Thermochemical reactor and process

Abstract

A reactor is described which is useful for the generation of hydrocarbon products by thermochemical treatment. The reactor comprises a feeding means for the addition of feedstock material to the reactor; an outlet for the extraction of hydrocarbon products from the reactor; a devolatilization zone; and a cracking zone; wherein the devolatilization zone comprises a first gas distribution base plate for the generation of a fluidised bed of material in the devolatilization zone, the cracking zone comprises a second gas distribution base plate for the generation of a fluidised bed of material in the cracking zone, and the devolatilization zone is in fluid communication with the cracking zone through a plurality of apertures within the second gas distribution base plate permitting the passage of gas from the devolatilization zone into the cracking zone. Processes of producing hydrocarbon products by thermochemical treatment are also described. The hydrocarbon products may be useful as drop-in fuel products and/or chemical feedstock.

1 . A reactor for the generation of hydrocarbon products by thermochemical treatment, comprising
 a feeding means for the addition of feedstock material to the reactor;   an outlet for the extraction of hydrocarbon products from the reactor;   a devolatilization zone; and   a cracking zone; wherein   the devolatilization zone comprises a first gas distribution base plate for the generation of a fluidised bed of material in the devolatilization zone,   the cracking zone comprises a second gas distribution base plate for the generation of a fluidised bed of material in the cracking zone, and   the devolatilization zone is in fluid communication with the cracking zone through a plurality of apertures within the second gas distribution base plate permitting the passage of gas from the devolatilization zone into the cracking zone.   
     
     
         2 . A reactor according to  claim 1 , wherein the cracking zone comprises a further gas distribution base plate for the generation of a second fluidised bed of material in the cracking zone. 
     
     
         3 . A reactor according to  claim 1 or 2 , wherein the reactor is for the generation of hydrocarbon products by thermochemical treatment of one or more polymers. 
     
     
         4 . A reactor according to  claim 3 , wherein the one or more polymers are each independently selected from polypropylene, polyethylene and polystyrene. 
     
     
         5 . A reactor according to any one of  claims 1 to 4 , wherein the hydrocarbon products comprise C5-C19 hydrocarbons. 
     
     
         6 . A reactor according to any one of  claims 1 to 5 , wherein the devolatilization zone is configured to operate at a temperature of 400 to 450° C. during operation of the reactor and the cracking zone is configured to operate at a temperature of 500 to 650° C. during operation of the reactor. 
     
     
         7 . A reactor according to any one of  claims 1 to 6 , wherein the second gas distribution base plate further comprises an overflow aperture for the passage of solid materials from the cracking zone into the devolatilization zone. 
     
     
         8 . A reactor according to any one of  claims 1 to 7 , wherein the feeding means comprises a feedstock inlet located within an internal wall of the reactor between the first gas distribution base plate and the second gas distribution base plate, at a distance from the first gas distribution base such that feedstock material is fed into the reactor within a particle-free zone, above the surface of a fluidised bed of material in the devolatilization zone. 
     
     
         9 . A reactor according to any one of  claims 1 to 8 , wherein the feeding means comprises a feedstock inlet located within an internal wall of the reactor and a cooling element upstream of the feedstock inlet to cool the feedstock material before entry into the reactor. 
     
     
         10 . A reactor according to any one of  claims 1 to 9 , comprising means for feeding a fluidising gas comprising one or more of steam, CO 2 , N 2  and H 2  to the first gas distribution base plate. 
     
     
         11 . A reactor according to any one of  claims 1 to 10 , further comprising a refining zone, wherein the refining zone comprises a third gas distribution base plate for the generation of a fluidised bed of material in the refining zone, wherein the refining zone is in fluid communication with the cracking zone through a plurality of apertures within the third gas distribution base plate permitting the passage of fluids from the cracking zone into the refining zone. 
     
     
         12 . A reactor according to  claim 11 , wherein the refining zone is configured to operate at a temperature of 400 to 450° C. during operation of the reactor. 
     
     
         13 . A reactor according to  claim 11 or 12 , comprising means for feeding a hydrotreating gas comprising H 2  to the third gas distribution base plate. 
     
     
         14 . A reactor according to any one of  claims 1 to 13 , wherein the reactor further comprises a catalyst regeneration zone connected to the devolatilization zone to receive solid catalyst material from the devolatilization zone for regeneration. 
     
