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 process, comprising the steps of:
 (a) providing a heated container that encloses a moving bed granular filter, wherein the moving bed granular filter comprises a granular heat carrier;   (b) heating the granular heat carrier in the heated container to produce a heated granular heat carrier that is conveyed to a pyrolysis reactor;   (c) pyrolyzing a biomass feedstock in the pyrolysis reactor to produce pyrolysis vapors comprising a residual amount of entrained char particles, wherein rapid heating of the biomass feedstock is facilitated by contact with the heated granular heat carrier;   (d) conveying the pyrolysis vapors out of the pyrolysis reactor and through the moving bed granular filter to separate at least a portion of the residual entrained char particles, thereby producing low-particulate pyrolysis vapors and a solid stream comprising char and the heated granular heat carrier of step (a).   
     
     
         2 . The process of  claim 10 , further comprising contacting the low-particulate upgraded pyrolysis vapors with at least one upgrading catalyst within the heated container to produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel or a component thereof. 
     
     
         3 . The process of  claim 1 , further comprising contacting the low-particulate upgraded pyrolysis vapors with at least one upgrading catalyst within the moving bed granular filter to produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         4 . The process of  claim 1 , wherein the granular heat carrier additionally comprises an upgrading catalyst or is impregnated with at least one catalyst that contacts the pyrolysis vapors and catalytically converts them to a hydrocarbon mixture that is fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         5 . The process of  claim 1 , wherein the char in the solid stream is conveyed to the pyrolysis reactor along with the heated granular heat carrier. 
     
     
         6 . The process of  claim 1 , wherein the solid stream is separated to remove at least a portion of the char prior to conveying the heated granular heat carrier to the pyrolysis reactor. 
     
     
         7 . The process 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 . The process of  claim 1 , wherein the granular heat carrier is heated to greater than 480° C. within the heated container. 
     
     
         9 . The process of  claim 1 , wherein the pyrolysis reactor comprises at least one auger that facilitates movement of the granular heat carrier and the biomass feedstock through the reactor in a unidirectional manner. 
     
     
         10 . A biomass pyrolysis process, comprising the steps of:
 (a) providing a heated container that encloses a moving bed granular filter, wherein the moving bed granular filter comprises a mixture that in turn comprises granular heat carrier and at least one catalyst;   (b) heating the mixture in the heated container to temperature greater than 350° C. to produce a heated mixture that is conveyed to a pyrolysis reactor;   (c) pyrolyzing a biomass feedstock in the pyrolysis reactor to produce pyrolysis vapors comprising a residual amount of entrained char particles, wherein rapid heating of the biomass feedstock is facilitated by contact with the heated mixture;   (d) conveying the pyrolysis vapors out of the pyrolysis reactor and through the moving bed granular filter of step (a) to separate at least a portion of the residual entrained char particles and to catalytically upgrade the pyrolysis vapors, thereby producing low-particulate upgraded pyrolysis vapors and a solid stream comprising char and the mixture of step (a).   
     
     
         11 . The process of  claim 10 , further comprising contacting the low-particulate upgraded pyrolysis vapors with at least one additional upgrading catalyst to produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         12 . The process of  claim 10 , wherein the moving bed granular filter additionally comprises at least one upgrading catalyst that contacts the pyrolysis vapors and catalytically converts them to a hydrocarbon mixture that is fungible with a petroleum-derived transportation fuel, hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         13 . The process of  claim 10 , wherein the granular heat carrier additionally comprises an upgrading catalyst or is impregnated with at least one catalyst that contacts the pyrolysis vapors and catalytically converts them to a hydrocarbon mixture that is fungible with a petroleum-derived transportation fuel, hydrocarbon transportation fuel component, or mixtures thereof. 
     
     
         14 . The process of  claim 10 , wherein the char in the solid stream is conveyed to the pyrolysis reactor along with the heated granular heat carrier. 
     
     
         15 . The process of  claim 10 , wherein the solid stream is separated to remove at least a portion of the char prior to conveying the heated granular heat carrier to the pyrolysis reactor. 
     
     
         16 . The process of  claim 10 , 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. 
     
     
         17 . The process of  claim 10 , wherein the mixture is heated to a temperature greater than 480° C. in the heated container to produce the heated mixture. 
     
     
         18 . The process of  claim 10 , wherein the pyrolysis reactor comprises at least one auger that facilitates movement of the granular heat carrier and the biomass feedstock through the reactor in a unidirectional manner. 
     
     
         19 . A biomass pyrolysis process, comprising the steps of:
 (a) providing a heated container that encloses a moving bed granular filter, wherein the moving bed granular filter comprises a mixture that in turn comprises granular heat carrier and at least one catalyst;   (b) heating the mixture to greater than 480° C. in the heated container to produce a heated mixture that is conveyed to a pyrolysis reactor comprising at least one auger that facilitates movement of the granular heat carrier and the biomass feedstock through the pyrolysis reactor in a unidirectional manner;   (c) pyrolyzing a biomass feedstock in the pyrolysis reactor to produce pyrolysis vapors comprising a residual amount of entrained char particles, wherein rapid heating of the biomass feedstock is facilitated by contact with the heated mixture;   (d) conveying the pyrolysis vapors out of the pyrolysis reactor and through the moving bed granular filter of step (a) to separate at least a portion of the residual entrained char particles and to catalytically upgrade the pyrolysis vapors, thereby producing low-particulate upgraded pyrolysis vapors and a solid stream comprising char and the mixture of step (a).   (e) contacting the low-particulate upgraded pyrolysis vapors with at least one additional upgrading catalyst to produce a hydrocarbon mixture fungible with a petroleum-derived transportation fuel, a hydrocarbon transportation fuel component, or mixtures thereof.   
     
     
         20 . The process of  claim 19 , wherein the solid stream is separated to remove at least a portion of the char prior to conveying the heated granular heat carrier to the pyrolysis reactor. 
     
     
         21 . The process of  claim 19 , 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.