Char-handling processes in a pyrolysis system.

(54) Title: PROCESSES FOR HANDLING CARBONIZED MATERIAL IN A SYSTEM FOR PYROLYSIS. (54) Title: CHAR-HANDLING PROCESSES IN A PYROLYSIS SYSTEM.

(57) Summary

The present invention provides processes for handling carbonized materials to control total heat balance, ash accumulation, and subsequent combustion in a reheater. The carbonaceous biomass feed stream is pyrolyzed using a heat transfer medium that forms products of pyrolysis and an exhausted heat transfer medium. The spent heat transfer medium is separated into the segregated carbonized material and the spent heat transfer medium, depleted of carbonaceous material. The exhausted heat transfer medium depleted of carbonaceous material is introduced into a dense bed of fluidized heat transfer medium by a stream of regeneration gas containing oxygen. All or part of the carbonized, segregated material is burned in the dense bed using the regeneration gas stream containing oxygen. A part of the carbonized, segregated material can be exported out of the pyrolysis system in order to control the total heat balance and ash accumulation.

(57) Abstract

Char-handling processes for controlling overall heat balance, ash accumulation, and afterburn in a reheater are provided. Carbonaceous biomass feedstock is pyrolyzed using a heat transfer medium forming pyrolysis products and a spent heat transfer medium. The spent heat transfer medium is separated into segregated char and char-depleted spent heat transfer medium. The char-depleted spent heat transfer medium is introduced into a dense bed of heat transfer medium fluidized by a stream of oxygen-containing regenerated gas. All or a portion of the segregated char is combusted in the dense bed using the stream of oxygen-containing regeneration gas. A portion of the segregated char may be exported out of the pyrolysis system to control the overall heat balance and ash accumulation.

Institute

Mexican Property

Industrial

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_SE_ i®

PATENT TITLE NO. 336403

Owner (s): ENSYN RENEWABLES, INC.

Address: Brandywine Plaza, West Bullding, 1521 Concord Pike, Suite 205A, Wilmington,

Delaware, 19803-3645, USA

Name: PROCESSES FOR HANDLING CARBONIZED MATERIAL IN A SYSTEM FOR PYROLYSIS.

Classification: lnt.CI.8: C10B53 / 02; C10G3 / 00; C10J3 / 72; C10L1 / 02; F23B90 / 04; F23G7 / 02;

25J1 / C ^

EY J.

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^us i

Validity: Twenty &lt;years Venjmien Date

Λ patent for "affection

3rd conformity with the ionized to paritir gives the rights. i lustrlal.

unenforceable, before the ey of &lt;05/1999, action V subsection a), 4th and 12th fractions I and ill of the Regulation of the Mexican Institute of Industrial Property (DOF 12/14/1999, amended on 07/01/96 2002 , 07/15/2004, 07/28/2004 and 07/09/2007); articles 1 ·, 3 °, 4 °, 5 · fraction V subsection a), 16 sections I and III and 30 of the Organic Statute of the Mexican Institute of Industrial Property (DOF 12/27/1999, amended on 10/10/2002, 07/29/2004, 04/08/2004 and 09/13/2007); 1 », 3º and 5º Clause a) of the Agreement that delegates powers to the Deputy Directors General, Coordinator, Divisional Directors, Holders of the Regional Offices, Divisional Deputy Directors, Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004. 04/08/2004 and 09/13/2007).

3who subscribes the preeer i title lo »ce based on the di

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Issue Date: January 18, 2016

DIRECT DIVISIONAL OR OF PATENTS

I

NAHANNY CANAL REYES

Arenal No. 550, floor 1,

Coi Pueblo Santa María Tepepsn, Xochímiico Delegation,

CP 16020, Mexico, DP Te !. (55) 53 34 07 (X) www impi qob, rnx

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III

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MX / 2016/4554

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Instituí MexicaiK

PROCESSES FOR HANDLING CARBONIZED MATERIAL IN A SYSTEM70

You mused;

FOR PYROLYSIS

PRIORITY STATEMENT

This application claims priority before US Application No. 12 / 837,376, which was filed on July 15, 2010.

FIELD OF THE INVENTION

The present invention generally relates to processes for handling charred material in a pyrolysis system, and more particularly relates to processes for handling charred material to control total heat balance, ash accumulation, and subsequent combustion in a reheater of a pyrolysis system.

DESCRIPTION OF THE RELATED TECHNIQUE Pyrolysis is a thermal process during which the solid carbonaceous biomass feed stream, that is, biomass, such as wood, agricultural residues, algae, forest by-products, cellulose and lignin, municipal residues, waste from construction / demolition, or the like, quickly heats up to pyrolysis temperatures of 300 ° C to 900 ° C

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_t Institute

Mexican give it in the absence of air using a pyrolysis reactor. Biomass can be pyrolyzed using various methods for pyrolysis, including the Rapid Thermal Process method and catalytic pyrolysis. Under these conditions, solid and gaseous pyrolysis products are formed. The gaseous pyrolysis products (pyrolysis gases) contain a non-condensable part and a condensable part (vapors) that can condense into the liquid pyrolysis oil derived from biomass. Solid pyrolysis products include combustible solids containing carbon, referred to as carbonized material.

