Patent Application
20220389329
The present disclosure relates to the conversion of fatty acid material to hydrocarbon material.
There are increasing social and economic pressures to develop renewable energy sources as well as renewable and biodegradable industrial and consumer products and materials. There is a new focus on biorefining, which can be described as the processing of agricultural and forestry feedstocks capturing increased value by processing them into multiple products including biodiesel. Conversion of such feedstocks into multiple products, using existing technologies, however, can still be improved.
In one respect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
recovering the hydrocarbon material-comprising product from the conversion zone; and
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provide a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
removing solid material from at least the recirculating externally-disposed liquid hydrocarbon material-comprising product, such that the externally-disposed liquid hydrocarbon material-comprising product, being recirculated to the reaction zone, is depleted in solids relative to the externally-disposed liquid hydrocarbon material-comprising product being discharged from the process vessel.
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
In another aspect, there is provided a process for producing hydrocarbon material from a hydrocarbon material precursor which includes free fatty acid material, comprising:
Other aspects will be apparent from the description and drawings provided herein.
The embodiments will now be described with reference to the following accompanying drawings, in which:
Referring to
FA material consists of at least one FA species. Each one of the at least one FA species, independently, is defined by a free fatty acid or its corresponding salt. In this respect, in some embodiments, for example, the FA material consists of free fatty acid material, and the free fatty acid material consists of one or more free fatty acid compounds.
The fatty acid can be a saturated fatty acid or an unsaturated fatty acid. Suitable fatty acids include butyric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, alpha-linolenic acid, docosahexaenoic acid, eicosapentaenoic acid, linoleic acid, arachidonic acid, oleic acid, erucic acid, or any naturally derived fatty acid from a plant or animal source.
The FA material of the HM precursor defines a FA material-defined precursor component. In some embodiments, for example, the HM precursor includes at least 80 weight percent (such as, for example, at least 85 weight percent, such as, for example, at least 90 weight percent) of the FA material-defined precursor component based on the total weight of the HM precursor.
In some embodiments, for example, at least a fraction of the FA material-defined precursor component is derived from FA precursor material. Suitable FA precursor material include vegetable oils, plant oils, animal fats, fungal oils, tall oils, animal fats, biosolids, cooking oil, spent cooking oil, waste greases, or soapstock, or any combination thereof. Suitable vegetable oils include corn oil, cottonseed oil, canola oil, rapeseed oil, olive oil, palm oil, peanut oil, ground nut oil, safflower oil, sesame oil, soybean oil, sunflower oil, algal oil, almond oil, apricot oil, argan oil, avocado oil, ben oil, cashew oil, castor oil, grape seed oil, hazelnut oil, hemp seed oil, linseed oil, mustard oil neem oil, palm kernel oil, pumpkin seed oil, tall oil, rice bran oil, or walnut oil, or any combination thereof. Suitable animal fats include blubber, cod liver oil, ghee, lard, tallow, derivatives thereof (e.g., yellow grease, used cooking oil, etc.), or any combination thereof.
The FA precursor material includes at least one FA precursor compound. Exemplary FA precursor compounds include lipids, phospholipids, triglycerides, diglycerides, and monoglycerides.
In some embodiments, for example, the deriving of the FA material-defined precursor component from the FA precursor material is effected in response to conversion of at least one FA precursor compound, wherein the conversion is to a product material including at least one FA species. In this respect, in some embodiments, for example, the process includes, prior to the producing of the hydrocarbon material from the HM precursor, converting at least one FA precursor compound, of the FA precursor material, to a product material including at least one FA species, such that the FA material-defined precursor component, of the HM precursor, includes at least one FA species that is obtained from the converting of the at least one FA precursor compound. In some embodiments, for example, the conversion includes a reactive process, such as, for example, hydrolysis.
