Process and rotary machine type reactor

• US 9,234,140 B2
• Filed: 02/22/2013
• Issued: 01/12/2016
• Est. Priority Date: 02/22/2013
• Status: Active Grant

• Current Assignee: Coolbrook Oy
• Original Assignee: Coolbrook Oy
• Inventors: Seppala, Jukka, Purola, Veli-Matti, Hiltunen, Jyrki
• Primary Examiner(s): Young, Natasha
• Application Number:
  US13/774,096
• Publication Number:
  US 20140243569A1
• Time in Patent Office: 1,054 Days
• US Class Current: 1/1
• CPC Class Codes: B01J 19/1806 resulting in a turbulent flow of the reactants, such as in centrifugal-type reactors, or having a high Reynolds-number
• CPC Class Codes: B01J 3/08 Application of shock waves for chemical reactions or for modifying the crystal structure of substances
• CPC Class Codes: C10G 3/00 Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids production from non-melting solid oxygen-containing carbonaceous materials C10G1/00
• CPC Class Codes: C10G 3/40 Thermal non-catalytic treatment
• CPC Class Codes: C10G 9/00 Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

A rotary machine type shock wave reactor suitable for thermal cracking of hydrocarbon-containing materials includes a casing, a rotor whose periphery contains an axial-flow blade cascade, and a directing rim, provided with at least two stationary vane cascades, adjoining an axial-flow rotor cascade, wherein the casing substantially encloses the periphery of the rotor and the directing rim. The cascades are configured to direct feedstock containing process stream to repeatedly pass the cascades in a helical trajectory while propagating within the duct between the inlet and exit and to generate stationary shock-waves to heat the feedstock. The axial-flow rotor cascade is configured to provide kinetic energy and add velocity to feedstock containing process stream, and the stationary vanes located downstream the rotor cascade are configured to reduce the velocity of the stream and convert kinetic energy into heat. The reactor may also process carbohydrate-and glyceride-based feedstock, and gaseous biomass matter.

Claims

1. A shock wave reactor for thermal cracking of hydrocarbon-containing feedstock, comprising:

a casing wherein a duct is formed with at least one inlet and at least one outlet;

a rotor, the periphery of which contains an axial-flow blade cascade;

wherein the casing substantially encloses the periphery of the rotor and a number of stationary vane cascades inside the duct, and further wherein the stationary vane cascades are configured to direct a feedstock containing process stream to repeatedly pass said stationary vane cascades in accordance with a helical trajectory while propagating within the duct between the inlet and outlet and to generate stationary shock-waves to heat the feedstock.

2. The reactor of claim 1, wherein the duct has a substantially ring-shaped meridian section.

3. The reactor of claim 1, wherein the stationary vane cascades comprise at least two cascades, the first stationary vane cascade being configured upstream and the second stationary vane cascade being configured downstream the axial-flow blade cascade.

4. The reactor of claim 1, wherein the stationary vane cascades comprise at least two cascades, the first stationary vane cascade being configured upstream and the second stationary vane cascade being configured downstream the axial-flow blade cascade, and wherein the stationary vane cascades are arranged such that a vaneless space is created between the first cascade entrance point and second cascade exit point.

5. The reactor claim 1, comprising a stationary directing rim inside the casing, the outer surface of which rim substantially defines the duct to remain therebetween with the inner surface of the casing.

6. The reactor of claim 1, comprising a stationary directing rim inside the casing, the outer surface of which rim substantially defines the duct to remain therebetween with the inner surface of the casing, and wherein the outer surface of the rim is provided with at least some of the stationary vane cascades.

7. The reactor of claim 1, wherein the cascades are substantially adjacent inside the duct.

8. The reactor of claim 1, provided with two inlets and two outlets.

9. The reactor of claim 1, wherein the duct is configured to define a substantially conical, truncated cone-or cylindrical-shaped chamber.

10. The reactor of claim 1, wherein the duct is configured to define a substantially conical, truncated cone-or cylindrical-shaped chamber, wherein blades of the axial-flow rotor cascade(s) are configured to alternate with vanes of corresponding stationary vane cascades in longitudinal direction of the rotor forming sequential cascading units, each unit comprising rotor blade spatially located between stationary vanes.

11. The reactor of claim 1, wherein the duct is configured to define a substantially conical, truncated cone-or cylindrical-shaped chamber, wherein blades of the axial-flow rotor cascade(s) are configured to alternate with vanes of corresponding stationary vane cascades in longitudinal direction of the rotor forming sequential cascading units, each unit comprising rotor blade spatially located between stationary vanes, and wherein the first stationary vane cascade comprises a plurality of nozzle vanes and the second stationary vane cascade comprises a plurality of diffusing vanes, said nozzle and diffusing vanes being configured to mutually alternate in longitudinal direction of the rotor.

12. The reactor of claim 1, wherein the axial-flow blade cascade is configured to provide kinetic energy and to add velocity to feedstock containing process stream, and at least one stationary vane cascade is configured to reduce the velocity of the stream and convert kinetic energy into heat.

13. The reactor of claim 1, wherein the flow velocity of the feedstock containing process stream is supersonic at the cascades and subsonic in the vaneless space within the duct.

14. The reactor of claim 1, wherein at least some of the stationary vane cascades are arranged on the duct wall-defining inner surface of the casing.