As is known in the art, heat for the endothermic pyrolysis reaction is produced in a reheater zone of a pyrolysis reactor or in a separate reheater (collectively referred to herein as a reheater) by combustion of non-condensable pyrolysis gases and combustible solids produced in the pyrolysis reaction. Heat is transferred from the reheater to the pyrolysis reactor by a heat transfer medium. Although the heat for the pyrolysis reaction and the environmental heat losses (together heat demand) are normally balanced with the heat

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&lt;3 © Ια supplied by the combustion in the superheater, the heat balance is always achieved. Pyrolysis of certain types of biomass generates considerably more combustible solids and thus more thermal energy is required to meet the heat demand of the pyrolysis reactor. If too much heat is generated, the pyrolysis system requires large amounts of excess dilution air or the addition of expensive cooling systems.

transfer continuously

The heat transfer medium normally contains inert solids such as sand. In catalytic pyrolysis, catalytic solids, in place of or in addition to inert solids, may be used as the heat transfer medium. During pyrolysis, combustible solids mix with inert solids, catalytic solids, if present, or both, forming an exhausted heat transfer medium. The exhausted heat transfer medium has reduced availability for heat transfer, and in the case of catalytic solids, it also has reduced catalytic activity. To restore the heat transfer medium, the exhausted heat medium is transferred from the pyrolysis reactor to the

<img file="MX336403B_D0009.tif" />

of the superheater after the separation of the pyrolysis gases. The exhausted heat transfer medium is regenerated in the superheater by combustion of the combustible solids contained in the mixture. The regenerated heat transfer medium is then recirculated to the pyrolysis reactor.

When the combustible solids are burned in the reheater, the metals contained therein, usually the alkali metals, are released as ash to mix with the regenerated heat transfer medium. Since the ashes are continuously produced in the pyrolysis system, ash removal is necessary to balance the pyrolysis system. When the regenerated heat transfer medium is recirculated to the pyrolysis reactor with ash present, the pyrolysis of the biomass can be disadvantageously affected by the increased gas production.

The heat transfer medium is maintained as a fluidized dense bed at the bottom of the superheater by the upward passage of an oxygen-containing regeneration gas stream along the fluidized dense bed. Combustion gas from transfer medium

<img file="MX336403B_D0010.tif" />

depleted in the superheater is in a diluted phase on top of the superheater. During the regeneration of the superheater, part of the combustible solids is trapped in the combustion gas of the superheater. The low height of the dense bed in the superheater and the small size and low density of the combustible solids result in a considerable amount of the combustible solids escaping from the dense bed and combustion in the dilute phase

Fuels (also solids called post-combustion) can also be fueled from the dense bed into the dilute phase due to the velocity (typically 0.76 meters to 0.91 meters / second (2.5-3 feet / second)) of the regeneration gas it contains. Oxygen through the dense bed in the superheater to the combustion gas from the superheater in the dilute phase. Subsequent combustion may also occur in the plenum and flue gas transfer lines through which the flue gas leaves the superheater, rather than in the dense bed of the superheater.

In addition to subsequent combustion of combustible solids, subsequent combustion may occur.

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of the goodness of carbon monoxide in the regeneration gas that IfldUStflG?

Contains oxygen to CO2 in the dilute phase. Reheaters are normally designed to operate so that virtually all of the carbon monoxide (CO) in the oxygen-containing regeneration gas is burned to form carbon dioxide (C0₂), thereby imparting the heat of reaction to the reheater. However, there may be incomplete combustion of the superheater flue gas in the dilute phase CO to C0₂or incomplete O consumption₂ in the diluted phase. Any problem also causes subsequent combustion. Subsequent combustion is exothermic, and must be extinguished with additional injection of the oxygen-containing regeneration gas, or the combustion gas must absorb the heat of combustion, which undesirably decreases the amount of heat transferred to the dense bed.

Accordingly, it is desirable to provide processes for controlling total heat balance, ash accumulation, and subsequent combustion in a reheater of a pyrolysis system. Furthermore, other peculiarities and features of the present invention will be apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the invention drawings.

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companions and is antecedent of the insLw

SUMMARY OF THE INVENTION

Processes are provided for pyrolysis of a carbonaceous biomass feed stream in a pyrolysis system. According to an exemplary embodiment, the process consists of pyrolyzing a carbonaceous biomass feed stream, using a heat transfer medium to form the products of pyrolysis and an exhausted heat transfer medium. The spent heat transfer medium is separated into segregated charred material and spent heat transfer medium, depleted of charred material. The exhausted heat transfer medium, depleted of carbonized material, is introduced into a dense bed of the heat transfer medium fluidized by a stream of regeneration gas containing oxygen.