In some embodiments, for example, prior to the converting, the FA precursor material is subjected to pretreatment to remove moisture, metals, gums, proteins, and colour which may cause emulsification during hydrolysis. In some embodiments, for example, the pretreatment includes an acid treatment followed by an addition of an absorbent (bleaching clay or activated carbon). The absorbent is removed by filtration. Residual moisture in the FA precursor material is removed under vacuum.
In some embodiments, for example, the process includes, within a conversion zone 10, converting the HM precursor-comprising feed material 12 to at least a gaseous hydrocarbon material-comprising product 14. The gaseous hydrocarbon material-comprising product 14 includes gaseous hydrocarbon material (hereinafter, “GHM”). The GHM consists of one or more hydrocarbon compounds. In some embodiments, for example, the GHM includes gaseous target hydrocarbon material. Each one of the at least one hydrocarbon of the gaseous target hydrocarbon material, independently, includes a total number of carbon atoms of at least one (1) and no more than 24. In some embodiments, for example, the gaseous hydrocarbon material includes at least 50 weight percent (such as, for example, at least 60 weight percent, such as, for example, at least 70 weight percent, such as, for example, at least 80 weight percent) of gaseous target hydrocarbon material, based on the total weight of the gaseous hydrocarbon material.
In some embodiments, for example, the conversion of the HM precursor-comprising feed material 12 includes reactively transforming at least a portion of the HM precursor-comprising feed material 12 via a reactive process. In some embodiments, for example, at least a portion of the FA material-defined precursor component of the HM precursor-comprising feed material 12 is reactively transformed to the GHM. In some of these embodiments, for example, during the conversion, at least a portion of the FA material-defined precursor component of the HM precursor-comprising feed material 12 remains unreacted, or is reactively transformed to another material (such that the FA material-defined precursor component is only partially reactively transformed to the GHM). In this respect, in addition to the GHM, the GHM-comprising product 14 includes gaseous FA material, and the gaseous FA material includes unconverted and/or partially converted FA material-defined precursor component. The gaseous FA material of the GHM-comprising product 14 is derived from the FA material-defined precursor component. In this respect, in some embodiments, for example, the gaseous FA material includes one or more FA species, of the FA material-defined precursor component, that are vapourized during the converting of the HM precursor, and/or includes one or more gaseous FA species that are obtained from partial reactive transformation of one or more FA species of the FA material-defined precursor component. The gaseous FA material typically includes relatively lower molecular weight compounds characterized by relatively lower boiling points, such as, for example, short chain fatty acids.
Referring to
In some embodiments, for example, the converting includes, within the conversion zone 10, heating the HM precursor-comprising feed material 12. In some of these embodiments, for example, the heating includes, prior to supplying the feed material 12 to the process vessel, heating of the HM precursor-comprising feed within a pre-heater 121. In some embodiments, for example, the heating includes additionally, or alternatively, heating the feed material 12 within the conversion zone 10. In this respect, and referring to
The reactive transformation of at least a portion of the HM precursor-comprising feed material 12 is effected by a reactive process within a reaction zone 18 of the conversion zone 10. An exemplary reactive process is pyrolysis (high temperature decomposition). Exemplary reactive processes occurring during pyrolysis include decarbonylation, decarboxylation, and thermal cracking, and condensation, or any combination thereof. During pyrolysis, oxygen groups are removed via decarboxylation and decarbonylation and the long chain hydrocarbons are cracked into the smaller chain molecules that comprise naphtha and diesel. The products of the pyrolysis include the