Improved process for converting carbon-based energy carrier material

Abstract

A catalytic process is disclosed for converting solid or high viscosity carbon-based energy carrier materials, such as heavy crudes, oil sands, synthetic polymeric wastes and cellulosic or aquatic biomass. The conversion temperature is less than 450° C. The reaction products are separated from the catalyst within 10 seconds after being formed. The temperature of the reaction products is lowered to less than 200° C. within 10 seconds after being formed. The process results in less deterioration of the reaction products.

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) 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., thereby forming reaction products in the vapor phase;   c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed;   d) optionally quenching the reaction products to a temperature below 200° C.   
   
   
       2 . The process of  claim 1  comprising the additional step of stripping reaction products from the particulate catalyst material. 
   
   
       3 . The process of  claim 1  or  2  comprising the additional step of burning off any coke formed on the particulate catalyst material. 
   
   
       4 . The process of  claim 2  or  3  comprising the further step of recycling the particulate catalyst material to step a) or b). 
   
   
       5 . The process of any one of the preceding claims whereby a reactive gas is present during step b). 
   
   
       6 . The process of  claim 5  wherein the reactive gas has oxidative or reductive properties. 
   
   
       7 . The process of  claim 5  wherein the reactive gas is reactive in isomerisation or alkylation reactions. 
   
   
       8 . The process of  claim 6  wherein the reactive gas comprises oxygen, hydrogen, hydrogen sulfide, or carbon monoxide. 
   
   
       9 . The process of  claim 7  wherein the reactive gas comprises iso-butane, naphtene, or a volatile organic acid. 
   
   
       10 . The process of any one of the preceding claims 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. 
   
   
       11 . The process of any one of the preceding claims wherein the carbon-based energy carrier material is of mineral origin. 
   
   
       12 . The process of  claim 11  wherein the carbon-based energy carrier material is a tar, a heavy crude, or a bitumen. 
   
   
       13 . The process of any one of  claims 1  through  10  wherein the carbon-based energy carrier material is a synthetic polymer. 
   
   
       14 . The process of any one of  claims 1  through  10  wherein the carbon-based energy carrier material is a solid biomass. 
   
   
       15 . The process of  claim 14  wherein the solid biomass comprises cellulose, lignin, or lignocellulose. 
   
   
       16 . The process of  claim 14  wherein the solid biomass is of aquatic origin. 
   
   
       17 . The process of any one of  claims 3 - 16  whereby the CO 2  is utilized in the production of biomass. 
   
   
       18 . The process of  claim 17  whereby the CO 2  is utilized in the production of aquatic biomass. 
   
   
       19 . The process of any one of the preceding claims wherein step a) comprises milling of the carbon-based energy carrier material in the presence of the particulate catalyst material. 
   
   
       20 . The process of any one of the preceding claims wherein step a) comprises the steps of:
 (i) taking up the particulate catalyst material in a stream of a carrier gas;   (ii) causing the gas stream to flow such that the particulate catalyst material reaches a velocity of at least 1 m/s, preferably at least 10 m/s   (iii) impinging the catalyst particles onto the carbon-based energy carrier material.   
   
   
       21 . The process of  claim 17  wherein the carrier gas further comprises a particulate inert material. 
   
   
       22 . The process of  claim 17  or  18  wherein step a) is carried out in a fluidized bed, a riser reactor, or a downer reactor. 
   
   
       23 . The process of any one of the preceding claims wherein the reaction temperature in step b) is less than 350° C., preferably less than 300° C., more preferably less than 250° C. 
   
   
       24 . The process of any one of the preceding claims wherein the vapor phase reaction products comprise steam, hydrocarbons, or a mixture thereof. 
   
   
       25 . The process of  claim 3  wherein the coke is burned off with air. 
   
   
       26 . The process of  claim 3  or  22  comprising the further step of cooling the particulate catalyst material after the coke has been burned off. 
   
   
       27 . The process of  claim 23  whereby heat recovered from the particulate catalyst material is used for generating steam, hot water, or electricity. 
   
   
       28 . The process of any one of the preceding claims whereby at least step b) is carried out in an FCC unit. 
   
   
       29 . The process of any one of the preceding claims whereby at least step b) is carried out in a downer.