IMPROVED PROCESS FOR CONVERTING CARBON-BASED ENERGY CARRIER MATERIAL
A catalytic process is disclosed for converting solid or high viscosity carbon-based energy carrier materials, such as heavy crudes, oil sands, synthetic polymeric wastes and cellulosic or aquatic biomass. The conversion temperature is less than 450° C. The reaction products are separated from the catalyst within 10 seconds after being formed. The temperature of the reaction products is lowered to less than 200° C. within 10 seconds after being formed. The process results in less deterioration of the reaction products.
1 . A process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of:
a) contacting the carbon-based energy carrier material with a particulate catalyst material
b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., thereby forming reaction products in the vapor phase;
c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed;
d) optionally quenching the reaction products to a temperature below 200° C.
2 . The process of claim 1 comprising the additional step of stripping reaction products from the particulate catalyst material.
3 . The process of claim 1 or 2 comprising the additional step of burning off any coke formed on the particulate catalyst material.
4 . The process of claim 2 or 3 comprising the further step of recycling the particulate catalyst material to step a) or b).
5 . The process of any one of the preceding claims whereby a reactive gas is present during step b).
6 . The process of claim 5 wherein the reactive gas has oxidative or reductive properties.
7 . The process of claim 5 wherein the reactive gas is reactive in isomerisation or alkylation reactions.
8 . The process of claim 6 wherein the reactive gas comprises oxygen, hydrogen, hydrogen sulfide, or carbon monoxide.
9 . The process of claim 7 wherein the reactive gas comprises iso-butane, naphtene, or a volatile organic acid.
10 . The process of any one of the preceding claims wherein the catalytic material comprises cationic clays, anionic clays, natural clays, hydrotalcite-like materials, layered materials, ores, minerals, metal oxides, hydroxides and carbonates of the alkaline and alkaline earth metals, or mixtures thereof.
11 . The process of any one of the preceding claims wherein the carbon-based energy carrier material is of mineral origin.
12 . The process of claim 11 wherein the carbon-based energy carrier material is a tar, a heavy crude, or a bitumen.
13 . The process of any one of claims 1 through 10 wherein the carbon-based energy carrier material is a synthetic polymer.
14 . The process of any one of claims 1 through 10 wherein the carbon-based energy carrier material is a solid biomass.
15 . The process of claim 14 wherein the solid biomass comprises cellulose, lignin, or lignocellulose.
16 . The process of claim 14 wherein the solid biomass is of aquatic origin.
17 . The process of any one of claims 3 - 16 whereby the CO 2 is utilized in the production of biomass.
18 . The process of claim 17 whereby the CO 2 is utilized in the production of aquatic biomass.
19 . The process of any one of the preceding claims wherein step a) comprises milling of the carbon-based energy carrier material in the presence of the particulate catalyst material.
20 . The process of any one of the preceding claims wherein step a) comprises the steps of:
(i) taking up the particulate catalyst material in a stream of a carrier gas;
(ii) causing the gas stream to flow such that the particulate catalyst material reaches a velocity of at least 1 m/s, preferably at least 10 m/s
(iii) impinging the catalyst particles onto the carbon-based energy carrier material.
21 . The process of claim 17 wherein the carrier gas further comprises a particulate inert material.
22 . The process of claim 17 or 18 wherein step a) is carried out in a fluidized bed, a riser reactor, or a downer reactor.
23 . The process of any one of the preceding claims wherein the reaction temperature in step b) is less than 350° C., preferably less than 300° C., more preferably less than 250° C.
24 . The process of any one of the preceding claims wherein the vapor phase reaction products comprise steam, hydrocarbons, or a mixture thereof.
25 . The process of claim 3 wherein the coke is burned off with air.
26 . The process of claim 3 or 22 comprising the further step of cooling the particulate catalyst material after the coke has been burned off.
27 . The process of claim 23 whereby heat recovered from the particulate catalyst material is used for generating steam, hot water, or electricity.
28 . The process of any one of the preceding claims whereby at least step b) is carried out in an FCC unit.
29 . The process of any one of the preceding claims whereby at least step b) is carried out in a downer.