Generating deoxygenated pyrolysis vapors

Abstract

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

1 . A process for the production and upgrading of a pyrolysis product, comprising the steps of:
 (a) pyrolyzing a biomass feedstock in a first reactor comprising at least one auger that conveys the feedstock through the reactor from a first end towards a second end, wherein said pyrolyzing forms primary pyrolysis products comprising a primary gaseous product and char;   (b) passing the primary gaseous product through a first outlet at or near the top of the first reactor and to an upgrading reactor;   (c) contacting the primary gaseous product with an upgrading catalyst in the upgrading reactor that is isolated from contact with the char, wherein the primary gaseous product does not condense prior to the contacting and comprises compounds containing less than 16 carbon atoms.   
     
     
         2 . The process of  claim 1 , wherein the total metal content entrained in the primary gaseous product in the upgrading reactor is less than 250 ppm. 
     
     
         3 . The process of  claim 1 , wherein the total metal content entrained in the primary gaseous product in the upgrading reactor is less than 100 ppm. 
     
     
         4 . The process of  claim 1 , wherein greater than 99.5 wt. % of char is prevented from leaving the first reactor via the first outlet, thereby extending the activity of the upgrading catalyst. 
     
     
         5 . The process of  claim 1 , wherein greater than 99.9 wt. % of char is prevented from leaving the first reactor via the first outlet, thereby extending the activity of the upgrading catalyst. 
     
     
         6 . The process of  claim 1 , wherein the elapsed time prior to the contacting is less than the time required for the primary gaseous product to oligomerize to form a secondary product comprising compounds containing more than 15 carbon atoms. 
     
     
         7 . The process of  claim 4 , wherein the elapsed time is less than three seconds. 
     
     
         8 . The process of  claim 4 , wherein the elapsed time is less than one second. 
     
     
         9 . The process of  claim 4 , wherein the elapsed time is less than 0.25 seconds. 
     
     
         10 . The process of  claim 4 , wherein the secondary product is more difficult to upgrade to a biofuel than the primary gaseous product. 
     
     
         11 . The process of  claim 1 , wherein the upgrading catalyst comprises two or more upgrading catalysts that may be arranged to contact the primary gaseous product in parallel, in series or as mixtures of catalyst. 
     
     
         12 . The process of  claim 9 , wherein the two or more upgrading catalysts contact the primary gaseous product under different conditions that comprise at least one of temperature, pressure, and humidity. 
     
     
         13 . The process of  claim 1 , wherein the primary gaseous product flows through two or more upgrading reactors, wherein each upgrading reactor is maintained at a temperature and pressure that optimize the upgrading reactions taking place therein. 
     
     
         14 . The process of  claim 4 , wherein the secondary product comprises phenolic dimers, phenolic oligomers, cross-linked lignin, char or combinations thereof. 
     
     
         15 . The process of  claim 1 , wherein the primary product comprises one or more of aromatic monomers, furan monomers, anhydrosugar monomers, olefins, alcohols, aldehydes, carboxylic acids, ketones, ethers, esters and hydrocarbons. 
     
     
         13 . The process of  claim 1 , wherein a sweep gas assists in moving the primary gaseous product from the first reactor to the second reactor.