Claims
- 1. A continuous process for recovery of values contained in solid carbonaceous materials which comprises the steps of:
- (a) providing a feed stream containing a particulate solid carbonaceous material, a substantial portion of the particulate solid carbonaceous material being of a particle size less than about 1000 microns in diameter;
- (b) subjecting the solid carbonaceous material particles to flash pyrolysis by continuously:
- (i) transporting the solid carbonaceous material containing feed stream contained in a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the solid carbonaceous material to a solids feed inlet of a substantially vertically oriented, descending flow pyrolysis reactor having a substantially vertically oriented pyrolysis zone operated at a pyrolysis temperature above about 600.degree. F.;
- (ii) feeding a particulate source of heat at a required temperature above the pyrolysis temperature to a substantially vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing section of the vertically oriented descending flow pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therewith of an aerating gas substantially nondeleteriously reactive with respect to products of pyrolysis of the solid carbonaceous material;
- (iii) discharging the particulate source of heat over said weir and downwardly into said mixing region at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature;
- (iv) injecting the solid carbonaceous material feed stream and carrier gas from the solids feed inlet into the mixing region to form a resultant turbulent mixture of the particulate source of heat, the solid carbonaceous material particles and carrier gas;
- (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid carbonaceous material particles and yield a pyrolysis product stream containing as particulate solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the solid carbonaceous material particles, and a vapor mixture of carrier gas and pyrolytic vapors comprising volatilized hydrocarbons and tars;
- (c) passing the pyrolysis product stream from said pyrolysis reactor to a separation zone to separate at least the bulk of the particulate solids from the vapor mixture;
- (d) forming the particulate source of heat by:
- (i) transporting the separated solids from the separation zone to a cyclone oxidation-separation zone with a transport gas containing free oxygen with resultant carbon monoxide formation from the carbon in the solids; and
- (ii) combining the transported particulate solids, carbon monoxide and transport gas in the cyclone oxidation-separation zone with a source of free oxygen in an amount at least equal to 50 mole percent of the carbon monoxide entering the cyclone oxidation-separation zone, the total free oxygen in the transport gas and combined in the cyclone oxidation-separation zone being sufficient to raise the solids to the temperature required for feed to the substantially vertically oriented chamber,
- while simultaneously separating the bulk of the particulate source of heat from the gases present in the cyclone oxidation-separation zone to form the feed to the substantially vertically oriented chamber; and
- (e) recovering hydrocarbon values from the vapor by progressively cooling the vapor mixture in a plurality of gas-liquid cooling-condensation stages in series, each stage having a liquid coolant, a vapor feed, a vapor effluent, and liquid condensate, the liquid coolant of each stage including condensate of the stage, the liquid coolant of each stage being below the temperature of the vapor feed to the stage and vapor effluent of the stage, the condensate of each stage being progressively lower in average boiling point and tar content.
- 2. A process as claimed in claim 1 in which the pyrolysis temperature is from about 600.degree. to about 2000.degree. F.
- 3. A process as claimed in claim 1 in which the pyrolysis temperature is from about 600.degree. to about 1400.degree. F.
- 4. A process as claimed in claim 1 in which the pyrolysis temperature is from about 900.degree. to about 1400.degree. F.
- 5. A process as claimed in claim 1 in which a substantial portion of the particles of the solid carbonaceous material are particles in the range from about 10 to about 1000 microns in diameter.
- 6. A process as claimed in claim 1 in which the solid carbonaceous material is an agglomerative coal, and a substantial portion of the particulate solid carbonaceous material is of a particle size less than about 250 microns in diameter.
- 7. A process as claimed in claim 1 in which the particulate solid carbonaceous material is an agglomerative coal, and a substantial portion of the particulate solid carbonaceous material is of a particle size in the range of from about 10 to about 250 microns in diameter.
- 8. A process as claimed in claim 1 in which the resultant turbulent mixture has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the resultant turbulent mixture and a weight ratio of the particulate source of heat to solid carbonaceous material feed of from about 2 to about 20:1.
- 9. A process as claimed in claim 1 having a pyrolysis time of less than about 5 seconds.