GEM-comprising product 14 and a liquid hydrocarbon material-comprising product 42. In some embodiments, for example, the GEM-comprising product 14 includes the GHM, the FA material, carbon monoxide carbon dioxide, and diatomic hydrogen. In some embodiments, for example, the liquid hydrocarbon material-comprising product 42 includes liquid hydrocarbon compounds, such as, for example, liquid hydrocarbon compounds containing a total number of six (6) to 16 carbon atoms, free fatty acid compounds containing a total number of four (4) to 18 carbon atoms, water, and a solid carbon by-product made up of high molecular weight species such as large, polycyclic aromatics. In some embodiments, for example, the reactive process is effected in the absence of a catalyst. In some embodiments, for example, the reactive process is effected in the absence of adscititious diatomic hydrogen. In some embodiments, for example, the reactive process is effected in the absence of adscititious diatomic oxygen. In some embodiments, for example, the reactive process is effected in the absence of a catalyst and in the absence of adscititious diatomic hydrogen. In some embodiments, for example, the reactive process is effected in the absence of a catalyst, and in the absence of adscititious diatomic hydrogen, and in the absence of adscititious diatomic oxygen. In some embodiments, for example, the conversion zone and the supplying of the hydrocarbon material precursor-comprising feed material to the conversion zone 10 co-operate such that the space time, defined by the time required by the supplied hydrocarbon material precursor-comprising feed material to occupy the entirety of the conversion zone 10, is at least 10 minutes, such as, for example, at least 15 minutes. In some embodiments, for example, the conversion zone and the supplying of the hydrocarbon material precursor-comprising feed material to the conversion zone 10 co-operate such that the space time, defined by the time required by the supplied hydrocarbon material precursor-comprising feed material to occupy the entirety of the conversion zone 10, is from ten (10) minutes to 120 minutes, such as, for example, from ten (10) minutes to 90 minutes. In some embodiments, for example, the temperature within the reaction zone 18 is from 350 degrees Celsius to 500 degrees Celsius, such as, for example, from 360 degrees Celsius to 450 degrees Celsius. In some embodiments, for example, the pressure within the reaction zone 18 is from 100 psig to 250 psig.
In some embodiments, for example, the process is a continuous process and, in this respect, the process includes, while: (i) the HM precursor-comprising feed material 12 is being supplied to the conversion zone 10, and (ii) the HM precursor-comprising feed material 12 is being converted to the GEM-comprising product 14 within the conversion zone:
After the GEM-comprising product 14 is recovered, a portion of the recovered GHM-comprising product 14 is condensed such that a condensed HM-comprising product 28 is obtained, and the condensed HM-comprising product 28 (in the liquid state) is recycled to the conversion zone 10 for at least effecting further conversion of the GEM-comprising product 28 (such as, for example, via a reactive process within the reaction zone 19A of the conversion zone 19). In this respect, the HM-comprising product 28 functions as a reflux 28. In some embodiments, for example, the reflux 28 returns longer chain fatty acid material for further conversion within the conversion zone 10, and also returns longer chain hydrocarbon material for further conversion within the conversion zone 10. In some embodiments, for example, the HM-comprising product 28 which is returned to the conversion zone 10 defines a reflux ratio. An increased reflux ratio promotes obtaining a greater portion of shorter chain hydrocarbon material, and a reduced portion of longer chain FA material, within the recovered GEM-comprising product 14. In some embodiments, for example, the reflux ratio in based upon at least one parameter, and the at least one parameter includes at least one of: (i) chain length of hydrocarbon material within the hydrocarbon material-comprising product (14 or 28), and (ii) chain length of FA material (such as, for example, free fatty acid material) within the hydrocarbon material-comprising product (14 or 28).
