Co-Processing of Biomass and Synthetic Polymer Based Materials in a Pyrolysis Conversion Process

Abstract

Disclosed is a process for biomass conversion which includes co-processing the biomass with thermoplastic and non-thermoplastic polymer based materials in a catalytic pyrolysis reactor to convert such to liquid hydrocarbons; wherein hydrogen atoms originating with the polymer materials can remove oxygen from oxygenated hydrocarbons produced in the conversion of the biomass in the reactor.

What is claimed is: 
     
         1 . A process comprising charging a feed comprising a biomass and a synthetic thermoplastic polymer based material to a reactor for contact with a catalyst and conversion to a product comprising liquid hydrocarbons, wherein the weight ratio of said biomass to said synthetic thermoplastic polymer based material is greater than about 1:4. 
     
     
         2 . The process of  claim 1 , wherein hydrogen atoms originating with said synthetic thermoplastic polymer based material remove oxygen from oxygenated hydrocarbons produced in the conversion of said biomass in said reactor. 
     
     
         3 . The process of  claim 1 , wherein the weight ratio of said biomass to said synthetic thermoplastic polymer based material is greater than about 1:2. 
     
     
         4 . The process of  claim 1 , wherein the weight ratio of said biomass to said synthetic thermoplastic polymer based material is greater than about 1:1. 
     
     
         5 . The process of  claim 1 , wherein said reactor is a fluid bed reactor, a moving bed reactor, or a cyclone reactor. 
     
     
         6 . The process of  claim 1 , wherein said reactor is operated at a temperature of from about 150 to about 600° C. and in an oxygen-poor atmosphere. 
     
     
         7 . The process of  claim 1 , wherein said reactor is operated at a temperature of from about 250 to about 550° C. and in an oxygen-poor atmosphere. 
     
     
         8 . The process of  claim 1 , wherein said biomass portion of said feed is subjected to pretreatment prior to charging to said reactor, wherein said pretreatment comprises a method selected from the group consisting of: a) drying; b) heat treatment in an oxygen-poor or oxygen-free atmosphere; c) solvent explosion; d) mechanical treatment with catalyst particles; e) demineralization; f) swelling in an aqueous solvent; g) impregnation of catalytic agents, mineral acids, organic acids, mineral bases; or h) a combination thereof. 
     
     
         9 . The process of  claim 8 , wherein said mechanical treatment forms at least one of (a) an activated feed coated with said catalyst particles and (b) an activated feed having said catalyst particles embedded therein. 
     
     
         10 . The process of  claim 1 , wherein said catalyst is selected from the group consisting of a solid base, a clay, an inorganic oxide, an inorganic hydroxide, a zeolite, a supported metal, and combinations thereof. 
     
     
         11 . The process of  claim 10 , wherein said solid base comprises hydrotalcite; a hydrotalcite-like material; a clay; a layered hydroxy salt; a metal oxide; a metal hydroxide; a mixed metal oxide; or a mixture thereof. 
     
     
         12 . The process of  claim 10 , wherein said catalyst is an E-cat. 
     
     
         13 . The process of  claim 1  wherein said synthetic thermoplastic polymer based material comprises at least about 10 wt. % hydrogen. 
     
     
         14 . The process of  claim 1  wherein said synthetic thermoplastic polymer based material is selected from the group consisting of polyethylene, polypropylene, and combinations thereof. 
     
     
         15 . The process of  claim 1  wherein said feed further comprises materials selected from the group consisting of paper, cotton, and combinations thereof. 
     
     
         16 . The process of  claim 1 , wherein said catalyst is charged to said reactor separately from said biomass and synthetic thermoplastic based material. 
     
     
         17 . A process comprising charging a feed comprising a biomass and a synthetic thermoplastic polymer based material to a reactor for contact with a catalyst and conversion to a product comprising liquid hydrocarbons, wherein the weight ratio of said biomass to said synthetic thermoplastic polymer based material is greater than about 1:4, and wherein said catalyst is an E-cat. 
     
     
         18 . The process of  claim 17 , wherein said catalyst is charged to said reactor separately from said biomass and synthetic thermoplastic based material.