Processes for decreasing char entrainment during pyrolysis

Abstract

The present disclosure relates generally to novel biomass pyrolysis processes and systems that decrease entrainment of char and other contaminants with the produced pyrolysis vapors.

1 . A biomass pyrolysis process, comprising the steps of:
 (a) providing a particulate biomass feedstock;   (b) mixing the particulate biomass feedstock with a binder material to produce a mixture, and compressing the mixture to form pellets;   (c) pyrolyzing the pellets in a reactor to form a product comprising pyrolysis vapors and char particles, wherein the presence of the binder material in the pellets decreases the rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 300 microns in diameter either prior to, or during the pyrolyzing;   (d) obtaining pyrolysis vapors from an outlet of the reactor that comprise less entrained char (by weight) due to the increased average diameter of the char particles of step (c).   
     
     
         2 . The biomass pyrolysis process of  claim 1 , wherein during the pyrolyzing the binder material catalytically transforms at least a portion of the pyrolysis vapors to compounds fungible with a petroleum-derived transportation fuel, transportation fuel component, mixtures thereof, or a catalytically upgradeable intermediate that is further upgraded to compounds fungible with a petroleum-derived transportation fuel, transportation fuel component or mixtures thereof. 
     
     
         3 . The biomass pyrolysis process of  claim 1 , wherein the binder material additionally functions to alter the variety and complexity of chemical compounds produced during the pyrolyzing of step (c). 
     
     
         4 . The biomass pyrolysis process of  claim 1 , wherein the pyrolysis vapors of step (d) comprise less entrained metals (by weight) due to the decreased rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 300 microns either prior to, or during the pyrolyzing. 
     
     
         5 . The biomass pyrolysis process of  claim 1 , wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         6 . The biomass pyrolysis process of  claim 5 , wherein the pyrolysis vapors of step (d) comprise less entrained metals (by weight) due to the decreased rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns either prior to, or during the pyrolyzing. 
     
     
         7 . The biomass pyrolysis process of  claim 1 , and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         8 . The biomass pyrolysis process of  claim 1 , wherein the mixture is compressed to form pellets that are in a range from 750 microns to 1250 microns in diameter, and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter while the pellets remain inside the reactor. 
     
     
         9 . The biomass pyrolysis process of  claim 1 , wherein the mixture is compressed to form pellets that are in a range from 300 microns to 1250 microns in diameter, and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter while the pellets remain inside the reactor. 
     
     
         10 . A biomass pyrolysis process, comprising the steps of:
 (a) providing a particulate biomass feedstock;   (b) mixing the particulate biomass feedstock with a binder material to produce a mixture, and compressing the mixture to form pellets;   (c) pyrolyzing the pellets in a reactor to form a product comprising pyrolysis vapors and char particles, wherein the presence of the binder material in the pellets decreases the rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 300 microns in diameter either prior to, or during the pyrolyzing,
 wherein during the pyrolyzing, the binder material catalytically transforms at least a portion of the pyrolysis vapors to product compounds suitable for use as a hydrocarbon fuel, a hydrocarbon fuel component, a catalytically upgradeable intermediate or mixtures thereof, 
 wherein the product compounds obtained from an outlet of the reactor comprise less entrained char (by weight) due to the presence of the binder material in the pellets. 
   
     
     
         11 . The process of  claim 10 , wherein during the pyrolyzing, the binder material catalytically transforms at least a portion of the pyrolysis vapors to compounds suitable for use as a transportation fuel, component thereof, or upgraded pyrolysis vapors that are further upgraded to compounds suitable for use as a transportation fuel or component thereof. 
     
     
         12 . The process of  claim 10 , wherein the binder material additionally functions to reduce the variety and complexity of chemical compounds produced during the pyrolyzing of step (c). 
     
     
         13 . The process of  claim 10 , wherein the pyrolysis vapors of step (d) comprise less entrained metals (by weight) due to the decreased rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 300 microns in diameter in step (c). 
     
     
         14 . The process of  claim 10 , wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         15 . The process of  claim 10 , wherein the pyrolysis vapors of step (d) comprise less entrained metals (by weight) due to the decreased rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns in diameter in step (c). 
     
     
         16 . The process of  claim 10 , and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         17 . The process of  claim 10 , wherein the mixture is compressed to form pellets that are in a range from 750 microns to 1250 microns in diameter, and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter while the pellets remain inside the reactor. 
     
     
         18 . The process of  claim 10 , wherein the mixture is compressed to form pellets that are in a range from 300 microns to 1250 microns in diameter, and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter while the pellets remain inside the reactor. 
     
     
         19 . A biomass pyrolysis process, comprising the steps of:
 (a) providing a particulate biomass feedstock;   (b) mixing the particulate biomass feedstock with a binder material to produce a mixture, and compressing the mixture to form pellets;   (c) pyrolyzing the pellets in a reactor to form a product comprising pyrolysis vapors and char particles, wherein the presence of the binder material in the pellets decreases the rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 300 microns in diameter either prior to, or during the pyrolyzing, wherein the binder material also functions to reduce the variety and complexity of chemical compounds produced during the pyrolyzing;   (d) obtaining pyrolysis vapors from an outlet of the reactor that comprise less entrained char (by weight) due to the increased average diameter of the char particles of step (c).   
     
     
         20 . The process of  claim 19 , wherein during the pyrolyzing, the binder material catalytically transforms at least a portion of the pyrolysis vapors to compounds suitable for use as a transportation fuel, component thereof, or upgraded pyrolysis vapors that are further upgraded to compounds suitable for use as a transportation fuel or component thereof. 
     
     
         21 . The biomass pyrolysis process of  claim 19 , wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         22 . The biomass pyrolysis process of  claim 19 , wherein the pyrolysis vapors of step (d) comprise less entrained metals (by weight) due to the decreased rate of mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 500 microns in diameter in step (c). 
     
     
         23 . The biomass pyrolysis process of  claim 19 , and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter either prior to, or during the pyrolyzing. 
     
     
         24 . The biomass pyrolysis process of  claim 19 , wherein the mixture is compressed to form pellets that are in a range from 750 microns to 1250 microns in diameter, and wherein the presence of the binder material in the pellets decreases mechanical attrition, thermal attrition and dissociation of the pellets into particles smaller than 750 microns in diameter while the pellets remain inside the reactor.