In some embodiments, for example, the process further comprises sensing of chain length of hydrocarbon material within the HM-comprising product (14 or 28), and, in some of these embodiments, for example, the process further comprises modulating the reflux ratio based upon at least the sensing of the chain length of hydrocarbon material within the hydrocarbon material-comprising product (14 or 28). In some embodiments, for example, the process further comprises sensing of chain length of FA material (such as, for example, free fatty acid material) within the hydrocarbon material-comprising product (14 or 28), and, in some of these embodiments, for example, the process further comprises modulating the reflux ratio based upon at least the sensing of the chain length of FA material within the hydrocarbon material-comprising product (14 or 28). In some embodiments, for example, the process further comprises (i) sensing the hydrocarbon material-comprising product (14 or 28) for the chain length of hydrocarbon material within the hydrocarbon material-comprising product (14 or 28), and (ii) sensing the hydrocarbon material-comprising product (14 or 28) for the chain length of free fatty acid material within the hydrocarbon material-comprising product (14 or 28), and, in some of these embodiments, for example, the process further comprises modulating the reflux ratio based upon at least: (i) sensing of chain length of hydrocarbon material within the hydrocarbon material-comprising product (14 or 28); (ii) sensing of chain length of free fatty acid material within the hydrocarbon material-comprising product (14 or 28); or (iii) sensing of chain length of hydrocarbon material within the hydrocarbon material-comprising product (28) and sensing of chain length of free fatty acid material within the hydrocarbon material-comprising product (28).
In some embodiments, for example, the condensing of the portion of the GEM-comprising product 14 is effected via cooling of the GEM-comprising product 14 that is effected in response to emplacement of the GEM-comprising product 14 in heat transfer communication with a heat sink. In some embodiments, for example, the heat sink is a a cooling fluid, and the heat transfer communication is an indirect heat transfer communication. In some embodiments, for example, the indirect heat transfer communication is effected via a heat exchanger 30.
In some of these embodiments, for example, the process is a continuous process and, in this respect, the process includes, while: (i) the HM precursor-comprising feed material 12 is being supplied to the conversion zone 10, with effect that the HM precursor-comprising feed material 12 is converted to at least a GEM-comprising product 14, and (ii) the GEM-comprising product 14 is being recovered from the conversion zone 10:
Referring to
With respect to the intermediate conversion, the HM precursor-comprising feed material 12 is converted to a GEM-comprising intermediate product 16 within an intermediate conversion zone 19. In this respect, the converting includes converting the HM precursor-comprising feed material 12 to a GEM-comprising intermediate product 16 within the intermediate conversion zone 19. The converting of the HM precursor-comprising feed material 12 to a GHM-comprising intermediate product 16 includes reactive transformation of at least a portion of the HM precursor-comprising feed material 12. The reactive transformation of at least a portion of the HM precursor-comprising feed material 12 is effected by a reactive process within a reaction zone 19A of the intermediate conversion zone 19. In this respect, the intermediate conversion includes reactive transformation of at least a portion of the HM precursor-comprising feed material 12 via a reactive process within the reaction zone 19A of the intermediate conversion zone 19. An exemplary reactive process is pyrolysis (high temperature decomposition). Exemplary reactive processes occurring during pyrolysis include decarbonylation, decarboxylation, thermal cracking, and condensation or any combination thereof. During pyrolysis, oxygen groups are remo6ved via decarboxylation and decarbonylation and the long chain hydrocarbons are cracked into the smaller chain molecules that comprise naphtha and diesel. The products of the pyrolysis include the GEM-comprising product 14 and a liquid hydrocarbon material-comprising product 42. In some embodiments, for example, the GHM-comprising product 14 includes the GHM, the FA material, carbon monoxide, carbon dioxide, methane, ethane, propane, and diatomic hydrogen. In some embodiments, for example, the liquid hydrocarbon material-comprising product 42 includes liquid hydrocarbon compounds, such as, for example, liquid hydrocarbon compounds containing a total number of six (6) to 16 carbon atoms, free fatty acid compounds containing a total number of four (4) to 18 carbon atoms, water, and a solid carbon by-product made up of high molecular weight species such as large, polycyclic aromatics. In some embodiments, for example, the reactive process is effected in the absence of a catalyst. In some embodiments, for example, the reactive