Processes are provided to control heat balance, post combustion, and ash accumulation in a reheater in accordance with yet another exemplary embodiment of the present invention. The process involves separating the spent heat transfer medium from a

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Mexicano cte the Pre0í @ ^ tí pyrolysis reactor to a heat transfer medium idí§§ hOí exhausted, depleted of charred material and charred material. The depleted, carbonized material depleted heat transfer medium is introduced into a fluidized dense bed of the heat transfer medium. The fluidized dense bed is maintained by a stream of regeneration gas containing oxygen and a dilute phase above the fluidized dense bed.

At least part of the segregated carbonized material is introduced into the superheated fluidized dense bed below the elevation where the spent heat depleting medium, depleted of carbonized material, is introduced into the oxygen-containing regeneration gas stream outside the superheater. , or both, for the combustion of the carbonized material segregated below the dilution phase.

Processes are provided to control heat balance, post combustion, and ash accumulation in a reheater in accordance with yet another exemplary embodiment of the present invention. The superheater includes a dense fluidized bed of the heat transfer medium and a dilute phase. The diluted phase is positioned above the fluidized dense bed. The process consists practically in the

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separation of the carbonized material from an exhausted heat transfer medium to form segregated carbonized material and exhausted heat transfer medium, depleted of carbonized material. The depleted, depleted heat transfer medium of carbonized material consists of a mixture of residual carbonized material and inert solids, catalytic solids, or both. The depleted, carbonized material depleted heat transfer medium is introduced to a superheater with combustion of the residual carbonized material to convert the depleted, carbonized material depleted heat transfer medium to a heat transfer medium using a regeneration gas which contains oxygen. The oxygen-containing regeneration gas is introduced into a reheater through an inlet riser. The segregated carbonized material is burned with an effective amount of the fluidized dense bed heat transfer medium in the oxygen-containing regeneration gas outside the reheater.

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BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be described hereafter together with the following figures, where equal numbers indicate equal elements, and where:

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IndusTfet

FIG. 1 is a flow chart of a carbonized material handling process, in accordance with exemplary embodiments of the present invention;

FIG. 2 is a diagram of an exemplary total pyrolysis process apparatus including a double stage cyclone separator of a gas solid separator, in accordance with exemplary embodiments of the present invention;

FIGS. 3A and 3B are schematic diagrams of different modes of operation in the double stage cyclone separator of FIG. 2, in accordance with exemplary embodiments of the present invention;

FIG. 4 is a diagram of another exemplary total pyrolysis process apparatus including a cyclone separator coupled to an elutriation chamber in another gas-solid separator, in accordance with exemplary embodiments of the present invention;

FIG. 5 is a schematic diagram of the mode of operation in the cyclone separator and elutriation chamber of FIG. 4, according to an example of the present invention; and

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FIGS. 6A-6E are schematic diagrams of various exemplary embodiments of the superheater of the present invention.

DETAILED DESCRIPTION

The following detailed description of the invention is merely exemplary and is not intended to limit the invention or the application and uses of the invention.

Furthermore, there is no intention to join any theory presented in the background of the invention or the following detailed description of the invention.

Various exemplary embodiments of the present invention are directed to processes for handling combustible solids (hereinafter combustible solids or carbonized material produced during pyrolysis of the carbonaceous biomass feed stream). The carbonized material is segregated from the heat transfer medium to control subsequent combustion in a reheater during regeneration of the heat transfer medium. A part of the material

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Segregated carbonized can be exported to control the total heat balance and ash accumulation in the pyrolysis system.

FIG. 1 is a flow chart of a process for handling carbonized material 10, according to a

<td>modality</td><td>copy</td><td>of</td><td>the present</td><td>invention.</td><td>FIG. 2</td>

<td>illustrates a</td><td>system</td><td>of</td><td>pyrolysis 5</td><td>what do you use</td><td>the process</td>

<td>10 of the</td><td>FIG. one.</td><td>With</td><td colspan="2">reference to FIGS.</td><td>1 and 2, the</td>

Process 10 begins by pyrolyzing the carbonaceous biomass feed stream 15 (hereafter biomass) in a pyrolysis reactor 20 using a heat transfer medium and forming products of the pyrolysis and an exhausted heat transfer medium (step 12). The spent heat transfer medium leaving the pyrolysis reactor is trapped in the gaseous pyrolysis products (pyrolysis gases), the pyrolysis gases with the trapped spent heat transfer medium referred to in the FIG. 2 under the reference number 35. As noted above, the pyrolysis products contain solid and gaseous products. The gaseous pyrolysis products 45 contain a condensable part and a non-condensible part 47. The condensable part can be condensed into a liquid pyrolysis oil obtained

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biomass 49. Solid pyrolysis products include combustible solids containing carbon (also referred to herein as carbonized material).

