Biomass processing devices, systems, and methods

Abstract

Biomass processing devices, systems and methods used to convert biomass to, for example, liquid hydrocarbons, renewable chemicals, and/or composites are described. The biomass processing system can include a pyrolysis device, a hydroprocessor and a gasifier. Biomass, such as wood chips, is fed into the pyrolysis device to produce char and pyrolysis vapors. Pyrolysis vapors are processed in the hydroprocessor, such as a deoxygenation device, to produce hydrocarbons, light gas, and water. Water and char produced by the system can be used in the gasifier to produce carbon monoxide and hydrogen, which may be recycled back to the pyrolysis device and/or hydroprocessor.

I/We claim: 
     
         1 . A pyrolysis device comprising:
 a housing having an inlet and an outlet; and   an auger positioned within the housing, the auger having:
 an upstream end adjacent the inlet of the housing; 
 a downstream end adjacent the outlet of the housing; 
 a core extending between the upstream end and the downstream end; and 
 a helical blade wound around the core between the upstream end and the downstream end; 
   wherein:
 the inlet of the housing is configured to receive biomass; and 
 the pyrolysis device is configured to convert the biomass to a pyrolysis vapor and to 
 produce a pressure seal formed by material in transition between biomass and pyrolysis vapor, the pressure being seal positioned between the inlet of the housing and the outlet of the housing. 
   
     
     
         2 . The pyrolysis device of  claim 1 , wherein the core of the auger is tapered from a first diameter at the upstream end to a second diameter at the downstream end, the first diameter being smaller than the second diameter. 
     
     
         3 . The pyrolysis device of  claim 2 , wherein:
 the helical blade has a blade height measured from an outer surface of the core in a direction perpendicular to a rotational axis of the core to a terminal end of the helical blade; and   the height of the helical blade varies from the upstream end to the downstream end of the auger.   
     
     
         4 . The pyrolysis device of  claim 3 , wherein the height of the helical blade decreases from the upstream end to the downstream end. 
     
     
         5 . The pyrolysis device of  claim 4 , wherein the height of the helical blade decreases at a rate proportional to the increase in the diameter of the core of the auger such that a distance between the terminal end of the blade and the rotational axis of the auger is substantially constant along the length of the auger. 
     
     
         6 . The pyrolysis device of  claim 1 , further comprising:
 a heater surrounding a portion of the auger between the inlet of the housing and the outlet of the housing.   
     
     
         7 . The pyrolysis device of  claim 1 , wherein during operation:
 a pressure within the housing between the inlet and the pressure seal is approximately atmospheric pressure; and   a pressure within the housing between the pressure seal and the outlet is at least 300 psia.   
     
     
         8 . The pyrolysis device of  claim 1 , wherein the inlet of the housing is configured to receive biomass in the form of wood chips, sawdust, or a combination thereof. 
     
     
         9 . The pyrolysis device of  claim 1 , further comprising a gas inlet for introducing gas into the housing. 
     
     
         10 . The pyrolysis device of  claim 1 , wherein the gas inlet is in fluid communication with a carbon monoxide source or a hydrogen source. 
     
     
         11 . A biomass processing system comprising:
 a pyrolysis device configured to receive biomass, pyrolyze the biomass to produce pyrolysis vapors, and output the pyrolysis vapors; and   a deoxygenation device in fluid communication with the pyrolysis device, the deoxygenation device configured to receive the pyrolysis vapors and deoxygenate the pyrolysis vapors to produce a deoxygenation product stream comprising at least two of water, hydrocarbons, and fuel gas.   
     
     
         12 . The biomass processing system of  claim 11 , wherein deoxygenating the pyrolysis vapors is performed without condensing the pyrolysis vapors to bio-oil. 
     
     
         13 . The biomass processing system of  claim 11 , wherein the pyrolysis device outputs pyrolysis vapors at a pressure of at least 300 psia. 
     
     
         14 . The biomass processing system of  claim 11 , wherein pyrolyzing the biomass further produces char, and the system further comprises a filter in fluid communication with the pyrolysis device, the filter being configured to separate the char from the pyrolysis vapors. 
     
     
         15 . The biomass processing system of  claim 14 , further comprising:
 a separator in fluid communication with the deoxygenation device, the separator configured to separate the deoxygenation product stream into a water stream, a hydrocarbons stream, and a fuel gas stream.   
     
     
         16 . The biomass processing system of  claim 15 , further comprising:
 a gasifier in fluid communication with the separator, the gasifier configured to receive the water stream produced by the separator and the char produced by the filter and produce a hydrogen stream and a carbon monoxide stream.   
     
     
         17 . The biomass processing system of  claim 16 , wherein the pyrolysis device is in fluid communication with the gasifier and the pyrolysis device is configured to receive the carbon monoxide stream. 
     
     
         18 . The biomass processing system of  claim 16 , wherein the deoxygenation device is in fluid communication with the gasifier and the deoxygenation device is configured to receive the hydrogen stream. 
     
     
         19 . The biomass processing system of  claim 15 , wherein the separator comprises a cyclone. 
     
     
         20 . The biomass processing system of  claim 11 , further comprising:
 a filter in fluid communication with the pyrolysis device, the filter being configured to separate sulfur from the pyrolysis vapors.