process is effected in the absence of adscititious diatomic hydrogen. In some embodiments, for example, the reactive process is effected in the absence of adscititious diatomic oxygen. In some embodiments, for example, the reactive process is effected in the absence of a catalyst and in the absence of adscititious diatomic hydrogen. In some embodiments, for example, the reactive process is effected in the absence of a catalyst, and in the absence of adscititious diatomic hydrogen, and in the absence of adscititious diatomic oxygen. In some embodiments, for example, the conversion zone and the supplying of the hydrocarbon material precursor-comprising feed material to the reaction zone 19A co-operate such that the space time, defined by the time required by the supplied hydrocarbon material precursor-comprising feed material to occupy the entirety of the reaction zone 19A, is at least 10 minutes, such as, for example, at least 15 minutes. In some embodiments, for example, the reaction zone 19A and the supplying of the hydrocarbon material precursor-comprising feed material to the conversion zone 10 co-operate such that the space time, defined by the time required by the supplied hydrocarbon material precursor-comprising feed material to occupy the entirety of the reaction zone 19A, is from ten (10) minutes to 120 minutes, such as, for example, from ten (10) minutes to 90 minutes. In some embodiments, for example, the temperature within the reaction zone 18 is from 350 degrees Celsius to 500 degrees Celsius, such as, for example, from 360 degrees Celsius to 450 degrees Celsius. In some embodiments, for example, the pressure within the reaction zone 18 is from 100 to 250 psig.
With respect to the fractionation, the GEM-comprising intermediate product 16 is fractionated within a fractionating zone 26 with effect that the GEM-comprising product 14 is obtained. In this respect, the converting includes fractionating the GEM-comprising intermediate product 16 within the fractionating zone 26 with effect that the GEM-comprising product 14 is obtained. In some embodiments, for example, the fractionation is effected in response to contacting, within the fractionation zone 26, of the GEM-comprising intermediate product 16 with the above-described reflux 28. In some embodiments, for example, while the contacting between the reflux 28 and the GEM-comprising intermediate product 16 is being effected, the reflux 28 is being flowed in an opposite direction relative to the flow of the GHM-comprising intermediate product 16. In this respect, in some embodiments, for example, the fractionating is effected in response to contacting of the reflux 28 and the GEM-comprising intermediate product 16 while the reflux 28 is flowing countercurrent to the flow of the GHM-comprising intermediate product 16. In some embodiments, for example, the flow of the GHM-comprising intermediate product 16 is in an upwardly direction and the flow of the reflux 28 is in a downwardly direction. In some of these embodiments, for example, the contacting between the GEM-comprising intermediate product 16 and the reflux 28 is encouraged by contacting media disposed within the fractionation zone 26. Suitable contacting media includes trays, plates, and packing.
In some of these embodiments, for example, the process is a continuous process and, in this respect, the process includes, while: (i) a HM precursor-comprising feed material 12 is being supplied to the intermediate conversion zone 19, with effect that the HM precursor-comprising feed material 12 is converted to at least a GEM-comprising intermediate product 16, (ii) the GEM-comprising intermediate product 16 is being emplaced within the fractionation zone 26, (iii) a portion of a GEM-comprising product 14 is being condensed such that a condensed HM-comprising product is obtained 28, and (v) the condensed HM-comprising product 28 is recycled to the fractionation zone 26:
Referring to
As discussed above, in some embodiments, for example, the converting of the HM precursor-comprising feed material 12 is with effect that the liquid hydrocarbon material-comprising product 42 is obtained. Referring to
In those embodiments where the converting includes an intermediate conversion, where the HM precursor-comprising feed material 12 is converted to at least a GEM-comprising intermediate product 16 within an intermediate conversion zone 19, and also includes a second conversion, where the GEM-comprising intermediate product 16 is fractionated within a fractionating zone 26 with effect that the GEM-comprising product 14 is obtained, in some of these embodiments, for example, the intermediate conversion effects production of the liquid hydrocarbon material-comprising product 42. In this respect, in some of these embodiments, the process further includes separating the GEM-comprising intermediate product 16 from the liquid hydrocarbon material-comprising product 42. In some embodiments, for example, the separating of the GEM-comprising intermediate product 16 from the liquid hydrocarbon material-comprising product 42 includes a gravity separation and is effected in response to at least buoyancy forces.