The heat transfer medium contains inert solids, such as sand, catalytic solids, or both. The heat transfer medium leaving the pyrolysis reactor is said to be depleted, because it contains carbon-containing combustible solids from the pyrolysis process. Gaseous pyrolysis products with trapped, exhausted heat transfer medium 35 are transferred from pyrolysis reactor 20 to gas-solid separator 30a (FIG. 2) to separate the gaseous pyrolysis products 45 from the spent heat transfer medium and separate the spent heat transfer medium into separate streams of segregated carbonized material 65 and spent heat transfer medium, depleted of charred material 75 (step 70). The term spent carbonized material depleted heat transfer medium as used herein means spent heat transfer medium from which all charred material has been removed and depleted heat transfer medium, from which a

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π part of the carbonized material has been residual carbonized material.

removed but

In one embodiment, as shown in FIGS. 2, 3A and 3B, the gas-solid separator 30a contains a double stage cyclone separator. The double stage cyclone separator contains a first stage cyclone separator 31 and a second stage cyclone separator 33. As shown in FIGS. 3A and 3B, first stage cyclone separator 31 has a first outlet 37 coupled to an inlet of the second second stage cyclone separator 33 and a second outlet 39 coupled to an inlet of the superheater 60. The heat transfer medium depleted, depleted of charred material 75 exits the first stage cyclone separator 31 and is directed to the reheater 60 through a suction tube or tube 41. The level of solids in the suction tube or tube 41 can be controlled by a first solids flow control device

43 such as an L valve, J valve, slide valve, or the like to control the flow of solids from depleted, carbon-depleted heat transfer medium 75 (inert solids, catalytic solids, or both) to reheater 60 (FIGS. 3A and 3B).

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i iⁱF © 0í &amp; sÍí2d

In accordance with an exemplary embodiment, and as shown in FIGS. 2, 3A and 3B, the stream of gaseous pyrolysis products with the entrapped spent heat transfer medium 35 is transferred to the cyclone separator of the first stage of the gas-solid separator 30a. Preferably, the first stage cyclone separator collects the depleted, carbon-depleted heat transfer medium 75 and transfers a mixture 46 of pyrolysis gases with the trapped carbonized material to the second stage 33 cyclone separator. shown in FIG. 3A, the cyclone separator of the first stage 31 generally runs practically empty of solids with the continuous phase being the pyrolysis gases gaseous. The solids from the depleted, carbonized material depleted heat transfer medium 75 do not become a continuous phase until they leave the first stage cyclone separator in the suction tube or pipe 41 due to the gas vortex of cyclone 24 in the first stage cyclone separator 31 it would otherwise lift the solids from the spent, carbonized material depleted heat transfer medium 75 out of the suction tube or tube. A high surface 51 of the depleted, carbonized material depleted heat transfer medium is shown in FIG. 3A in the tube

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suction 41 below the bottom of the first stage cyclone separator 31. A nitrogen purge (not shown) can be introduced into the top of the first stage cyclone separator to re-trap the carbonized material from the separator from the first stage cyclone to the second stage cyclone separator, if necessary.

To improve the separation of carbonized material in a retrofitted double stage cyclone separator, as shown in FIG. 3B, the first solids flow control device 43 allows the solid particles from the depleted, carbonized material depleted heat transfer medium 75 to return to the bottom of the first stage cyclone separator (i.e. near or in the vortex of the cyclone 24 gases from the cyclone separator) so that the upper surface 51 of the exhausted heat transfer medium, depleted of charred material is at a higher level than that shown in Figure 3A. By exposing the vortex of the cyclone gases to the depleted heat transfer medium of carbonized material, the vortex of the cyclone gases separate the lighter and / or smaller solid fuel particles (i.e., carbonized material). of the

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iFíEpW d © I® solid particles of the heat transfer medium in jMuS'ífe '' the cyclone separator of the first stage raising them and taking them out of the cyclone separator of the first stage 31 in the cyclone separator of the second stage 33 in the product fluidizing gas and vapor stream composed of the pyrolysis gases with the entrapped carbonized material 46.

Still referring to FIGS. 2, 3A and 3B, the second stage cyclone separator 33 collects the pyrolysis gases with the trapped carbonized material 46 of the first stage cyclone separator 31, resulting in the separate streams of the pyrolysis gases 45 and segregated carbonized material 65. The pyrolysis gas stream 45 is transferred from the second stage cyclone separator 33 to a condenser 81 (FIG. 2). The condensable pyrolysis gases are condensed in the condenser in the liquid pyrolysis oil obtained from biomass 49. The non-condensable pyrolysis gases 47 can be recirculated to the reheater 60 for combustion and / or to the pyrolysis reactor 20 as a lifting means for the heat transfer medium (as shown by arrow F in FIG. 2).

