Flash pyrolosis method for carbonaceous materials

Abstract

Methods are disclosed for pyrolizing carbonaceous materials to carbonaceous materials having lower boiling points by heating the carbonaceous material to a desired reaction temperature and holding the carbonaceous material in contact with the heat for a sufficient time to achieve the desired reaction to a lower boiling point carbonaceous materials, then rapidly cooling the desired reaction products. The heating source is a jet which will provide hot and high velocity gas streams to the carbonaceous material to be heated.

1 . A method for the conversion of a carbonaceous feed material to a carbonaceous material with lower normal boiling point comprising means to
 a) produce a hot gas at elevated pressure;   b) convert said hot gas at elevated pressure to a hot high velocity gas jet or array of jets at lower pressure;   c) feed carbonaceous feed material mesial to the hot, high velocity jet or array of jets to rapidly heat the carbonaceous feed material;   d) provide sufficient residence time to achieve the desired conversion of the carbonaceous feed material to lower boiling point material; and   e) rapidly cool the lower boiling point material reaction products.   
     
     
         2 . The method as claimed in  claim 1  wherein said carbonaceous feed material has components with normal boiling point greater than 524° C. 
     
     
         3 . The method as claimed in  claim 1  wherein said carbonaceous feed material is selected from a material consisting essentially of heavy crude oil, petroleum resid, petroleum tar, coal tar, bitumen, coal, oil shale and mixtures thereof. 
     
     
         4 . The method as claimed in  claim 1  wherein said carbonaceous material with a lower normal boiling point is selected from a material consisting essentially of distillates. 
     
     
         5 . The method as claimed in  claim 1  wherein said hot high velocity gas stream is between 500° C. and 2500° C. 
     
     
         6 . The method as claimed in  claim 1  wherein said jet or array of jets is a burnjector lance. 
     
     
         7 . The method as claimed in  claim 1  wherein said sufficient residence time is sufficient to convert between about 0.5 and 0.95 mass fraction of the residual heavy oil feed to distillates 
     
     
         8 . The methods claimed in  claim 1  wherein said reaction products are rapidly cooled by distillate carbonaceous material, water, steam or a mixture thereof. 
     
     
         9 . The method as claimed in  claim 1  wherein said reaction products are cooled to a temperature of less than about 400° C. 
     
     
         10 . The method as claimed in  claim 1  wherein the velocity of said hot high velocity gas is greater than 500 meters per second. 
     
     
         11 . The method as claimed in  claim 1  wherein said hot gas is produced by combustion of a fuel with substantially pure oxygen. 
     
     
         12 . The method as claimed in  claim 11  wherein said substantially pure oxygen contains greater than 70 mole percent oxygen. 
     
     
         13 . The method as claimed in  claim 1  wherein the pressure ratio of said hot gas to said reaction product is between 20:1 and 2:1 
     
     
         14 . A pyrolysis process for converting a feed carbonaceous material having a first boiling point to a carbonaceous material having a second lower normal boiling point comprising the steps:
 a) heating said feed carbonaceous material to a desired reaction temperature;   b) cooling the reaction products produced in step (a); and   c) recovering said reaction products.   
     
     
         15 . The process as claimed in  claim 14  wherein said heating is provided by a hot high velocity jet or an array of jets. 
     
     
         16 . The method as claimed in  claim 14  wherein said carbonaceous feed material has components with normal boiling points greater than 524° C. 
     
     
         17 . The method as claimed in  claim 14  wherein said carbonaceous feed material is selected from a material consisting essentially of heavy crude oil, petroleum resid, petroleum tar, coal tar, bitumen, coal, oil shale, and mixtures thereof. 
     
     
         18 . The method as claimed in  claim 14  wherein said carbonaceous material with a lower normal boiling point is selected from a material consisting essentially of distillates. 
     
     
         19 . The method as claimed in  claim 15  wherein said hot high velocity gas stream is between 500° C. and 2500° C. 
     
     
         20 . The method as claimed in  claim 15  wherein said jet or array of jets is produced by a burnjector lance. 
     
     
         21 . The method as claimed in  claim 14  wherein said reaction products are rapidly cooled by distillate carbonaceous material, water, steam or a mixture thereof. 
     
     
         22 . The method as claimed in  claim 14  wherein the velocity of said hot high velocity gas is greater than 500 meters per second. 
     
     
         23 . The method as claimed in  claim 14  wherein said hot gas is produced by combustion of a fuel with substantially pure oxygen. 
     
     
         24 . The method as claimed in  claim 23  wherein said substantially pure oxygen contains greater than 70 mole percent oxygen. 
     
     
         25 . The method as claimed in  claim 18  wherein sufficient residence time is allowed after step (a) to convert between about 0.5 and 0.95 mass fraction of the residual heavy oil feed to distillates 
     
     
         26 . A process for converting a feed carbonaceous material having a first normal boiling point to a carbonaceous material having a second lower normal boiling point comprising directing a high velocity hot gas stream to said feed carbonaceous material, cooling the reaction products of the heating of said feed carbonaceous material, and recovering said reaction products. 
     
     
         27 . The method as claimed in  claim 26  wherein said carbonaceous feed material has components with normal boiling point greater than 524° C. 
     
     
         28 . The method as claimed in  claim 26  wherein said carbonaceous feed material is selected from a material consisting essentially of heavy crude oil, petroleum resid, petroleum tar, coal tar, bitumen, coal, oil shale and mixtures thereof. 
     
     
         29 . The method as claimed in  claim 26  wherein said carbonaceous material with a lower normal boiling point is selected from a material consisting essentially of distillates. 
     
     
         30 . The method as claimed in  claim 26  wherein said hot high velocity gas jet is between 500° C. and 2500° C. 
     
     
         31 . The method as claimed in  claim 26  wherein said heat is provided by a jet or array of jets. 
     
     
         32 . The method as claimed in  claim 26  wherein said jet or array of jets is produced by a burnjector lance. 
     
     
         33 . The method s claimed in  claim 26  wherein said reaction products are rapidly cooled by distillate carbonaceous material, water, steam or a mixture thereof. 
     
     
         34 . The method as claimed in  claim 26  wherein the velocity of said hot high velocity gas is greater than 500 meters per second. 
     
     
         35 . The method as claimed in  claim 26  wherein said hot gas is produced by combustion of a fuel with substantially pure oxygen. 
     
     
         36 . The method as claimed in  claim 34  wherein said substantially pure oxygen contains greater than 70 mole percent oxygen. 
     
     
         37 . The method as claimed in  claim 29  wherein sufficient residence time is allowed after step (a) to convert between about 0.5 and 0.95 mass fraction of the residual heavy oil feed to distillates