In some embodiments, for example, an intermediate material mixture 24 is disposed within the intermediate conversion zone 19 and includes reaction products (resulting from the reactive transformation) and unreacted HM precursor-comprising feed material 12. At least a portion of the unreacted HM precursor-comprising feed material 12 is reactively transformable into reaction products, as described above.
In those embodiments where the GEM-comprising intermediate product 16 is separated from the liquid hydrocarbon material-comprising product 42, in some of these embodiments, for example, the separation is effected by separation of the intermediate material mixture 24 into at least the GEM-comprising intermediate product 16 and the liquid hydrocarbon material-comprising product 42, and the separation includes a gravity separation and is effected in response to at least buoyancy forces.
In some of these embodiments, for example, the process is a continuous process and, in this respect, the process includes, while: (i) the intermediate material mixture 24 is disposed within the intermediate conversion zone 19, and (ii) the HM precursor-comprising feed material 12 is being supplied to the intermediate conversion zone 10, independently:
In some embodiments, for example, the separated liquid hydrocarbon material-comprising product 42 is discharged from the process vessel 20. At least a portion of the discharged liquid hydrocarbon material-comprising product 42 is recirculated externally of the internal space 21 via a pump 60. In this respect, in some embodiments, for example, a recirculation loop 62 is provided for recirculating at least a portion of the discharging liquid hydrocarbon material-comprising product 42 externally of the internal space 21 such that the discharged liquid hydrocarbon material-comprising product 42 is returned to the internal space 21 of the process vessel 20, such that the converting of the HM-precursor-comprising feed material, within the internal space 21 of the process vessel 20, is effected, as above described. In this respect, in some embodiments, the intermediate conversion zone 19 includes the recirculation loop 62. The residual liquid material product 58, which is not recirculated, can be further processed.
Referring to
In some embodiments, for example, the process, including the recirculation of the discharged liquid hydrocarbon material-comprising product 42, is continuous. In this respect, in some embodiments, for example, the process includes, while: (i) within an internal space 21 of the process vessel 20, converting the HM precursor to an intermediate material mixture 24, wherein the converting includes reactive transformation of at least a portion of the HM precursor via a reactive process within a reaction zone 18; (ii) in response to at least buoyancy forces, separating the intermediate material mixture 24 into a GEM-comprising product 14 and a liquid hydrocarbon material-comprising product 42; (iii) discharging the separated liquid hydrocarbon material-comprising product 42 from the process vessel 20 such that an externally-disposed liquid hydrocarbon material-comprising product 42 is obtained; and (iv) recirculating at least a portion 50 of the externally-disposed liquid hydrocarbon material-comprising product 42 to the internal space 21 of the process vessel 20:
Referring to
Referring to
Referring to
With respect to the separation, in some embodiments, for example, the residual liquid material product 58 is fractionated into the recoverable gaseous material portion 64 and the rejectable residual slurry material portion 66 in response to heating of the residual liquid material product 58. In this respect, the fractionation is based on volatility differences, fractionating at least a portion of the externally-disposed liquid hydrocarbon material-comprising product into a recoverable gaseous material portion and a rejected residual slurry material portion. In some embodiments, for example, the heating is effected under vacuum conditions. In this respect, in some embodiments, for example, the heating is effected within a heating zone 68 disposed at a temperature from 250 degrees Celsius to 350 degrees Celsius and at a pressure that is less than atmospheric pressure, such as, for example, at a pressure from 0.0725 psia (0.5 kPa) to 0.725 psia (5 kPa).