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At least a portion of the segregated carbonized material 65 is transferred to the reheater 60 and processed as described below in accordance with FIGS. 6A-6E. In accordance with an exemplary embodiment, and as shown in FIGS. 2, 3A and 3B, a part of the segregated carbonized material can be exported (hereinafter exported segregated carbonized material 53) out of the pyrolysis system after exiting the gas-solid separator 30a and before the reheater 60 (step 300). Exporting a part of the carbonized material segregated before combustion helps to maintain the heat balance in the pyrolysis system and to manage the accumulation of ash by removing a part of the combustible solids before they can be burned. The exported segregated carbonized material 53 may further be processed, used as a final product (eg, as a fertilizer), shipped for disposal, or a combination of these. The exported segregated carbonized material can be removed sooner or later by a second solids flow control device 57 in the export stream (FIGS. 3A and 3B). The following is the calculation to determine the amount of exported segregated carbonized material 53 to be removed from the pyrolysis system in order to balance the heat from the pyrolysis system:

Charred material that will heat balance (kg / h) =

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Ht £ i

Ü i'v be eliminated for the

FY - {G Cp.po (Trg'T ») + F (I- Xto) Hr» + Ρ (Ο ».ρ (Tr * - TfH H_w) + Gim »+ A CpA (Τ_βΜ|) f where:

F = Feeding rate of wet biomass (kg / h)

G = Combustion gas velocity (kg / h)

Gloss ⁼ Heat loss from the pyrolysis system through the walls to the atmosphere (J / h)

A = Air added for the complete combustion of carbonized material (kg / h)

Y = Yield of carbonized material (kg of carbonized material / kg of wet biomass feed)

Xh2O ⁼ Fraction of water mass in the wet biomass feed (kg of water / kg of wet biomass feed)

Gp, fg = Heat capacity of the combustion gas (J / kg / ° C)

TFG = Combustion gas temperature leaving the sand combustion bed (° C)

Ιίψ;

J;

^Tair = Air inlet temperature (° C) WtEJ_L '

Tp = Inlet temperature of the wet biomass feed (° C)

Tsand ⁼ Sand bed temperature in the carbonized material combustion zone (° C)

Trx = Temperature of pyrolysis reaction (° C) ^cpF = sensible heat capacity of the wet biomass feed (J / kg / ° C)

Cp, A = Air heat capacity (J / kg / ° C) ^hRx ⁼ Heat of reaction of pyrolytic conversion of biomass to pyrolysis products (J / kg dry biomass)

Hcomb = Heat of combustion of carbonized material before or in the sand combustion bed (J / kg of carbonized material)

Hvap ⁼ Latent heat of vaporization of wet biomass (J / kg wet biomass)

In an alternative modality, as shown in

FIGS. 4 and 5, the stream containing the gaseous pyrolysis products with the exhausted, trapped heat transfer medium 35 is transferred from the pyrolysis reactor 20 to a gas-solid separator 30b (FIG. 4). Gas-solid separator 30b contains a cyclone separator

200 coupled to the material elutriation chamber

<img file="MX336403B_D0027.tif" />

carbonized baati 210. The gaseous products of the indusÍffat pyrolysis with the exhausted, trapped heat transfer medium 35 are transferred to the cyclone separator 200 for the separation in different streams of the pyrolysis gases 45 and the exhausted heat transfer medium 55 . The pyrolysis gases 45 are transferred from the cyclone separator 200 of the gas-solid separator 30b to the condenser 81 to condense the gaseous, condensable pyrolysis products into the liquid pyrolysis oil obtained from biomass 49. Non-condensable pyrolysis gases 47 exit condenser 81 and can be recirculated to reheater 60, as a source of fluidizing elutriation gas 59 for carbonized material elutriation chamber 210, and / or to pyrolysis reactor 20 as a lifting medium for the heat transfer medium (as shown by arrow F in FIG. 4). A larger first part of the spent heat transfer medium 55 (with the pyrolysis gaseous products already removed) can be transferred to the reheater 60 and a smaller second part of this is transferred to the carbonized material elutriation chamber 210. The Flow to the reheater is controlled by a third solids flow control device 69 such as a slide valve (FIG. 5). The flow to the chamber of

<img file="MX336403B_D0028.tif" />

M &amp; jpsci ¿&lt;ο &lt;tetobe $ @ $ afi elutriation of carbonized material is controlled by a fourth solids flow control device 71.

The second smaller part of the spent heat transfer medium 55 is introduced into a fluidized bed 63 of the heat transfer medium which is held in the carbonized material elutriation chamber 210 for separation in one stream of the heat transfer medium depleted, depleted of charred material 75 and a stream of segregated charred material and the fluidizing elutriation gas (collectively referred to in FIGS. 4 and 5 with the reference number 67). The stream of depleted, carbon-depleted heat transfer medium 75 from the carbonized material elutriation chamber 210 is transferred to reheater 60 through a fifth solids flow control device 61 or to pyrolysis reactor 20.

The stream 67 of the carbonized material and the fluidizing elutriation gas are transferred to the elutriation solids-gas separator 68 such as a bag housing, electrostatic precipitator, the cyclone water stream or the like for separation into segregated carbonized material 65 and the fluidizing elutriation exhaust gas 73. As the

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catalytic particles, easily combustible solid particles (i.e. carbonized material) have much lower density and / or smaller particle size than solid particles in the heat transfer medium (i.e. inert solids, solid particles, or both) ), the carbonized material is elutriated by the fluidizing elutriation gas 59 of the non-condensable pyrolysis gases 47 or other suitable fluidizing gas. Elutriation is a known process for separating lighter particles from heavier particles using a vertically directed elutriation gas stream. Combustible particles rise to the top because their terminal velocities are lower than the velocity of the ascending fluid.