15. The reactor of claim 1, wherein at least one inlet and at least one outlet are integrated within the duct.

16. The reactor of claim 1, wherein at least two dividing partitions are arranged within the duct symmetrically relative to a rotor axis so as to form at least two substantially identical operational chambers, each being associated with inlet and exit for the process stream.

17. The reactor of claim 1, wherein the first stationary vane cascade comprises a plurality of nozzle vanes having a curved profile and being disposed by their convex sides in the direction of rotor rotation, and wherein the second stationary vane cascade comprises a plurality of diffusing vanes having a curved supersonic compressor profile and being disposed by convex sides in the direction of rotor rotation.

18. The reactor of claim 1, wherein the axial-flow blade cascade contains a plurality of blades having a profile of active turbine blade, the blades being installed by concave side thereof in the direction of rotor rotation.

19. The reactor of claim 1, configured to process gasified carbohydrate-containing feedstock matter.

20. The reactor of claim 1, configured to process gasified glyceride-containing feedstock matter.

21. The reactor of claim 1, configured to process gasified preprocessed cellulosic biomass material.

22. The reactor of claim 1, configured with a number of catalytic surfaces.

23. The reactor of claim 1, configured with a number of catalytic surfaces, wherein the catalytic surface(s) are formed by catalytic coating of at least several of the individual blades or vanes within the reaction zone and/or by catalytic coating of the duct wall-defining inner surface of the casing.

24. The reactor of claim 1, configured with a number of catalytic surfaces, further comprising a number of catalytic modules defined by ceramic or metallic substrate(s) or support carrier(s) with an active coating optionally realized as monolithic honeycomb structures.

25. The reactor of claim 1, wherein the reactor contains intermediate cooling or heating element.

26. The reactor of claim 1, where the reactor is configured for intermediate injection of diluent or reactive material.

27. The reactor of claim 1, configured such that the time gaseous feedstock spends in the reaction zone is substantially equal or less than about 10 milliseconds.

28. Use of the reactor of claim 1 in executing at least one procedure selected from the group consisting of:

processing hydrocarbon feedstock containing medium and light weight hydrocarbon fractions;

processing gaseous, oxygen-containing, fatty acid-based feedstock material;

processing gaseous, fatty-acid based feedstock material, which material is preprocessed pine oil;

processing gaseous cellulose-derived, and in particular, lignocellulose-derived feedstock material; and

fast pyrolysis process comprising converting biomass-derived feedstock material into oil.

29. A reactor assembly, comprising at least one reactor according to claim 1 and at least one further element selected from the group consisting of:

a drive engine, a heat recovery unit, a quenching unit, a pyrolysis furnace, a pyrolysis furnace with external heating, a pre-heating apparatus or an air filter.

30. A pyrolysis plant, comprising at least two reactors according to claim 1, functionally connected in series or in parallel.

31. A method for thermal cracking of hydrocarbon-containing feedstock, comprising:

a. providing a shock wave reactor comprising, a casing wherein a duct is formed with at least one inlet and at least one outlet;

a rotor, the periphery of which contains an axial-flow blade cascade;

wherein the casing substantially encloses the periphery of the rotor and a number of stationary vane cascades inside the duct, and further wherein the stationary containing process stream to repeatedly pass said stationary vane cascades in accordance with a helical trajectory while propagating within the duct between the at least one inlet and at least one outlet and to generate stationary shock-waves to heat the feedstock;

b. elevating a rotation speed of the rotor to reach a predetermined process speed or speed range;

c. feeding the feedstock containing process stream into the at least one inlet, whereupon both the stationary vane cascades and the rotor axial-flow blade cascade begin directing the feedstock containing process stream to repeatedly pass through said stationary vane cascades in accordance with the helical trajectory while propagating within the duct between the at least one inlet and at least one outlet, and sequentially generating the stationary shock-waves to heat the feedstock stream within the reactor, causing thermal degradation or pyrolysis thereof; and

d. directing the pyrolized product stream through the at least one outlet to a predetermined post-processing unit.

32. Method of claim 31, wherein the feedstock comprises medium or light weight hydrocarbon fractions.

33. Method of claim 31, wherein the feedstock is lignocellulose-derived preprocessed biomass, supplied into the reactor in substantially gaseous form.

34. Method for importing energy for fast endothermic- or fast exothermic reaction produced from mechanical energy of rotating blade cascades, said method comprising:

a. providing a shock wave reactor comprising, a casing wherein a duct is formed with at least one inlet and at least one outlet;

a rotor, the periphery of which contains an axial-flow blade cascade;

wherein the casing substantially encloses the periphery of the rotor and a number of stationary vane cascades inside the duct, and further wherein the stationary containing process stream to repeatedly pass said stationary vane cascades in accordance with a helical trajectory while propagating within the duct between the at least one inlet and at least one outlet and to generate stationary shock-waves to heat the feedstock; and

b. passing a preheated, feedstock containing gaseous phase into the reactor to carry out endothermic gaseous phase reactions, wherein the heat is provided by impulses, generated by shock waves resulting from mechanical energy derived from rotation of internal rotor blades.

35. Method of claim 34, wherein the feedstock comprises medium or light weight hydrocarbon fractions.

36. Method of claim 34, wherein the feedstock is cellulose-derived or, in particular, lignocellulose-derived preprocessed biomass, supplied into the reactor in substantially gaseous form.