Process for the conversion of biomass to liquid fuels and specialty chemicals

• US 9,000,245 B2
• Filed: 08/01/2011
• Issued: 04/07/2015
• Est. Priority Date: 05/05/2006
• Status: Expired due to Fees

• Current Assignee: MARD Incorporated
• Original Assignee: Kior Inc.
• Inventors: O'Connor, Paul, Stamires, Dennis, Daamen, Sjoerd
• Primary Examiner(s): BHAT, NINA NMN
• Application Number:
  US13/195,493
• Publication Number:
  US 20120190062A1
• Time in Patent Office: 1,345 Days
• Field of Search: 585/240, 585/242, 201/2.5, 201/21, 201/31, 446/05, 446/06, 162/71, 162/77, 162/24
• US Class Current: 585/242
• CPC Class Codes: C10G 1/006 Combinations of processes provided in groups C10G1/02 - C10G1/08
• CPC Class Codes: C10G 1/02 by distillation
• CPC Class Codes: C10G 2300/1014 of vegetal origin
• CPC Class Codes: C10G 2300/4006 Temperature
• CPC Class Codes: C10G 2300/4081 Recycling aspects
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

A process is disclosed for converting biomass to fuels and/or valuable chemicals. The process comprises the steps of a) activating biomass to make it more susceptible to conversion; c) partially converting the biomass to a solubilized material; and d) subjecting the unconverted biomass to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated biomass. In a preferred embodiment the solubilized biomass obtained in step c) is removed before the unconverted biomass is subjected to step d).

Claims

1. A process for converting biomass to bio-oil, the process comprising:

(a) mixing biomass and at least one inorganic material having catalytic properties, wherein the at least one inorganic material includes a kaolin, a zeolite, or a mixture thereof; and

(b) converting at least a portion of the biomass to liquid organic compounds.

2. The process of claim 1, wherein the at least one inorganic material includes a kaolin selected from the group consisting of:

dealuminated kaolin, acid leached kaolin, calcined kaolin, and a combination thereof.

3. The process of claim 1, wherein the at least one inorganic material includes a zeolite.

4. The process of claim 3, wherein the at least one inorganic material is selected from the group consisting of:

zeolite X, zeolite REY, zeolite RE-USY, zeolite Y, zeolite USY, dealuminated USY zeolite, zeolite ZSM-5, beta zeolite, a silicalite, and a mixture of any two or more of the foregoing.

5. The process of claim 4, wherein the at least one inorganic material includes ZSM-5.

6. The process of claim 5, wherein the at least one inorganic material includes a mixture of ZSM-5 and dealuminated kaolin.

7. The process of claim 5, wherein the at least one inorganic material includes a mixture of ZSM-5 and calcined kaolin.

8. The process of claim 1, wherein the at least one inorganic material includes solid particles.

9. The process of claim 8, wherein the solid particles have a mean particle diameter ranging from 1 μ

m to 500 μ

m.

10. The process of claim 1, wherein the at least one inorganic material is thermally treated prior to step (a).

11. The process of claim 1, wherein the at least one inorganic material is a heat transferring medium, and step (b) includes heating the combination at an elevated temperature.

12. The process of claim 1, wherein the biomass includes wood chips.

13. The process of claim 1, further including milling the biomass before step (a).

14. The process of claim 13, wherein the biomass following milling has a mean particle diameter of less than 3 mm.

15. The process of claim 13, further including mixing the milled biomass and a solvent to form a slurry before step (a).

16. The process of claim 15, wherein the solvent includes water, alcohol, bio-oil, a liquid acid, an aqueous acid solution, an aqueous basic solution, liquid CO₂, or mixtures thereof.

17. The process of claim 1, wherein the biomass includes water, the process further including removing at least a portion of the water from the biomass before step (a).

18. The process of claim 17, further including removing the water from the biomass by heating the biomass at a drying temperature above 100°

C.

19. The process of claim 1, wherein step (a) further includes ball milling or grinding the biomass with the at least one inorganic material.

20. The process of claim 1, wherein step (a) further includes adding an acid or a base to the biomass.

21. The process of claim 1, wherein step (b) includes converting at least a portion of the biomass to bio-oil via at least one conversion process, wherein the at least one conversion process includes hydrothermal upgrading, at least partial pyrolysis, or enzymatic fermentation.

22. The process of claim 1, wherein step (b) further includes converting at least a portion of the biomass to the liquid organic compounds via a first conversion process, wherein the liquid organic compounds include a bio-oil.

23. The process of claim 22, wherein step (b) further includes separating unconverted biomass from the liquid organic compounds after the first conversion process.

24. The process of claim 23, wherein the unconverted biomass includes solid material.

25. The process of claim 23, wherein step (b) further includes converting at least a portion of the unconverted biomass to bio-oil via a second conversion process.

26. The process of claim 23, wherein the second conversion process operates at a temperature greater than an operating temperature of the first conversion process.

27. The process of claim 26, wherein the second conversion process is a pyrolysis process.

28. The process of claim 1, further including:

(c) converting the liquid organic compounds to fuel.

29. The process of claim 28, wherein step (c) further includes converting the liquid organic compounds to fuel via at least one of fluid catalytic cracking, hydroconversion, thermal conversion, or combinations thereof.

30. The process of claim 28, wherein step (c) further includes blending the liquid organic compounds with crude oil-based feedstock.

31. A process for converting biomass to liquid organic compounds, comprising:

milling biomass into particles having a mean particle diameter of less than 3 mm;

drying the milled biomass to at least partially remove water present within the biomass;

utilizing a catalyst comprising;

     1) ZSM-5 and

     2) a kaolin; and

converting at least a portion of the milled and dried biomass to the liquid organic compounds by heating the biomass in the presence of the catalyst.

32. The process of claim 31, wherein the biomass includes wood chips.

33. The process of claim 31, wherein the biomass is milled into particles having a mean particle diameter ranging from about 0.1 mm to about 1.0 mm.

34. The process of claim 31, wherein the catalyst comprising ZSM-5 and dealuminated kaolin is thermally treated.

35. The process of claim 31, wherein the step of converting at least a portion of the milled and dried biomass to the liquid organic compounds includes a pyrolysis reaction.

36. The process of claim 31 further including:

converting the liquid organic compounds to fuel via at least one of fluid catalytic cracking, hydroconversion, thermal conversion, or combinations thereof.

37. The process of claim 36, wherein the wood chips are milled to a mean particle diameter ranging from about 0.1 mm to about 1.0 mm.

38. The process of claim 36, further including combining the milled and dried wood chips and a solvent to produce a slurry following the drying step.