At least a portion of the segregated carbonized material 65 is transferred to the reheater 60 and processed as described below in accordance with FIGS. 6A-6E. In accordance with an exemplary embodiment, and in the same manner as described above with respect to FIGS. 2, 3A and 3B, and as shown in FIGS. 4 and 5, a part of the segregated carbonized material can be exported out of the pyrolysis system after it leaves the gas-solid separator 30b and before the

<img file="MX336403B_D0030.tif" />

reheater (FIG. 1, step 300). As noted above, exporting a portion of the segregated carbonized material prior to combustion helps maintain the heat balance in the pyrolysis system and manage ash accumulation by removing some of the combustible solids before they are burned. The exported segregated carbonized material can also be processed, used as a final product (p. eg as fertilizer), sent for disposal, or a combination of these. The exported segregated carbonized material can be removed before or after a solids flow control device in the export stream. The amount of segregated carbonized material to be exported from the pyrolysis system in order to balance the heat from the pyrolysis system is calculated in the same way as already described with respect to FIGS. 2, 3A and 3B. It is noted that since the solids flux in the elutriation chamber of the gas-solid separator 30b is relatively small compared to the total solids flux, the use of the gas-solid separator 30b is preferred when only a small fraction is desired to be exported of the charred material. Although gas-solid separators 30a and 30b have been described, other types of gas-solid separators can be used to separate gases from the

<img file="MX336403B_D0031.tif" />

Give pyrolysis of the spent heat transfer medium and at least a portion of the carbonized material from the spent heat transfer medium.

<img file="MX336403B_D0032.tif" />

The depleted, carbonized material depleted heat transfer medium 75 of the gas-solid separator 30a and the gas-solid separator 30b are hereinafter processed in the superheater 60 of FIGS. 2 and 4 are illustrated in FIGS. 6A-6E. The depleted, carbonized material depleted heat transfer medium 75 of the first stage cyclone separator (of the gas-solid separator 30a in FIG. 2) and from the carbonized material elutriation chamber (from the gas-solid separator 30b in FIG. 4) are introduced into a fluidized dense bed 110 of the superheater 60 to burn at least a part of any residual carbonized material using a stream of regeneration gas containing oxygen 115, preferably air (step 80). An exemplary reheater 60 (shown in FIGS. 6A-6E) consists of a large, vertical, practically cylindrical, container 120 where the heat transfer medium is maintained as the fluidized dense bed 110 in the superheater by the upward passage of the regeneration gas stream containing oxygen 115 (also referred to as hvf / χ fj /

<img file="MX336403B_D0033.tif" />

be © d® te PfQ ^ teded Sridusfrteí herein as a primary oxidizing stream), preferably air, which fluidizes the heat transfer medium. The oxygen-containing regeneration gas stream also stirs the heat transfer medium within the fluidized dense bed. The oxygen-containing regeneration gas stream rises in inlet riser 130 through the bottom of the superheater and into a superheater manifold 140a (FIG. 6A), 140b (FIGS. 6B and 6C), 140c (FIGS. 6D and 6E) towards the superheater. Inlet riser 130 may include first and second inlet conduits 128 and 195 (FIGS. 6C and 6E) near a distant end thereof for the purposes described below. The fluidized dense bed 110 formed by the heat transfer medium is in a lower part of the container and a dilute phase 150 is in an upper part of the container. The superheater is normally kept at a temperature of 400 ° C to 1000 ° C.

The combustion gas produced by combustion 85 (FIGS. 2 and 4) in the diluted phase, obtained from the regeneration gas stream that contains oxygen, contains gases that arise from the combustion of combustible solids such as carbon dioxide. monoxide

<img file="MX336403B_D0034.tif" />

carbon from the regeneration gas stream containing oxygen, inert gases such as nitrogen from the air, and unreacted oxygen. The combustion gas from combustion 85 also contains entrapped combustible solids, inert solids, catalytic solids, or a combination of these as well as at least a portion of carbon combustion ash from the combustible particles.

The part of the ash that is not trapped in the combustion gas produced by the combustion remains in the dense fluidized bed of the heat transfer medium. Depending on the performance of ash and ash trapped in the combustion gas produced by the combustion, the amount of ash in the regenerated heat transfer medium may vary. According to an exemplary embodiment, the accumulation of ash in the superheater is controlled by removing the segregated carbonized material, exported from the pyrolysis system before combustion (to produce less ash), or by burning the segregated carbonized material in the fluidized dense bed in the superheater which results in more ash leaving the superheater in the combustion gas resulting from combustion, as described below.

