System and Method for Flexible Conversion of Feedstock to Oil and Gas

Abstract

A feedstock flexible process for converting feedstock into oil and gas includes (i) indirectly heated hydrous devolatilization of volatile feedstock components, (ii) indirectly heated thermochemical conversion of fixed carbon feedstock components, (iii) heal integration and recovery, (iv) vapor and gas pressurization, and (v) vapor and gas clean-up and product recovery. A system and method for feedstock conversion includes a thermochemical reactor integrated with one or more hydrous devolatilization and solids circulation subsystems configured to accept a feedstock mixture, comprised of volatile feedstock components and fixed carbon feedstock components, and continuously produce a volatile reaction product stream therefrom, while simultaneously and continuously capturing, transferring, and converting the fixed carbon feedstock components to syngas.

1 . (canceled) 
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . A feedstock conversion system for producing synthetic crude oil from a feedstock, the system comprising:
 an indirectly-heated hydrous devolatilization system configured to produce a coarse mixed stream containing char and volatile reaction products;   a fine separation device configured to separate the volatile reaction products from char in the coarse mixed stream to create a fine mixed stream and a char stream; and   a gas clean-up system configured to condense at least a portion of the volatile reaction products in the fine mixed stream to produce synthetic crude oil.   
     
     
         6 . The feedstock conversion system of  claim 5 , wherein the system is configured to operate continuously. 
     
     
         7 . The feedstock conversion system of  claim 5 , comprising:
 two indirectly-heated hydrous devolatilization systems, each receiving a different feedstock; and   two fine separation devices, each returning a respective fine mixed stream to the gas clean-up system.   
     
     
         8 . A feedstock conversion system configured to produce synthetic crude oil from a feedstock, the system having a hydrous devolatilization and solids circulation subsystem comprising:
 a first devolatilization chamber connected at a first end to a source for the feedstock and at a second end to a riser;   the riser connected at a first end to said first devolatilization chamber and at a second end to a coarse separation device;   the coarse separation device connected to a coarse separation device discharge conduit and to a coarse separation device dipleg;   the coarse separation device discharge conduit connected at a first end to a coarse separation device and at a second end to a fine separation device; and   the fine separation device connected to a fine separation device discharge conduit and to a fine separation device dipleg.   
     
     
         9 . The feedstock conversion system according to  claim 8 , wherein the first devolatilization chamber further comprises fluidization media, optional sorbent, and bed solids. 
     
     
         10 . The feedstock conversion system according to  claim 8 , wherein the first devolatilization chamber is configured to receive the feedstock and fluidization media and generate first volatile reaction products. 
     
     
         11 . The feedstock conversion system according to  claim 8 , wherein the riser is configured to convey bed solids and first volatile reaction products to a the coarse separation device. 
     
     
         12 . The feedstock conversion system according to  claim 8 , wherein the coarse separation device is configured to accept bed solids, fixed carbon feedstock components, and first volatile reaction products and, in response, output a coarse mixed stream via a coarse separation device discharge conduit, wherein the coarse mixed stream comprises first volatile reaction products and char. 
     
     
         13 . The feedstock conversion system according to  claim 12 , wherein the coarse separation device discharge conduit is configured to transport the coarse mixed stream to the fine separation device. 
     
     
         14 . The feedstock conversion system according to  claim 12 , wherein the fine separation device is configured to accept the coarse mixed stream and, in response output, a fine mixed stream via a fine separation device discharge conduit, wherein the fine mixed stream comprises first volatile reaction products. 
     
     
         15 . The feedstock conversion system according to  claim 12 , wherein the fine separation device is configured to receive the coarse mixed stream and, in response, separate a char stream therefrom which is conveyed to the reactor via a fine separation device dipleg. 
     
     
         16 . The feedstock conversion system according to  claim 15 , wherein the fine separation device dipleg is configured to convey the separated char stream from the fine separation device to a reactor. 
     
     
         17 . The feedstock conversion system according to  claim 8 , wherein the coarse separation device is configured to accept bed solids, fixed carbon feedstock components, and first volatile reaction products and separate into an intermediate solids mixture comprising bed solids and fixed carbon feedstock components. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . The feedstock conversion system according to  claim 8 , having a feedstock inlet configured to receive feedstock at a pressure below ambient pressure. 
     
     
         25 . The feedstock conversion system according to  claim 8 , wherein the hydrous devolatilization and solids circulation subsystem further comprising:
 a second devolatilization chamber configured to generate second volatile reaction products.   
     
     
         26 . The feedstock conversion system according to  claim 25 , wherein the second devolatilization chamber further comprises fluidization media, optional sorbent, and bed solids. 
     
     
         27 . The feedstock conversion system according to  claim 5 , wherein the indirectly-heated hydrous devolatilization system comprises one or more devolatilization chambers. 
     
     
         28 . The feedstock conversion system according to  claim 27 , wherein at least one of the one or more devolatilization chambers comprises fluidization media, optional sorbent, and bed solids. 
     
     
         29 . The feedstock conversion system according to  claim 5 , further comprising:
 a heat removal system configured to cool the volatile reaction products above a dew point of condensable vapors contained therein; and/or   a gas pressurization system configured to provide pressurization of the volatile reaction products.