- 10. A continuous process for recovery of values contained in solid carbonaceous materials comprising the steps of:
- (a) providing a particulate solid carbonaceous material feed stream substantially containing particles of a size from about 10 to about 1000 microns in diameter;
- (b) subjecting the solid carbonaceous material particles to flash pyrolysis by continuously:
- (i) transporting the solid carbonaceous material feed stream contained in a carrier gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the solid carbonaceous material to a solids feed inlet of a vertically oriented, descending flow pyrolysis reactor having a pyrolysis zone operated at a pyrolysis temperature of from about 600.degree. to about 2000.degree. F.;
- (ii) feeding a particulate source of heat at a required temperature above the pyrolysis temperature to a vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing section of the vertically oriented descending flow pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therewith of an aerating gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the solid carbonaceous material;
- (iii) discharging the particulate source of heat over said weir and downwardly into said mixing region at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature;
- (iv) injecting the solid carbonaceous material feed stream and carrier gas from the solids feed inlet into the mixing region to form a resultant turbulent mixture of said particulate source of heat, solid carbonaceous material particles and carrier gas;
- (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid carbonaceous material particles and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid product of pyrolysis of the solid carbonaceous material particles, and a vapor mixture of carrier gas and pyrolytic vapors comprising volatilized hydrocarbons and tars, the pyrolysis time being less than about 5 seconds;
- (c) passing the pyrolysis product stream from said pyrolysis reactor to a first cyclone separation stage to separate the bulk of the solids from the vapor mixture;
- (d) forming the particulate source of heat by:
- (i) passing at least a portion of the solids from the first cyclone separation zone to a fluidized bed around a substantially vertically oriented, open riser;
- (ii) educting solids from the fluidized bed into the riser by injecting a transport gas containing free oxygen upwardly into the riser to transport the solids through the vertically oriented riser to a cyclone oxidation-separation stage with resultant carbon monoxide formation from the carbon in the solids; and
- (iii) combining the particulate solids, carbon monoxide and transport gas in the cyclone oxidation-separation stage with a source of oxygen in an amount at least equal to 50 mole percent of the carbon monoxide entering the cyclone oxidation-separation stage, the total free oxygen in the transport gas and combined in the cyclone oxidation-separation stage being sufficient to raise the solids to the temperature required for introduction to the vertically oriented chamber by oxidizing a portion of the total carbon present to a higher oxidation stage, while simultaneously separating the bulk of the particulate source of heat from the gases present in the cyclone oxidation-separation stage to form the feed to the vertically oriented chamber; and
- (e) recovering hydrocarbon values from the vapor mixture by:
- (i) progressively cooling the vapor mixture in a plurality of gas-liquid cooling-condensation stages in series, each stage having a liquid coolant, a vapor feed, a vapor effluent, and liquid condensate, the liquid coolant of each stage including the condensate of the stage, the liquid coolant of each stage being below the temperature of the vapor feed to the stage and the vapor effluent of the stage, the condensate of each stage being progressively lower in average boiling point and tar content;
- (ii) passing the vapor effluent containing residual hydrocarbons from the last of said cooling stages to a quench cooling stage and admixing the effluent with water to form an immiscible mixture of water and a low boiling hydrocarbon oil condensate from the residual hydrocarbons and separating the water from the low boiling hydrocarbon condensate.
- 11. The process of claim 10 in which the fluidized bed is fluidized by a fluidizing gas containing oxygen.
- 12. A process as claimed in claim 10 in which the solid carbonaceous material is an agglomerative coal and the solid carbonaceous material feed stream substantially contains particles of a size from about 10 to about 250 microns.
- 13. A process as claimed in claim 10 in which the resultant turbulent mixture has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the resultant turbulent mixture and a weight ratio of the particulate source of heat to solid carbonaceous material feed of from about 2 to about 20:1.
- 14. A process as claimed in claim 10 in which the pyrolysis temperature is from about 900.degree. to about 1400.degree. F.
- 15. A process as claimed in claim 10 in which the pyrolysis temperature is from about 600.degree. to about 1400.degree. F.
- 16. A process as claimed in claim 10 in which the pyrolysis time is from about 0.1 to about 3 seconds.
- 17. A process as claimed in claim 10 in which the residence time in the cyclone oxidation-separation stage is less than about 5 seconds.