<img file="MX336403B_D0035.tif" />

depleted carbonized material 75 of the gas solid separator 30a or 30b is introduced to a small bottom of the fluidized dense bed to allow the residual carbonized material, if present, contained in the stream of depleted, carbonized material depleted heat transfer medium to be burned into the fluidized dense bed, as indicated by arrow A in FIGS. 6A-6E to designate the flow direction of the spent heat transfer medium depleted of charred material. Flow can be controlled by a first valve 175. As used herein, a lower part of the fluidized dense bed means that part closer to the lower surface of the fluidized dense bed than an upper surface of the fluidized dense bed. The depleted heat transfer medium, depleted of charred material introduces the oxygen-containing regeneration gas stream into the reheater under conditions sufficient to burn the residual charred material converting the depleted, carbonized material depleted heat transfer medium into medium heat transfer. The heat of combustion is transferred to the heat transfer medium in the dense fluidized bed. Combustion raises the temperature of the

<img file="MX336403B_D0036.tif" />

dense bed material (i.e. heat transfer medium) at the required operating conditions in the pyrolysis reactor, i.e. 300 ° C at

900 ° C.

The segregated carbonized material 65 from the gas-solid separator 30a and the segregated carbonized material 65 obtained from the gas-solid separator 30b are subsequently processed in the same way. Still referring to FIGS. 1, 2, 4 and 6A-6E, at least a part of the carbonized material segregated 65 from the second stage cyclone separator (gas-solid separator 30a (FIG. 2)) and from the solid-gas elutriation separator 68 ( FIG. 4) introduce at least part of the carbonized material segregated using the regeneration gas containing oxygen and increase the temperature of inert solids, catalytic solids, or both, in the fluidized dense bed of the superheater in the fluidized dense bed (step 90), as indicated by arrow B in FIGS. 6A-6E to designate the direction of flow of the segregated carbonized material. The flow of the carbonized material segregated in the fluidized dense bed can be controlled by a second valve 180. The segregation of the carbonized material stream from the spent heat transfer medium,

<img file="MX336403B_D0037.tif" />

Mexican depleted carbonized material allows its ^ dusfllaj deeper introduction into the fluidized dense bed and thus minimizing the potential for subsequent combustion in the dilute phase.

In one embodiment, as shown in FIG. 6A, the segregated carbonized material can be introduced directly into the fluidized dense bed to mix it with inert solids, catalytic solids, or both in the fluidized dense bed, where the segregated carbonized material 65 is then burned by the regeneration gas stream containing oxygen 115, which increases the temperature of the heat transfer medium to the pyrolysis temperature, as noted above.

The segregated carbonized material is introduced at an elevation below where the depleted, carbonized material depleted heat transfer medium is introduced, allowing for more efficient combustion and additional combustion time. The oxygen-containing regeneration gas stream 115 rises in the inlet riser 130 through the bottom of the superheater and into the superheater manifold

140a in the bottom part of the superheater. The superheater manifold includes an opening (not shown in FIG. 6A) through which the

<img file="MX336403B_D0038.tif" />

regeneration gas stream containing oxygen 115 to the reheater.

In alternative modalities as shown in the

FIGS. 6B-6E, the segregated carbonized material 65 can be burned in the dense bed and additionally burned (step 100) (FIG. 1) outside the superheater in the inlet riser 130 through which the oxygen-containing regeneration gas stream 115 is introduced upwards towards the dense bed. In the additional combustion step, the segregated carbonized material 65 is introduced into the oxygen-containing regeneration gas stream through the first inlet conduit 128 near the distal end of the inlet riser 130 and into the reheater 60 through the superheater distributor 140b or 140c, as described below. The segregated carbonized material is initially burned in the inlet riser and then the unburnt segregated carbonized material is burned in the dense bed. As shown in FIGS. 6C and 6E, the segregated carbonized material 65 can be mixed with an effective amount (equal to the A or C flow rate of the heated inert solids, catalytic solids, or both (i.e., the heat transfer medium), such as indicated by the

<img file="MX336403B_D0039.tif" />

give arrow D to the dense bed of the superheater which increases the rate of additional combustion of the segregated carbonized material. Heated inert solids, heated catalytic solids, or both can be introduced into the inlet riser through the second inlet conduit 195 to mix with the segregated carbonized material (FIGS. 6C and 6E). The flow of the heated inert solids, heated catalytic solids, or both from the reheater can be controlled by a third valve 185. The segregated carbonized material is at least partially burned out of the superheater as it flows upward into the inlet riser, with or without the heated heat transfer medium, in the regeneration gas containing oxygen, and furthermore burned in the dense bed fluidized, thereby minimizing its combustion, that is, subsequent combustion in the dilute phase or downstream of it, such as in a plenum 160 or a flue gas transfer line 170. The superheater manifold 140b (FIGS. 6B and 6C) may include at least one opening through which the oxygen-containing regeneration gas and the segregated carbonized material, or the oxygen-containing regeneration gas and the mixture of segregated carbonized material and the transfer medium of

<img file="MX336403B_D0040.tif" />

LSJL1

More heated heat can be discharged to the bottom 3? 7 ¿g '«bottom of the dense bed. The oxygen provided by the oxygen-containing regeneration gas stream 115 contains practically the stoichiometric amount of oxygen necessary to considerably complete the combustion of the carbonized material (residual and segregated carbonized material) (FIGS. 6A, 6B, and 6C). Otherwise, more than the stoichiometric amount of oxygen may be added in an amount of 10 to 15% more than the stoichiometric amount.

