Catalytic biomass pyrolysis process

Abstract

Described herein are processes for converting a biomass starting material (such as lignocellulosic materials) into a low oxygen containing, stable liquid intermediate that can be refined to make liquid hydrocarbon fuels. More specifically, the process can be a catalytic biomass pyrolysis process wherein an oxygen removing catalyst is employed in the reactor while the biomass is subjected to pyrolysis conditions. The stream exiting the pyrolysis reactor comprises bio-oil having a low oxygen content, and such stream may be subjected to further steps, such as separation and/or condensation to isolate the bio-oil.

1 - 32 . (canceled) 
     
     
         33 . A catalytic biomass pyrolysis system comprising:
 a reactor adapted for combining a biomass with a solid catalyst in a reduced state under pyrolysis conditions to form a pyrolysis product stream;   a separation unit in fluid connection with the reactor and adapted to form a first stream comprising a solids fraction from the pyrolysis product stream, said solids fraction comprising non-catalyst solids and solid catalyst, at least a portion of which is in an oxidized state, and a second stream comprising a vapors fraction from the pyrolysis reaction stream;   a condenser unit in fluid communication with the separation unit and adapted to condense a bio-crude from the vapors in the second stream separate from a gas component of the second stream;   an optional liquid separator unit in fluid communication with the condenser unit and adapted to separate water or another liquid from the bio-crude;   a catalyst regeneration unit in fluid communication with the separation unit and adapted to remove the non-catalyst solids from the solid catalyst present in the first stream;   a reduction unit in fluid communication with the catalyst regeneration unit and adapted to reduce the solid catalyst that is in the oxidized state received from the catalyst regeneration unit and provide solid catalyst in a reduced state; and   a catalyst delivery stream adapted to deliver the solid catalyst in the reduced state from the reduction unit to the reactor.   
     
     
         34 . The catalytic biomass pyrolysis system of  claim 33 , further comprising an oxidant stream in fluid communication with the catalyst regeneration unit and adapted to deliver an oxidant to the catalyst regeneration unit. 
     
     
         35 . The catalytic biomass pyrolysis system of  claim 33 , wherein the condenser unit is in fluid communication with the reduction unit via a gas flow stream adapted to transfer a portion of the gas component of the second stream to the reduction unit, and wherein the system optionally further comprises a blower unit interposed between and in fluid communication with the condenser unit and the reduction unit. 
     
     
         36 . (canceled) 
     
     
         37 . The catalytic biomass pyrolysis system of  claim 33 , further comprising a biomass preparation unit in fluid communication with the reactor and adapted to transfer the biomass to the reactor, optionally wherein the biomass preparation unit is adapted to particularize a solid biomass to a size of about 25 mm or less. 
     
     
         38 . (canceled) 
     
     
         39 . The catalytic biomass pyrolysis system of  claim 37 , wherein the reactor is adapted to combine the catalyst and the biomass in a ratio of about 1:1 to about 100:1 based on mass. 
     
     
         40 . The catalytic biomass pyrolysis system of  claim 33 , wherein the reactor is one or more of:
 a transport reactor;   adapted to accommodate flow of the biomass therethrough with a residence time of about 5 seconds or less;   adapted to function at a pressure of up to about 25 bar (2.5 MPa).   
     
     
         41 . (canceled) 
     
     
         42 . The catalytic biomass pyrolysis system of  claim 33 , wherein the reactor is adapted to a function at a temperature of about 200° C. to about 700° C. or a temperature of about 550° C. or less. 
     
     
         43 . (canceled) 
     
     
         44 . (canceled)