Fast pyrolysis system

Abstract

A fast pyrolysis system includes an auger housing having an inlet, an outlet, and an inner wall. A rotatable auger is mounted in the housing. The auger has surfaces defining at least one spiral channel. The spiral channel is tapered from a first depth adjacent the housing inlet to a second lesser depth adjacent the housing outlet. The auger is rotatable to propel particulate materials from the housing inlet toward the housing outlet to heat the particulate material to a first temperature sufficient to convert at least a portion of the particulate material into a vapor. A heat exchanger transfers a heat of vaporization from a heated medium to the auger housing inner wall. A filter assembly is connected downstream to the housing outlet in order to filter char fines from the vapor. A condenser is connected downstream to the filter assembly and is adapted to condense the vapor stream into bio-oil.

1 . In combination with an ablative gasification reactor having, an auger housing having an inner and an outer wall, an inlet and an outlet, a rotatable auger mounted in the housing, the auger having surfaces defining at least one spiral channel, the spiral channel being tapered from a first depth adjacent the housing inlet and to a second lesser depth adjacent the housing outlet, the auger rotatable to propel particulate materials from the housing inlet toward the housing outlet, and adapted to heat the particulate material to a first temperature sufficient to convert at least a portion of the particulate material into a vapor, a fast pyrolysis system, comprising:
 (a) a heat exchanger connected to the outer wall of the auger housing having a heated medium adapted for transferring a heat of vaporization to the auger housing inner wall;   (b) a filter assembly having an inner and an outer wall and an inlet and an outlet, the inlet connected to the auger housing outlet for receiving the vapor, the filter assembly adapted to filter a char component of the particulate material from the vapor; and   (c) a condenser having an inlet and an outlet, the inlet connected to the outlet of the filter assembly, the condenser adapted to thermally quench the vapor so that a bio-oil is captured from the vapor.   
     
     
         2 . The fast pyrolysis system according to  claim 1 , wherein the heated medium is circulated in the heat exchanger at a temperature in the range of 300° to 700° centigrade. 
     
     
         3 . The fast pyrolysis system according to  claim 1 , further comprising an internal combustion engine having a power take off connected to the auger adapted for rotation of the auger. 
     
     
         4 . The fast pyrolysis system according to  claim 1 , wherein the heat exchanger is further connected to a portion of the outer wall of the filter assembly for heating the filter assembly with the heated medium. 
     
     
         5 . The fast pyrolysis system according to  claim 1 , further comprising a catalytic reactor having an inlet and an outlet, the inlet connected to the outlet of the filter assembly and the outlet connected to the inlet of the condenser, the catalytic reactor adapted to catalyze the vapor to be condensed. 
     
     
         6 . The fast pyrolysis system according to  claim 1 , further comprising a membrane separator having an inlet and an outlet, the inlet connected to the outlet of the surface condenser and adapted to separate a hydrogen fraction from a gas reaction product after condensation. 
     
     
         7 . The fast pyrolysis system according to  claim 3 , wherein the heated medium is an exhaust combustion product of the internal combustion engine. 
     
     
         8 . The fast pyrolysis system according to  claim 3 , wherein the condenser includes a second outlet line connected to an intake manifold of the internal combustion engine to fuel the internal combustion engine. 
     
     
         9 . The fast pyrolysis system according to  claim 5 , wherein the catalytic reactor includes a catalytic static in-line mixer. 
     
     
         10 . A method for converting a particulate substrate into a bio-oil, comprising the steps of:
 (a) providing an auger housing having an inner and an outer wall, an inlet and an outlet, a rotatable auger mounted in the housing, the auger having surfaces defining at least one spiral channel, the spiral channel being tapered from a first depth adjacent the housing inlet and to a second lesser depth adjacent the housing outlet, the auger rotatable to propel the particulate materials from the housing inlet toward the housing outlet;   (b) providing a heat exchanger connected to the outer wall of the auger housing having a heated medium adapted for transferring a heat of vaporization to the auger housing inner wall;   (c) providing a filter assembly having an inner and an outer wall and an inlet and an outlet, the inlet connected to the housing outlet for receiving the vapor, the filter assembly adapted to filter a char component of the particulate material from the vapor;   (d) providing a condenser having an inlet and an outlet, the inlet connected to the outlet of the filter assembly, the condenser adapted to thermally quench the vapor so that a bio-oil is captured from the vapor;   (e) heating the auger housing with the heated medium;   (f) feeding the particulate material to be converted into the auger housing inlet;   (g) rotating the auger so that the particulate material is propelled from the housing inlet toward the housing outlet;   (h) heating the particulate material to a first temperature sufficient to convert at least a portion of the particulate material into a vapor;   (i) filtering a char portion of the particulate material from the vapor; and   (j) condensing the vapor into a bio-oil.   
     
     
         11 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , wherein the heated medium is circulated in the heat exchanger at a temperature in the range of 300° to 700° centigrade. 
     
     
         12 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , further comprising the step of providing an internal combustion engine having a power take off connected to the auger adapted for rotation of the auger. 
     
     
         13 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , wherein the heat exchanger is further connected to a portion of the outer wall of the filter assembly for heating the filter assembly with the heated medium. 
     
     
         14 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , further comprising providing a catalytic reactor having an inlet and an outlet, the inlet connected to the outlet of the filter assembly and the outlet connected to the inlet of the condenser, the catalytic reactor adapted to catalyze the vapor to be condensed. 
     
     
         15 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , further comprising providing a membrane separator having an inlet and an outlet, the inlet connected to the outlet of the surface condenser and adapted to separate a hydrogen fraction from a gas reaction product after condensation. 
     
     
         16 . The method for converting a particulate substrate into a bio-oil according to  claim 10 , further comprising connecting the heat exchanger to an exhaust manifold of the internal combustion engine and wherein the heated medium is an exhaust from the internal combustion engine. 
     
     
         17 . The method for converting a particulate substrate into a bio-oil according to  claim 3 , wherein the condenser further includes a second outlet line connected to an intake manifold of the internal combustion engine adapted to fuel the internal combustion in the engine. 
     
     
         18 . The method for converting a particulate substrate into a bio-oil according to  claim 14 , wherein the catalytic reactor includes a catalytic static in-line mixer. 
     
     
         19 . A bio-oil product produced by a process for converting a particulate substrate, the process comprising the steps of:
 (a) providing an auger housing having an inner and an outer wall, an inlet and an outlet, a rotatable auger mounted in the housing, the auger having surfaces defining at least one spiral channel, the spiral channel being tapered from a first depth adjacent the housing inlet and to a second lesser depth adjacent the housing outlet, the auger rotatable to propel particulate materials from the housing inlet toward the housing outlet;   (b) providing a heat exchanger connected to the outer wall of the auger housing having a heated medium adapted for transferring a heat of vaporization to the auger housing inner wall;   (c) providing a filter assembly having an inner and an outer wall and an inlet and an outlet, the inlet connected to the housing outlet for receiving the vapor, the filter assembly adapted to filter a char component of the particulate material from the vapor;   (d) providing a condenser having an inlet and an outlet, the inlet connected to the outlet of the filter assembly, the condenser adapted to thermally quench the vapor so that a bio-oil is captured from the vapor;   (e) heating the auger housing with the heated medium;   (f) feeding the particulate material to be converted into the auger housing inlet;   (g) rotating the auger so that the particulate material is propelled from the housing inlet toward the housing outlet;   (h) heating the particulate material to a first temperature sufficient to convert at least a portion of the particulate material into a vapor;   (i) filtering a char portion of the particulate material from the vapor; and   (i) condensing the vapor into the bio-oil.