In some embodiments, for example, in response to the heating of the residual liquid material product 58 within the heating zone 68, a product mixture 70 is generated within the conversion zone 68, such that the product mixture 70 is disposed within the heating zone 68. The product mixture 70 includes the recoverable gaseous material portion 64 and the rejectable residual slurry material portion 66. While the product mixture 70 is disposed within the conversion zone 68, in response to buoyancy forces, the product mixture 70 is separated into the recoverable gaseous material portion 64 and the rejectable residual slurry material portion 66.
In some embodiments, for example, the heating zone 68 is disposed within a process vessel 72, such that: (i) the recoverable gaseous material portion 64 accumulates at an upper portion 74 of the process vessel 72 and discharged as a recovered gaseous material portion 64A, and (ii) the rejectable residual slurry material portion 66 accumulates at a bottom portion 76 of the process vessel 74 and discharged as a rejected residual slurry material portion 66A, In some embodiments, for example, the discharging of the recovered gaseous material portion 64A is induced by a vacuum pump 78 disposed in flow communication with the upper portion 74 of the process vessel 70.
In some embodiments, for example, the process vessel 70 is a thin film evaporator.
In some embodiments, for example, prior to the supplying of the residual liquid material product 58 to the heating zone 68, the residual liquid material product 58 is cooled within a heat exchanger 86, so as to further mitigate coke formation.
In some embodiments, for example, by separating the rejected residual slurry material portion 66A from the recovered gaseous material portion 66A, coke formation within the system is mitigated. In this respect, the rejected residual slurry material portion 66A includes materials, such as long chain hydrocarbons and solids, which are susceptible to coke formation in response to exposure to high temperatures, and their removal effects the mitigation of coke formation.
With respect to the discharged recovered gaseous material portion 64A, in some embodiments, for example, the discharged recovered gaseous material portion 64A is condensed, within a condensation zone 82 of a condenser 80, to generate a condensed recovered residual material 64B. In some embodiments, for example, the condensation within the condensation zone 82 is with effect that condensed recovered residual material 64B is disposed at a temperature from 150 degrees Celsius to 200 degrees Celsius and at a pressure from 100 psig to 250 psig (for example, to match the pressure conditions within the process vessel 20, to which the condensed recovered residual material 64B is supplied, see below).
With respect to the condensed recovered residual material 64B, the condensed recovered residual material 64B is supplied to the internal space 21 of the process vessel 20 such that the converting of the condensed recovered residual material 64B, within the internal space 21, is effected, as above described.
In some embodiments, for example, prior to the supplying of the condensed recovered residual material 64B to the internal space 21 of the process vessel 20, the condensed recovered residual material 64B is heated, such that the condensed recovered residual material 64B is disposed at a temperature from 300 degrees Celsius to 400 degrees Celsius. In some embodiments, the heating includes emplacing the condensed recovered residual material 64B in heat transfer communication with the residual liquid material product 58 (such as, for example, via a heat exchanger), such that heat is transferred from the residual liquid material product 58 to the condensed recovered residual material 64B. In some embodiments, for example, the heating includes emplacing the condensed recovered residual material 64B in heat transfer communication with a heating fluid, such as via heat exchanger 84.
In some embodiments, prior to the supplying of the condensed recovered residual material 64B to the internal space 21 of the process vessel 20, the condensed recovered residual material 64B is admixed with material within the recirculation loop 62 for supply to the internal space 21 of the process vessel 20. In some of these embodiments, for example, prior to the admixing, the condensed recovered residual material 64B is heated (as above-described), such that the condensed recovered residual material 64B is disposed at a temperature from 300 degrees Celsius to 400 degrees Celsius. In some of these embodiments, for example, the material being recirculated within the recirculation loop 62 includes the HM-precursor-comprising feed material 12.
In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure. All references mentioned are hereby incorporated by reference in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2020/051508 | 11/6/2020 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 62931319 | Nov 2019 | US | |
| 62931300 | Nov 2019 | US | |
| 62931291 | Nov 2019 | US | |
| 62931281 | Nov 2019 | US |