In other embodiments, as shown for example in FIGS. 6D and 6E, less than the stoichiometric amount of oxygen is provided by the oxygen-containing regeneration stream (referred to hereafter as the primary oxidizing stream) and a secondary oxidizing stream 125 also enters the reheater. The secondary oxidizing stream preferably contains air. The secondary oxidizing stream provides 25 to 75% of the total oxygen gas necessary to considerably complete the combustion of charred material (residual and segregated charred material) in the reheater. The primary oxidizing stream is introduced into the superheater through the superheater distributor 140c. In an exemplary mode, the

<img file="MX336403B_D0041.tif" />

overheated dealer! 140c contains practically an L-shaped distributor and includes openings through which the primary oxidizing stream is introduced into the reheater together with the at least partially burned segregated carbonized material or a mixture of the at least partially burned carbonized material and the heated heat transfer. The secondary oxidizing stream enters the superheater through the superheater manifold 140d at a level below the superheater manifold 140c.

Combustion of the combustible solids from the spent heat transfer medium regenerates the heat transfer medium. The regenerated heat transfer medium 25 is removed from an upper part of the fluidized dense bed and returned to the pyrolysis reactor 20, as indicated by arrow C in FIGS. 6A-6E, for other use as the heat transfer medium, as shown in FIGS. 2 and 4. The flow of the regenerated heat transfer medium 25 from the reheater can be controlled by a fourth valve 190.

Referring again to FIGS. 2 and 4 and 6A-6E, the combustion gas produced by the combustion 85 passes from the superheater 60 through the discharge pipe of

<img file="MX336403B_D0042.tif" />

tto te f gas (not shown) towards plenum 160, located in the upper part of the superheater. The combustion product flue gas 85 is vented or otherwise removed from the reheater through the flue gas transfer line 170 from the plenum to the external flue gas-solid separator 72 such as a cyclone separator. At least a part of the solid particles trapped in the combustion gas produced by the combustion 85, such as a mixture

2. 3 from the heat transfer medium and ash, they are separated from the combustion gas produced by the combustion 85 in the external combustion gas-solids separator 72 forming the practically solids-free combustion gas 105. Virtually solid-free flue gas can contain residual combustible solid particles and residual ash particles since these particles are generally smaller (on average) than inert solid particles and catalytic solid particles and therefore are not easily separated of the flue gas in the external flue gas-solid separator 72. That the virtually solid-free flue gas can contain residual ash particles allows the ash particles to escape from the confines of the

<img file="MX336403B_D0043.tif" />

Mexican atí

Russe!

superheater, thus significantly preventing accumulation of ash in the superheater.

As shown in FIGS. 2 and 4, the mixture 23 of the separated heat transfer medium and ash from the flue gas-solid separator can be recirculated to the reheater for regeneration of the separated heat transfer medium. Otherwise, the mixture 23 of the separated heat transfer medium and ash can be removed from the pyrolysis system as indicated by arrow E in FIGS. 2 and 4. For economy, a heat transfer medium containing catalytic solids can be recirculated to the reheater while the usually less expensive sand is removed from the pyrolysis system for disposal. Ash from mixture 23 can also be removed by known methods and removed from the pyrolysis system (not shown).

From the above, it can be seen that exemplary modalities of the carbonized material handling process have been provided for the segregation of carbonized material and the selective removal of the pyrolysis system. Such carbonized material handling processes help control the balance of

<img file="MX336403B_D0044.tif" />

total heat, ash accumulation, and subsequent fossil fuel combustion in the superheater during regeneration of the heat transfer medium. Carbonized material handling processes contribute to the combustion of combustible solids and carbon monoxide below the dilute phase such as in the fluidized dense bed or in an inlet riser leading to the superheater, thereby minimizing the Combustion in the dilute phase, or downstream of it (that is, subsequent combustion) that also results in more ash coming out of the combustion gas from the combustion. Therefore, the amount of heat transferred to the dense bed of the superheater is increased for regeneration of the heat transfer medium and ash accumulation is decreased. In addition, such carbonized material handling processes allow the selective removal of a portion of the energy rich carbonized material stream from the pyrolysis system to provide a balance between the heat supplied from the combustion of carbonized material in the reheater with the demand for heat due to the latent and sensible heat of the cold feed stream, ambient heat losses, and the pyrolysis reaction.

<img file="MX336403B_D0045.tif" />

_____

Although at least one exemplary embodiment has been presented in the aforementioned description of the invention, it should be appreciated that there are a large number of variations. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the above detailed description will provide those skilled in the art with a convenient roadmap for implementing an exemplary embodiment of the invention, it being understood that various changes can be made based on and arrangement of the elements described in an exemplary embodiment without depart from the scope of the invention as set out in the appended claims and their legal equivalents.