Integrated two-stage thermochemical heat pipe reactor having a partitioned vessel

1. An integrated two-stage fluid bed reactor ( 50 ) comprising:

a vessel ( 100 ) having a longitudinal axis and a partition ( 130 ) extending along the longitudinal axis and separating the vessel ( 100 ) into a first chamber ( 110 ) and a second chamber ( 120 ) arranged side-by-side;

the first chamber ( 110 ) defining a stage 1 reaction chamber ( 200 ) having a stage 1 fluid bed ( 220 ) operating primarily in an endothermic reaction regime;

the second chamber ( 120 ) defining a stage 2 reaction chamber ( 300 ) having a stage 2 fluid bed ( 320 ) operating primarily in an exothermic reaction regime;

a plurality of heat pipes ( 400 ) passing through the partition ( 130 ) and extending between the first chamber ( 110 ) and the second chamber ( 120 ), the heat pipes ( 400 ) configured to remove heat from the second chamber ( 120 ) and provide heat to the first chamber ( 110 );

a first passageway ( 290 , 291 ) configured to transfer first chamber discharge materials ( 240 ) from a stage 1 freeboard zone ( 295 ) of the first chamber ( 110 ) to the second chamber ( 120 ) via a stage 1 primary particulate capture device ( 350 ); and,

a second passageway ( 390 , 391 ) configured to transfer second chamber discharge materials ( 340 ) from a stage 2 freeboard zone ( 395 ) of the second chamber ( 120 ) to the first chamber ( 110 ) via a stage 2 primary particulate capture device ( 260 ).

2. The integrated two-stage fluid bed reactor ( 50 ) according to claim 1 , wherein:

the stage 2 primary particulate capture device ( 260 ) is configured to:

receive said second chamber discharge materials ( 340 ) from the second chamber ( 120 );

transfer first particulates ( 900 a ) to the stage 1 fluid bed ( 220 ) in the first chamber; and,

output a first product gas ( 900 b ); and

the stage 1 primary particulate capture device ( 350 ) is configured to:

receive said first chamber discharge materials ( 240 ) from the first chamber ( 110 );

transfer second particulates ( 1100 a ) to the stage 2 fluid bed ( 320 ) in the second chamber ( 120 ); and

output a second product gas ( 1100 b ).

3. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , further comprising:

a stage 1 secondary particulate capture device ( 370 ) configured to:

receive the second product gas ( 1100 b ) from the stage 1 primary particulate capture device ( 350 );

output third particulates ( 1200 a ) to the stage 2 fluid bed ( 320 ) in the second chamber ( 120 ); and,

output a third product gas ( 1200 b ).

4. The integrated two-stage fluid bed reactor ( 50 ) according to claim 3 , further comprising:

a stage 2 secondary particulate capture device ( 600 ) configured to:

receive the first product gas ( 900 b ) from the stage 2 primary particulate capture device ( 260 );

output a fourth product gas ( 1300 b ); and

output fourth particulates ( 1300 a ).

5. The integrated two-stage fluid bed reactor ( 50 ) according to claim 4 , wherein at least a portion of the fourth particulates ( 1300 a ) are introduced into the second chamber ( 120 ).

6. The integrated two-stage fluid bed reactor ( 50 ) according to claim 4 further comprising:

a stage 2 tertiary particulate capture device ( 700 ) configured to:

receive the fourth product gas ( 1300 b ) from the stage 2 secondary particulate capture device ( 600 );

output a fifth product gas ( 1400 b ); and

output fifth particulates ( 1400 a ).

7. The integrated two-stage fluid bed reactor ( 50 ) according to claim 3 wherein

the stage 1 primary particulate capture device ( 350 ) and the stage 1 secondary particulate capture device ( 370 ) are both located within second chamber ( 220 ).

8. The integrated two-stage fluid bed reactor ( 50 ) according to claim 3 , wherein

the stage 1 primary particulate capture device ( 350 ) and the stage 1 secondary particulate capture device ( 370 ) are both located external to the vessel ( 100 ); and,

a particulates return passageway ( 392 ) connects the stage 1 secondary particulate capture device ( 370 ) to the stage 2 fluid bed ( 320 ) to transfer third particulates ( 1200 a ) to the stage 2 fluid bed ( 320 ).

9. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , further comprising:

a stage 2 secondary particulate capture device ( 600 ) configured to:

receive the first product gas ( 900 b ) from the stage 2 primary particulate capture device ( 260 );

output a fourth product gas ( 1300 b ); and

output fourth particulates ( 1300 a ).

10. The integrated two-stage fluid bed reactor ( 50 ) according to claim 9 , wherein at least a portion of the fourth particulates ( 1300 a ) are introduced into the second chamber ( 120 ).

11. The integrated two-stage fluid bed reactor ( 50 ) according to claim 9 , further comprising:

a stage 2 tertiary particulate capture device ( 700 ) configured to:

receive the fourth product gas ( 1300 b ) from the stage 2 secondary particulate capture device ( 600 );

output a fifth product gas ( 1400 b ); and

output fifth particulates ( 1400 a ).

12. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , wherein:

the stage 1 primary particulate capture device ( 350 ) is located within the second chamber ( 120 );

the stage 2 primary particulate capture device ( 260 ) is located within the first chamber ( 110 );

the first passageway ( 290 ) passes through the partition ( 130 ) to connect the first chamber ( 110 ) to the stage 1 primary particulate capture device ( 350 ) located within the second chamber ( 120 ); and,

the second passageway ( 390 ) passes through the partition ( 130 ) to connect the second chamber ( 120 ) to the stage 2 primary particulate capture device ( 260 ) located within the first chamber ( 110 ).

13. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , wherein:

the stage 1 primary particulate capture device ( 350 ) is located external to the second chamber ( 120 ) and the vessel ( 100 );

the stage 2 primary particulate capture device ( 260 ) is located external to the first chamber ( 110 ) and the vessel ( 100 );

the first passageway ( 291 ) does not pass through the partition ( 130 ) to connect the first chamber ( 110 ) to the stage 1 primary particulate capture device ( 350 ) located external to the vessel ( 100 ); and,

the second passageway ( 391 ) does not pass through the partition ( 130 ) to connect the second chamber ( 120 ) to the stage 2 primary particulate capture device ( 260 ) located external to the vessel ( 100 ).

14. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , wherein:

the stage 1 primary particulate capture device ( 350 ) is located within the second chamber ( 120 );

the stage 2 primary particulate capture device ( 260 ) is located external to the first chamber ( 110 ) and the vessel ( 100 );

the first passageway ( 290 ) passes through the partition ( 130 ) to connect the first chamber ( 110 ) to the stage 1 primary particulate capture device ( 350 ) located within second chamber ( 220 ); and

the second passageway ( 391 ) does not pass through the partition ( 130 ) to connect the second chamber ( 120 ) to the stage 2 primary particulate capture device ( 260 ) located external to the vessel ( 100 ).

15. The integrated two-stage fluid bed reactor ( 50 ) according to claim 2 , wherein:

the stage 1 primary particulate capture device ( 350 ) is located external to the second chamber ( 120 ) and the vessel ( 100 );

the stage 2 primary particulate capture device ( 260 ) is located within the first chamber ( 110 );

the first passageway ( 291 ) does not pass through the partition to connect the first chamber ( 110 ) to the stage 1 primary particulate capture device ( 350 ) located external to the vessel ( 100 ); and,

the second passageway ( 390 ) passes through the partition ( 130 ) to connect the second chamber ( 120 ) to the stage 2 primary particulate capture device ( 260 ) located within first chamber ( 110 ).

16. The integrated two-stage fluid bed reactor ( 50 ) according to claim 1 , wherein:

the second chamber ( 120 ) comprises a stage 2 freeboard zone fluid inlet port ( 312 ) configured to introduce at least one of steam, carbon dioxide, oxygen, or air, into the stage 2 freeboard zone ( 395 ) within the second chamber ( 120 ); and

the first chamber ( 110 ) comprises a stage 1 freeboard zone fluid inlet port ( 212 ) configured to introduce at least one of steam, carbon dioxide, oxygen, or air, into the stage 1 freeboard zone ( 295 ) within the first chamber ( 110 ).

