CONTROLLED ACTIVITY PYROLYSIS CATALYSTS
A catalyst system is disclosed for catalytic pyrolysis of a solid biomass material. The system comprises an oxide, silicate or carbonate of a metal or a metalloid. The specific combined meso and macro surface area of the system is in the range of from 1 m 2 /g to 100 m 2 /g. When used in a catalytic process the system provides a high oil yield and a low coke yield. The liquid has a relatively low oxygen content.
1 . A catalytic system for use in catalytic pyrolysis of solid biomass material, said catalytic system comprising at least one metal oxide or metalloid oxide and having a specific combined meso and macro surface area in the range of from 1 m 2 /g to 100 m 2 /g.
2 . The catalytic system of claim 1 having a specific combined meso and macro surface area in the range of from 2 m 2 /g to 60 m 2 g.
3 . The catalytic system of claim 1 having a specific combined meso and macro surface area in the range of from 3 to 40 m 2 g.
4 . The catalytic system of claim 1 comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 600° C.
5 . The catalytic system of claim 4 comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 800° C.
6 . The catalytic system of claim 4 comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 900° C.
7 . The catalytic system of claim 4 comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 1000° C.
8 . The catalyst system of claim 4 wherein the catalyst precursor comprises a phyllosilicate mineral.
9 . The catalyst system of claim 8 wherein the phyllosilicate mineral is a clay mineral.
10 . The catalyst system of claim 9 wherein the clay mineral comprises kaolinite.
11 . The catalyst system of claim 10 wherein the clay mineral comprises kaolin that has been exposed to temperatures of at least 500° C.
12 . The catalyst system of claim 10 wherein the clay mineral comprises bentonite that has been exposed to temperatures of at least 500° C.
13 . The catalyst system of claim 10 wherein the clay mineral comprises smectite.
14 . The catalyst system of claim 4 wherein the catalyst precursor is hydrotalcite or a hydrotalcite-like material.
15 . The catalyst system of claim 4 wherein the catalyst precursor is an aluminosilicate.
16 . The catalyst system of claim 15 wherein the aluminosilicate is a zeolite Y, ion exchange Y zeolite, and/or is terminally treated, or dealuminated.
17 . The catalyst system of claim 16 wherein the zeolite is zeolite ZSM-5.
18 . The catalytic system of claim 1 comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 400° C.
19 . The catalytic system of claim 18 comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 600° C.
20 . The catalytic system of claim 18 comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 800° C.
21 . The catalytic system of claim 1 wherein the catalytic system comprises a metal selected from the group consisting of: 1) the earth alkaline earth metals selected from, in particular calcium, barium, magnesium and iron; 2) the transition metals selected from iron, manganese, copper and zinc; and 3) rare earth metals selected from cerium and lanthanum.
22 . The catalyst system of claim 1 comprising alumina.
23 . The catalyst system of claim 22 wherein said alumina has been exposed to temperatures of at least 500° C.
24 . The catalyst system of claim 1 comprising silica.
25 . The catalyst system of claim 1 comprising a mixed metal oxide.
26 . The catalyst system of claim 1 in the form of microspheres.
27 . The catalyst system of claim 26 wherein the microspheres have a mean particle diameter in the range of from 20 to 200 μm.
28 . The catalyst system of claim 26 wherein the microspheres have a mean particle diameter in the range of from 40 to 100 μm.
29 . The catalyst system of claim 1 further comprising a binder.
30 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of claim 1 .
31 . The process of claim 30 wherein the yield of said bio-oil from said biomass is higher than the bio-oil yield resulting from use of catalyst systems having higher specific combined meso and macro surface area.
32 . The process of claim 30 wherein the temperature of the catalytic pyrolysis reactor is at least 850° F.
33 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of claim 8 .
34 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of claim 16 .
35 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of claim 21 .