- 18. A process as claimed in claim 10 in which the residence time in the cyclone oxidation-separation stage is from about 0.1 to about 3 seconds.
- 19. A continuous process for recovery of values contained in agglomerative coals which comprises the steps of:
- (a) providing a particulate agglomerative coal feed stream containing agglomerative coal particles of a size less than about 250 microns in diameter;
- (b) subjecting the particulate coal feed stream to flash pyrolysis by continuously:
- (i) transporting the particulate coal feed stream and a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal feed to a solids feed inlet of a vertically oriented, descending flow pyrolysis reactor having a pyrolysis zone operated at a pyrolysis temperature from about 600.degree. to about 2000.degree. F.
- (ii) feeding a particulate source of heat at a required temperature above the pyrolysis temperature, and comprising heated carbon containing solid residue of pyrolysis of coal, to a vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing section of the vertically oriented descending flow pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therewith of an aerating gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal feed;
- (iii) discharging the particulate source of heat over said weir and downwardly into said mixing region at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature;
- (iv) injecting the particulate coal stream and carrier gas from the solids feed inlet into the mixing region to form a resultant turbulent mixture of said particulate source of heat, particulate coal feed stream and carrier gas;
- (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the coal feed stream and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the coal feed, and a vapor mixture of carrier gas and pyrolytic vapors comprising volatilized hydrocarbons and tars, the pyrolysis time being less than about 5 seconds;
- (c) passing the pyrolysis product stream from said pyrolysis reactor to a cyclone separation zone to separate the solids from the vapor mixture;
- (d) forming the particulate source of heat by:
- (i) passing at least a portion of the separated solids to a fluidized bed around a substantially vertically oriented open riser;
- (ii) educting solids from the fluidized bed into the riser by injecting a transport gas containing free oxygen upwardly into the riser to transport solids through the vertically oriented riser to a cyclone oxidation-separation zone with resultant carbon monoxide formation from carbon in the solids; and
- (iii) combining the particulate solids, carbon monoxide and transport gas in the cyclone oxidation-separation zone with a source of free oxygen in an amount at least equal to 50 mole percent of the carbon monoxide entering the cyclone oxidation-separation zone, the total free oxygen in the transport gas and combined in the oxidation-separation zone being sufficient to raise the solids to the temperature required for introduction to the vertically oriented chamber while simultaneously separating the particulate source of heat from gaseous combustion products of the solids for feed to the vertically oriented chamber surrounding the upper portion of the pyrolysis reactor; and
- (e) recovering hydrocarbon values from the vapor mixture by:
- (i) progressively cooling the vapor mixture in a plurality of gas-liquid cooling-condensation stages in series, the liquid coolant of each stage including the condensate of the stage, each stage having a liquid coolant, a vapor feed, a vapor effluent and liquid condensate, the coolant of each stage condensate, the coolant of each stage being below the temperature of the vapor feed to the stage and vapor effluent of the stage, the condensate of each stage being progressively lower in boiling point and tar content;
- (ii) passing the vapor effluent containing residual hydrocarbons from the last of said cooling stages to a quench cooling stage and admixing the effluent with water to form an immiscible mixture of water and a low boiling hydrocarbon oil condensate from the residual hydrocarbons and separating the water from the low boiling hydrocarbon condensate.
- 20. The process of claim 19 in which the particulate source of heat is passed from the cyclone oxidation-separation zone to the vertically oriented chamber surrounding the upper portion of the pyrolysis reactor through a vertically oriented standpipe fluidized with a gas which is nondeleteriously reactive with respect to pyrolysis products of the coal feed.
- 21. A process as claimed in claim 19 in which the resultant turbulent mixture has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the resultant turbulent mixture, and a weight ratio of the particulate source of heat to the coal feed of from about 2 to about 20:1.
- 22. A process as claimed in claim 19 in which the pyrolysis temperature is from about 900.degree. to about 1400.degree. F.
- 23. A process as claimed in claim 19 in which a substantial portion of the agglomerative coal particles are particles in the range from about 10 to 250 microns.
- 24. A process as claimed in claim 19 in which the residence time in the cyclone oxidation-separation zone is less than about 5 seconds.
- 25. A process as claimed in claim 19 in which the residence time in the cyclone oxidation-separation zone is from about 0.1 to about 3 seconds.
