Systems 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 system, comprising:
 (a) a pelletized biomass feedstock comprising pellets greater than or equal to 300 microns in diameter;   (b) a pyrolysis reactor comprising at least one inlet for receiving the pelletized biomass feedstock, a reaction zone for pyrolyzing the pelletized biomass feedstock to form pyrolysis vapors and char particles, at least one outlet for the pyrolysis vapors, and at least one outlet for the char particles,
 wherein the pelletized biomass feedstock comprises a particulate biomass and a binder material that prevents mechanical attrition, thermal attrition and dissociation of the pelletized biomass feedstock into particles smaller than 300 microns in diameter either prior to, or during the pyrolyzing, thereby preventing entrainment of the char in the pyrolysis vapors. 
   
     
     
         2 . The biomass pyrolysis system of  claim 1 , wherein the pelletized biomass feedstock comprises pellets in a range from 750 microns to 1250 microns in diameter. 
     
     
         3 . The biomass pyrolysis system of  claim 1 , wherein the pelletized biomass feedstock comprises a particulate biomass and a binder material that prevents mechanical attrition, thermal attrition and dissociation of the pelletized biomass feedstock into particles smaller than 500 microns in diameter either prior to, or during the pyrolyzing, thereby preventing entrainment of the char in the pyrolysis vapors.
 The biomass pyrolysis system of  claim 1 , wherein the binder material is an upgrading catalyst that catalytically transforms at least a portion of the pyrolysis vapors to a bio-derived hydrocarbon fuel, bio-derived fuel component.   
     
     
         4 . The biomass pyrolysis system of  claim 1 , wherein the binder material is an upgrading catalyst for catalytically transforming at least a portion of the pyrolysis vapors to upgradeable intermediate compounds, and the system further comprises at least one upgrading reactor containing at least one upgrading catalyst for further upgrading the upgradeable intermediate compounds to a bio-derived hydrocarbon fuel, or bio-derived fuel component.