     
         15 . A reactor according to  claim 14 , comprising means for feeding a combustion gas comprising O 2  to the catalyst regeneration zone. 
     
     
         16 . A modular reactor system comprising a reactor according to any one of  claims 1 to 15  and one or more additional reactor system modules each independently selected from:
 a feedstock material separation module upstream of the reactor; 
 a feedstock material size reduction module upstream of the reactor; 
 a feedstock material drying module upstream of the reactor; 
 a hydrocarbon product filter module downstream of the reactor; 
 a hydrocarbon product condensation module downstream of the reactor; 
 a catalyst regeneration module; 
 an electrolyser module; and 
 a hydrocarbon product reforming module downstream of the reactor. 
 
     
     
         17 . A process for the generation of a hydrocarbon product, comprising
 (a) feeding a feedstock material into a reactor, wherein the reactor comprises
 a feeding means for the addition of the feedstock material to the reactor; 
 an outlet for the extraction of the hydrocarbon product from the reactor; 
 a devolatilization zone; 
 a cracking zone; 
 a first gas distribution base plate for the generation of a fluidised bed of material in the devolatilization zone, 
 a second gas distribution base plate for the generation of a fluidised bed of material in the cracking zone, and 
 the devolatilization zone is in fluid communication with the cracking zone through a plurality of apertures within the second gas distribution base plate permitting the passage of fluids from the devolatilization zone into the cracking zone; 
   (b) thermochemically treating the feedstock material within a fluidised bed of material supported on the first gas distribution base plate in the devolatilization zone, wherein the bed of material is fluidised by feeding a fluidising gas through the first gas distribution base plate; and   (c) cracking the intermediate product formed from the pyrolysis of the feedstock material, within a fluidised bed of material supported on the second gas distribution base plate in the cracking zone, wherein the bed of material in the cracking zone is fluidised by the passage of the intermediate product through the second gas distribution base plate.   
     
     
         18 . A process according to  claim 17 , wherein the feedstock material comprises one or more polymers. 
     
     
         19 . A process according to  claim 18 , wherein the one or more polymers are each independently selected from polypropylene, polyethylene and polystyrene. 
     
     
         20 . A process according to any one of  claims 17 to 19 , wherein the hydrocarbon product comprises C5-C19 hydrocarbons. 
     
     
         21 . A process according to any one of  claims 17 to 20 , wherein the temperature of the fluidised bed of material in the devolatilization zone is from 400 to 450° C. and the temperature of the fluidised bed of material in the cracking zone is from 500 to 650° C. 
     
     
         22 . A process according to any one of  claims 17 to 21 , wherein feeding the feedstock material into the reactor comprises feeding the feedstock material above the upper surface of the fluidised bed of material in the devolatilization zone. 
     
     
         23 . A process according to any one of  claims 17 to 21 , wherein the process further comprises cooling the feedstock material before entry into the reactor. 
     
     
         24 . A process according to any one of  claims 17 to 23 , wherein the fluidising gas fed through the first gas distribution base plate comprises one or more of steam, CO 2 , N 2  and H 2 . 
     
     
         25 . A process according to any one of  claims 17 to 23 , further comprising refining the product formed by cracking of the intermediate product to provide a refined product, wherein the refining takes place in a refining zone, wherein the refining zone comprises a third gas distribution base plate for the generation of a fluidised bed of material in the refining zone, wherein the refining zone is in fluid communication with the cracking zone through a plurality of apertures within the third gas distribution base plate permitting the passage of fluids from the cracking zone into the refining zone. 
     
     
         26 . A process according to  claim 25 , wherein the temperature of the fluidised bed of material in the devolatilization zone is from 400 to 450° C. 
     
     
         27 . A process according to  claim 25 or 26 , comprising feeding a hydrotreating gas comprising H 2  to the third gas distribution base plate. 
     
     
         28 . A process according to any one of  claims 17 to 27 , wherein one or more of (a) the fluidised bed of material supported on the first gas distribution base plate in the devolatilization zone and (b) the fluidised bed of material supported on the second gas distribution base plate in the cracking zone comprises a catalyst. 
     
     
         29 . A process according to  claim 28 , further comprising regeneration of catalyst within a regeneration zone and feeding of regenerated catalyst back into one or more of the devolatilization zone and cracking zone of the reactor.