- 26. A continuous process for recovery of values contained in solid carbonaceous materials which comprises the steps of:
- (a) providing a feed stream containing a particulate solid carbonaceous material, a substantial portion of the particulate solid carbonaceous material being of a particle size less than about 1000 microns in diameter;
- (b) subjecting the solid carbonaceous material particles to flash pyrolysis by continuously:
- (i) transporting the solid carbonaceous material feed stream contained in a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the solid carbonaceous material to a solids feed inlet of a substantially vertically oriented, descending flow pyrolysis reactor having a substantially vertically oriented pyrolysis zone operated at a pyrolysis temperature above about 600.degree. F.;
- (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature to a substantially vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing section of the vertically oriented descending flow pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therewith of an aerating gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the solid carbonaceous material;
- (iii) discharging the particulate source of heat over said weir and downwardly into said mixing region at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature;
- (iv) injecting the solid carbonaceous material feed stream and carrier gas from the solids feed inlet into the mixing region to form a resultant turbulent mixture of the particulate source of heat, the solid carbonaceous material particles and carrier gas;
- (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid carbonaceous material particles and yield a pyrolysis product stream containing as particulate solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the solid carbonaceous material particles, and a vapor mixture of carrier gas and pyrolytic vapors comprising volatilized hydrocarbons and tars;
- (c) passing the pyrolysis product stream from said pyrolysis reactor to a separation zone to separate at least the bulk of the particulate solids from the vapor mixture;
- (d) forming the particulate source of heat by subjecting carbon in the separated particulate solids to oxidation in at least one oxidation stage in the presence of an amount of free oxygen at least sufficient to raise the particulate solids to a temperature sufficient for feed to the substantially vertically oriented chamber, wherein said at least one oxidation stage comprises a cyclone oxidation-separation zone so that the bulk of the particulate source of heat is separated from the gases present in the cyclone oxidation-separation stage to form the feed to the substantially vertically oriented chamber; and
- (e) recovering hydrocarbon values from the vapor mixture by progressively cooling the vapor mixture in a plurality of gas-liquid cooling-condensation stages in series, each stage having a liquid coolant, a vapor feed, a vapor effluent, and liquid condensate, the liquid coolant of each stage including the condensate of the stage, the coolant of each stage being below the temperature of the vapor feed to the stage and vapor effluent of the stage, the condensate of each stage being progressively lower in average boiling point and tar content.
- 27. A process as claimed in claim 26 in which the pyrolysis temperature is from about 600.degree. to about 2000.degree. F.
- 28. A process as claimed in claim 26 in which the pyrolysis temperature is from about 600.degree. to about 1400.degree. F.
- 29. A process as claimed in claim 26 in which the pyrolysis temperature is from about 900.degree. to about 1400.degree. F.
- 30. A process as claimed in claim 26 in which a substantial portion of the particles of the solid carbonaceous material are particles in the range from about 10 to about 1000 microns in diameter.
- 31. A process as claimed in claim 26 in which the solid carbonaceous material is an agglomerative coal and a substantial portion of the particulate solid carbonaceous material is of a particle size less than about 250 microns in diameter.
- 32. A process as claimed in claim 26 in which the particulate solid carbonaceous material is an agglomerative coal, and a substantial portion of the particulate solid carbonaceous material is of a particle size in the range from about 10 to about 250 microns in diameter.
- 33. A process as claimed in claim 26 in which the resultant turbulent mixture has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the resultant turbulent mixture and a weight ratio of the particulate source of heat to solid carbonaceous material feed of from about 2 to about 20:1.
- 34. A process as claimed in claim 26 having a pyrolysis time of less than about 5 seconds.
