Pyrolysis vapor rapid filtration and conversion to fuel

Abstract

The present disclosure pertains to biomass pyrolysis processes and systems that decrease entrainment of char and other contaminants in the pyrolysis vapors by filtering the vapors in a heated container comprising a moving bed granular filter (MBGF), which in turn, comprises granular heat carrier. The granular heat carrier is heated within the MBGF and fed directly to the pyrolysis reactor, optionally along with filtered solids such as char. In certain embodiments, the MBGF additionally comprises at least one upgrading catalyst that contacts the vapors to produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof.

1 . A biomass pyrolysis system, comprising:
 (a) a pyrolysis reactor comprising:
 an inlet for a mixture comprising a granular heat carrier, said inlet positioned to contact the mixture with a biomass feedstock to form pyrolysis vapors comprising entrained char particles; 
 at least one auger that is operable to facilitate unidirectional movement of the mixture and the biomass feedstock through the pyrolysis reactor 
 an outlet operable to allow egress of the pyrolysis vapors; 
   (b) a container operable to heat the its contents to a temperature greater than 350° C., the container comprising:
 an inlet that is operable to allow entry of pyrolysis vapors and is connected to the outlet of the pyrolysis reactor, 
   a moving bed granular filter that is fully enclosed by the container and that comprises a mixture that comprises a granular heat carrier, wherein the inlet is operable to receive and direct the pyrolysis vapors through the moving bed granular filter, wherein the moving bed granular filter is operable to retain at least a portion of the entrained char particles to produce a low-particulate pyrolysis vapors;   a first outlet operable to allow egress of the granular heat carrier and the entrained char particles retained by the moving bed granular filter,   a second outlet operable to allow egress of the low-particulate upgraded pyrolysis vapors, the second outlet connected to the inlet of the pyrolysis reactor for granular heat carrier;   
     
     
         2 . The system of  claim 1 , wherein the moving bed granular filter comprises a mixture that comprises granular heat carrier and at least one upgrading catalyst operable to contact the pyrolysis vapors and produce a low-particulate upgraded pyrolysis vapors. 
     
     
         3 . The system of  claim 2 , additionally comprising at least one additional upgrading catalyst operable to contact the low-particulate upgraded pyrolysis vapors and produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         4 . The system of  claim 1 , wherein the container is operable to heat the contents to a temperature greater than 480° C. 
     
     
         5 . The system of  claim 1 , additionally comprising a separating device located between the first outlet of the container and the inlet for granular heat carrier of the pyrolysis reactor. 
     
     
         6 . The system of  claim 1 , wherein any inlet or outlet comprises multiple inlets or outlets operable for essentially the same purpose. 
     
     
         7 . The system of  claim 1 , wherein the pyrolysis vapors pass into and through the moving bed granular filter either perpendicularly or directly-opposed to the flow of the granular heat carrier through the moving bed granular filter 
     
     
         8 . A biomass pyrolysis system, comprising:
 (a) a pyrolysis reactor comprising:
 an inlet for a mixture comprising a granular heat carrier and at least one catalyst, the inlet positioned to contact the mixture with a biomass feedstock to form pyrolysis vapors comprising entrained char particles; 
 at least one auger that is operable to facilitate unidirectional movement of the mixture and the biomass feedstock through the pyrolysis reactor 
 an outlet for the pyrolysis vapors; 
   (b) a container operable to heat the its contents to a temperature greater than 350° C., the container comprising:
 an inlet that is operable to allow entry of pyrolysis vapors and is connected to the outlet of the pyrolysis reactor, 
 a moving bed granular filter that is fully enclosed by the container, wherein the moving bed granular filter comprises a mixture that comprises granular heat carrier and at least one catalyst, wherein the inlet is operable to receive and direct the pyrolysis vapors through the moving bed granular filter, wherein the moving bed granular filter is operable to retain at least a portion of the char particles and to catalytically upgrade the pyrolysis vapors to produce low-particulate upgraded pyrolysis vapors; 
 a first outlet for the mixture and char particles retained by the moving bed granular filter, 
 a second outlet for the low-particulate upgraded pyrolysis vapors that is connected to the at least one inlet of the pyrolysis reactor; 
   (c) at least one additional upgrading catalyst operable to contact the low-particulate upgraded pyrolysis vapors and produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof.   
     
     
         9 . The system of  claim 8 , wherein the container is operable to heat the contents to a temperature greater than 480° C. 
     
     
         10 . The system of  claim 8 , additionally comprising a separating device located between the first outlet of the container and the inlet for granular heat carrier of the pyrolysis reactor. 
     
     
         11 . The system of  claim 8 , wherein any inlet or outlet comprises multiple inlets or outlets operable for essentially the same purpose.