quality liquid hydrocarbon fuels. In particular, a catalytic hydropyrolysis reactor, containing a deep bed of fluidized catalyst particles is utilized to accept particles of biomass or other oxygenated feedstocks that are significantly smaller than the particles of catalyst in the fluidized bed. The reactor features an insert or other structure disposed within the reactor vessel that inhibits slugging of the bed and thereby minimizes attrition of the catalyst. Within the bed, the biomass feedstock is converted into a vapor-phase product, containing hydrocarbon molecules and other process vapors, and an entrained solid char product, which is separated from the vapor stream after the vapor stream has been exhausted from the top of the reactor. When the product vapor stream is cooled to ambient temperatures, a significant proportion of the hydrocarbons in the product vapor stream can be recovered as a liquid stream of hydrophobic hydrocarbons, with properties consistent with those of gasoline, kerosene, and diesel fuel. Separate streams of gasoline, kerosene, and diesel fuel may also be obtained, either via selective condensation of each type of fuel, or via later distillation of the combined hydrocarbon liquid.
121 Citations
55 Claims
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1. A method of hydropyrolysis comprising:
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a. introducing an oxygenated organic feedstock into a fluidized bed reactor, wherein said feedstock is rapidly heated from ambient temperature to the temperature of the fluidized bed, and is thereby devolatilized; b. introducing a stream of fluidizing gas comprising mostly molecular hydrogen into the fluidized bed reactor, creating conditions under which rapid mixing and heat transfer occur throughout the fluidized bed; c. maintaining a deep bed of solid particles of catalyst, the depth of which is significantly greater than 2 reactor diameters, in a state of vigorous motion, to promote reactions resulting in deoxygenation and chemical stabilization of vapors produced when the feedstock is devolatilized; d. removing solid residues, remaining after devolatilization and hydropyrolysis of the feedstock, from the fluidized bed reactor via entrainment in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor; e. removing attritted residues of catalyst, but not intact particles of catalyst, or particles of catalyst that have been minimally attritted, from the fluidized bed reactor via entrainment in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor; f. separating the solid residues, entrained in the stream of fluidizing gas and product vapors exiting the fluidized bed reactor, from the stream of fluidizing gas and product vapors exiting the fluidized bed reactor; g. recovering a product stream of hydrocarbon vapors comprising hydrocarbon species with atmospheric-pressure boiling points, consistent with those of at least one of gasoline, kerosene and diesel fuel, from the hydropyrolysis process as condensed liquid; h. releasing enough exothermic heat from the deoxygenation reactions occurring during hydropyrolysis of the feedstock to supply process heat required by endothermic processes occurring during hydropyrolysis of the feedstock, including chemical reactions, heating of feedstock, and evaporation of liquids; and i. dispersing one or more modifications to an interior of the reactor vessel, in such a manner that slugging does not occur within the fluidized bed reactor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55)
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Specification