17. The integrated two-stage fluid bed reactor ( 50 ) according to claim 1 , wherein:

the second chamber ( 120 ) further comprises a stage 2 secondary material inlet port ( 384 ) configured to introduce a stage 2 secondary material ( 382 ) into the stage 2 fluid bed ( 320 ), the stage 2 secondary material ( 382 ) comprising at least one from the group consisting of a sorbent, bed material agglomeration prevention additive, catalyst, tail-gas, syngas, tars, a hydrocarbon liquid, oil and a solvent.

18. The integrated two-stage fluid bed reactor ( 50 ) according to claim 1 , wherein:

the first chamber ( 110 ) further comprises a stage 1 secondary material inlet port ( 284 ) configured to introduce a stage 1 secondary material ( 282 ) into the stage 1 fluid bed ( 220 ), the stage 2 secondary material ( 282 ) comprising at least one from the group consisting of a sorbent, bed material agglomeration prevention additive, and catalyst.

19. The integrated two-stage fluid bed reactor ( 50 ) of claim 1 , wherein:

the first chamber ( 110 ) further comprises a stage 1 fluidization medium inlet port ( 231 ) configured to introduce a stage 1 fluidization medium ( 232 ) into the first chamber ( 110 ), the stage 1 fluidization medium ( 232 ) comprising at least one from the group consisting of steam, carbon dioxide, air, oxygen, hydrogen, syngas, and product gas, and mixtures thereof; and

the second chamber ( 120 ) further comprises a stage 2 fluidization medium inlet port ( 331 ) configured to introduce a stage 2 fluidization medium ( 332 ) into the second chamber ( 120 ), the stage 2 fluidization medium ( 332 ) comprising at least one from the group consisting of steam, carbon dioxide, air, oxygen, hydrogen, syngas, and product gas, and mixtures thereof.

20. The integrated two-stage fluid bed reactor ( 50 ) of claim 1 , wherein:

each of the heat pipes ( 400 ) is within a sealed thermowell ( 500 ) configured to be purged or pressurized with a gas ( 510 ) that is introduced via a gas injection port ( 505 ).

21. A feedstock conversion process for simultaneously producing volatile reaction products and syngas or flue gas from a carbonaceous feedstock, the process comprising:

providing a vessel ( 100 ) having a longitudinal axis and a partition ( 130 ) extending along the longitudinal axis and separating the vessel ( 100 ) into a first chamber ( 110 ) having a first bed and a first freeboard region, and a second chamber ( 120 ) having a second bed and a second freeboard region;

subjecting, in the first chamber ( 110 ), the carbonaceous feedstock to a first indirectly-heated endothermic reforming process operating under a first set of processing conditions to produce a first mixed stream containing syngas and unreacted fixed carbon and residual volatile feedstock components;

separating unreacted feedstock components present in the first freeboard region from the syngas and transferring said unreacted feedstock components to the second chamber;

subjecting, in the second chamber ( 120 ), the separated unreacted feedstock components to a partial or full exothermic process operating under a second set of processing conditions to produce a stream containing syngas or flue gas; and,

transferring heat generated from the exothermic process in the second chamber ( 120 ) through heat pipes to further promote the first endothermic reforming process in the first chamber ( 110 ).

22. A feedstock conversion process for simultaneously producing volatile reaction products and syngas or flue gas from a carbonaceous feedstock, the process comprising:

subjecting the carbonaceous feedstock, in a first chamber, to a first indirectly-heated endothermic hydrous devolatilization process operating under a first set of processing conditions including a temperature between 320° C. and 569.99° C., to produce first chamber discharge materials containing unreacted fixed carbon and residual volatile feedstock components in the form of particulates present in a first freeboard region of the first chamber, as well as a product gas comprised of volatile reaction products;

separating unreacted feedstock component particulates from the volatile reaction products and transferring said unreacted feedstock component particulates to a second chamber;

subjecting the separated and transferred unreacted feedstock component particulates to a partial or full exothermic process operating under a second set of processing conditions to produce second chamber discharge materials containing syngas or flue gas in a freeboard region of a second chamber;

transferring at least a portion of said second chamber discharge materials back to the first chamber; and

transferring heat generated from the second exothermic process through heat pipes to promote the first endothermic hydrous devolatilization process.