Reactive catalytic fast pyrolysis process and system

Abstract

This invention is directed to the discovery of a reactive catalytic fast pyrolysis (RCFP) process utilizing hydrogen at low pressures.

1 .- 39 . (canceled) 
     
     
         40 . A integrated reactive catalytic biomass pyrolysis system comprising:
 (a) a single primary catalytic reactor adapted for reacting a biomass with a hydrodeoxygenation (HDO) catalyst and an external hydrogen gas stream with about 10 volume % to about 90 volume % hydrogen gas at a pressure of less than about 6 bar under pyrolysis conditions to form a pyrolysis reaction stream;   (b) a separation unit in connection with the reactor and adapted to form a first stream comprising a solids fraction from the pyrolysis reaction stream and a second stream comprising a vapors fraction from the pyrolysis reaction stream; and   (c) a condenser unit in communication with the separation unit and adapted to condense a mixture of bio-crude, water and/or another liquid from the vapors in the second stream separate from a gas component of the second stream.   
     
     
         41 . The catalytic biomass pyrolysis system of  claim 40 , further comprising (d) a liquid separator unit in fluid communication with the condenser unit and adapted to separate water or another liquid from the bio-crude. 
     
     
         42 . The catalytic biomass pyrolysis system of  claim 41 , further comprising (e) a catalyst regeneration unit in fluid communication with the separation unit and adapted to remove non-catalyst solids from the solid catalyst present in the first stream. 
     
     
         43 . The catalytic biomass pyrolysis system of  claim 42 , further comprising (f) a catalyst delivery stream adapted to deliver regenerated catalyst from the catalyst regeneration unit to the reactor. 
     
     
         44 . The catalytic biomass pyrolysis system of  claim 43 , further comprising (g) a hydrogen production unit in communication with the condenser unit and adapted to generate hydrogen from methane or other hydrocarbons for introduction into the reactor. 
     
     
         45 . The catalytic biomass pyrolysis system of  claim 41 , further comprising a hydroprocessing unit in which the bio-crude from the liquid separator is further processed to remove oxygen and increase the hydrogen to carbon ratio of the bio-crude material. 
     
     
         46 . The catalytic biomass pyrolysis system of  claim 40 , wherein said reacting is carried out at a pressure of up to about 4.5 bar. 
     
     
         47 . The catalytic biomass pyrolysis system of  claim 40 , wherein said reacting is carried out at a pressure of up to about 2.5 bar. 
     
     
         48 . The catalytic biomass pyrolysis system of  claim 40 , wherein said reacting is carried out at about ambient pressure. 
     
     
         49 . The catalytic biomass pyrolysis system of  claim 40 , further comprising an oxidant stream in fluid communication with the catalyst regeneration unit and adapted to deliver an oxidant to the catalyst regeneration unit. 
     
     
         50 . The catalytic biomass pyrolysis system of  claim 40 , wherein the condenser unit is in fluid communication with the reactor via a gas flow stream adapted to transfer a portion of the gas component of the second stream to the reactor. 
     
     
         51 . The catalytic biomass pyrolysis system of  claim 50 , further comprising a blower unit interposed between and in fluid communication with the condenser unit and the reactor. 
     
     
         52 . The catalytic biomass pyrolysis system of  claim 40 , further comprising a biomass preparation unit in fluid communication with the reactor and adapted to transfer the biomass to the reactor. 
     
     
         53 . The catalytic biomass pyrolysis system of  claim 52 , wherein the biomass preparation unit is adapted to particularize a solid biomass to a size of about 25 mm or less. 
     
     
         54 . The catalytic biomass pyrolysis system of  claim 53 , wherein the primary catalytic reactor is adapted to combine the catalyst and the biomass in a ratio of about 1:10 to about 1000:1 based on mass. 
     
     
         55 . The catalytic biomass pyrolysis system of  claim 40 , wherein the primary catalytic reactor is a transport reactor. 
     
     
         56 . The catalytic biomass pyrolysis system of  claim 40 , wherein the primary catalytic reactor is adapted to a function at a temperature of about 200° C. to about 700° C. 
     
     
         57 . The catalytic biomass pyrolysis system of  claim 40 , wherein the primary catalytic reactor is adapted to function at a temperature of about 350° C. to about 550° C. 
     
     
         58 . The catalytic biomass pyrolysis system of  claim 40 , wherein the external hydrogen gas feed to the primary catalytic reactor is about 30 volume % to about 90 volume % hydrogen gas. 
     
     
         59 . The catalytic biomass pyrolysis system of  claim 40 , wherein the external hydrogen gas feed to the primary catalytic reactor is about 50 volume % to about 90 volume % hydrogen gas. 
     
     
         60 . The catalytic biomass pyrolysis system of  claim 40 , wherein the hydrodeoxygenation catalyst is a reduced metal oxide catalyst. 
     
     
         61 . The catalytic biomass pyrolysis system of  claim 40 , wherein the hydrodeoxygenation catalyst comprises a metal or metal oxide on an acidic support and the metal or metal oxide is tungsten, molybdenum, chromium, iron, ruthenium, cobalt, iridium, nickel, palladium, platinum, copper, silver, gold, tin, an oxide thereof, or a combination thereof. 
     
     
         62 . The catalytic biomass pyrolysis system of  claim 41 , wherein the acidic support is silica, alumina, zirconia, tungstated zirconia, sulfated zirconia, titania, ceria, a zeolite or a combination thereof. 
     
     
         63 . The catalytic biomass pyrolysis system of  claim 40 , wherein the biomass starting material is an agricultural residue, forest residues, a paper sludge, waste paper, or a municipal solid waste.