- 35. A continuous process for recovery of values contained in solid carbonaceous materials which comprises the steps of:
- (a) providing a feed stream containing a particulate solid carbonaceous material, a substantial portion of the particulate solid carbonaceous material being of a particle size less than about 1000 microns in diameter;
- (b) subjecting the particulate solid carbonaceous material to flash pyrolysis by continuously:
- (i) transporting the particulate solid carbonaceous material feed stream contained in a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the particulate solid carbonaceous material to a solids feed inlet of a substantially vertically oriented, descending flow pyrolysis reactor having a substantially vertically oriented pyrolysis zone operated at a pyrolysis temperature above about 600.degree. F.;
- (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature to a substantially vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing section of the vertically oriented descending flow pyrolysis reactor, the particulate source of heat in said chamber being maintained in a fluidized state by the flow therewith of an aerating gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the particulate solid carbonaceous material;
- (iii) discharging the particulate source of heat over said weir and downwardly into said mixing region at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature;
- (iv) injecting the particulate solid carbonaceous material feed stream and carrier gas from the solids feed inlet into the mixing region to form a resultant turbulent mixture of the particulate source of heat, the particulate solid carbonaceous material and carrier gas;
- (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate solid carbonaceous material and yield a pyrolysis product stream containing as particulate solids, the particulate source of heat and a particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material, and a vapor mixture of carrier gas and pyrolytic vapors comprising volatilized hydrocarbons including tars;
- (c) passing the pyrolysis product stream from said pyrolysis reactor to a separation zone to separate at least the bulk of the particulate solids from the vapor mixture; and
- (d) forming the particulate source of heat by subjecting carbon in the separated particulate solids to oxidation by:
- (i) transporting the separated particulate solids from the separation zone to a cyclone oxidation-separation stage with a transport gas containing free oxygen with resultant carbon monoxide formation from the carbon in the particulate solids; and
- (ii) combining the transported particulate solids, carbon monoxide and transport gas in the cyclone oxidation-separation stage with a source of free oxygen in an amount at least equal to 50 mole percent of the carbon monoxide entering the cyclone oxidation-separation stage, the total free oxygen in the transport gas and combined in the oxidation-separation stage being sufficient to raise the solids to the temperature required for introduction to the vertically oriented chamber, while simultaneously separating the gaseous products of oxidation from the heated particulate source of heat, the residence time in said cyclone oxidation-separation stage being less than about 5 seconds; and
- (e) recovering hydrocarbon values from the vapor mixture by progressively cooling the vapor mixture in a plurality of gas-liquid cooling-condensation stages in series, each stage having a liquid coolant, a vapor feed, a vapor effluent, and liquid condensate, the liquid coolant of each stage including the condensate of the stage, the coolant of each stage being below the temperature of the vapor feed to the stage and vapor effluent of the stage, the condensate of each stage being progressively lower in average boiling point and tar content.
- 36. A process as claimed in claim 35 in which the residence time in said cyclone oxidation-separation stage is from about 0.1 to about 3 seconds.
- 37. A process as claimed in claim 35 in which the pyrolysis temperature is from about 600.degree. to about 2000.degree. F.
- 38. A process as claimed in claim 35 in which the pyrolysis temperature is from about 600.degree. to about 1400.degree. F.
- 39. A process as claimed in claim 35 in which the pyrolysis temperature is from about 900.degree. to about 1400.degree. F.
- 40. A process as claimed in claim 35 in which a substantial portion of the particulate solid carbonaceous material are particles in the range from about 10 to about 1000 microns in diameter.
- 41. A process as claimed in claim 35 in which the solid carbonaceous material is an agglomerative coal and a substantial portion of the particulate solid carbonaceous material is of a particle size less than about 250 microns in diameter.
- 42. A process as claimed in claim 35 in which the particulate solid carbonaceous material is an agglomerative coal, and a substantial portion of the particulate solid carbonaceous material is of a particle size in the range from about 10 to about 250 microns in diameter.
- 43. A process as claimed in claim 35 in which the resultant turbulent mixture has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the resultant turbulent mixture and a weight ratio of the particulate source of heat to solid carbonaceous material feed of from about 2 to about 20:1.
- 44. A process as claimed in claim 35 having a pyrolysis time of less than about 5 seconds.
Parent Case Info
This is a continuation of application Ser. No. 699,991, filed June 25, 1976, now abandoned.
US Referenced Citations (13)
Foreign Referenced Citations (4)
Number |
Date |
Country |
520801 |
Jan 1956 |
CAX |
2509352 |
Sep 1975 |
DEX |
751163 |
Feb 1976 |
ZAX |
1398858 |
Jun 1975 |
GBX |
Continuations (1)
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Number |
Date |
Country |
Parent |
699991 |
Jun 1976 |
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