Pyrolysis process for producing condensed stabilized hydrocarbons

A continuous process for producing condensed stabilized hydrocarbons from a solid particulate carbonaceous material comprising:

• (a) pyrolyzing a solid particulate carbonaceous feed material under conditions of time and elevated temperature sufficient to produce therefrom a gas-solids mixture which is a pyrolysis product comprising particulate product solids and pyrolytic product vapors which comprise hydrocarbons which comprise newly formed volatilized hydrocarbon free radicals, a portion of said hydrocarbons containing larger hydrocarbons, said larger hydrocarbons being all the hydrocarbon vapors in said pyrolytic product vapors containing four or more carbon atoms;
• (b) separating solids which comprise said particulate product solids from a gaseous mixture which comprises said pyrolytic product vapors to form a substantially solids-free gaseous mixture stream;
• (c) contacting said substantially solids-free gaseous mixture stream with a quench fluid comprising a capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, under predetermined conditions of temperature and flow rate of capping agent sufficient for substantially simultaneously stabilizing substantially all of said newly formed volatilized hydrocarbon free radicals by the transfer of hydrogen from said capping agent to terminate said newly formed volatilized hydrocarbon free radicals, and substantially simultaneously condensing at least a major portion of said larger hydrocarbons, thereby forming a gaseous residue and a liquid mixture comprising condensed stabilized hydrocarbons, and a hydrogen depleted capping agent;
• (d) separating said liquid mixture from said gaseous residue;
• (e) hydrogenating at least a portion of said liquid mixture, after separation from said gaseous residue, to produce a hydrogenated capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals;
• and
• (f) utilizing at least a portion of said hydrogenated capping agent as at least a major portion of said capping agent contained in said quench fluid used for contacting said substantially solids-free gaseous mixture stream.

A continuous process for producing condensed stabilized hydrocarbons from a solid particulate carbonaceous material comprising:

• (a) pyrolyzing a solid particulate carbonaceous feed material under conditions of time and elevated temperature sufficient to produce therefrom a gas-solids mixture which is a pyrolysis product comprising particulate product solids and pyrolytic product vapors which comprise hydrocarbons which comprise newly formed volatilized hydrocarbon free radicals, a portion of said hydrocarbons containing larger hydrocarbons, said larger hydrocarbons being all the hydrocarbon vapors in said pyrolytic product vapors containing four or more carbon atoms, a portion of said hydrocarbons comprising a product agent suitable for use as a capping agent either directly or after hydrotreatment of said product agent;
• (b) separating solids which comprise said particulate product solids from a gaseous mixture which comprises said pyrolytic product vapors to form a substantially solids-free gaseous mixture stream;
• (c) contacting said substantially solids-free gaseous mixture stream with a quench fluid comprising a capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, under predetermined conditions of temperature and flow rate of capping agent sufficient for substantially simultaneously stabilizing substantially all of said newly formed volatilized hydrocarbon free radicals by the transfer of hydrogen from said capping agent to said newly formed volatilized hydrocarbon free radicals to terminate such free radicals, and substantially simultaneously condensing at least a major portion of said larger hydrocarbons, thereby forming a gaseous residue and a liquid mixture comprising condensed stabilized hydrocarbons, a hydrogen depleted capping agent, and said product agent;
• (d) separating said liquid mixture from said gaseous residue;
• (e) hydrogenating at least a portion of said liquid mixture, after separation from said gaseous residue, to produce a hydrogenated capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, at least a major portion of said hydrogenated capping agent being produced from said product agent;
• and
• (f) utilizing at least a portion of said hydrogenated capping agent as at least a major portion of said capping agent contained in said quench fluid used for contacting said substantially solids-free gaseous mixture stream.

A continuous process for producing condensed stabilized hydrocarbons from a solid particulate carbonaceous material comprising:

• (a) pyrolyzing a solid particulate carbonaceous feed material under conditions of time and elevated temperature sufficient to produce therefrom a gas-solids mixture which is a pyrolysis product comprising particulate product solids and pyrolytic product vapors which comprise hydrocarbons which comprise newly formed volatilized hydrocarbon free radicals, a portion of said hydrocarbons containing larger hydrocarbons, said larger hydrocarbons being all the hydrocarbon vapors in said pyrolytic product vapors containing four or more carbon atoms, a portion of said hydrocarbons comprising a product agent suitable for use as a capping agent either directly or after hydrotreatment of said product agent;
• (b) separating solids which comprise said particulate product solids from a gaseous mixture which comprises said pyrolytic product vapors to form a substantially solids-free gaseous mixture stream;
• (c) contacting said substantially solids-free gaseous mixture stream with a quench fluid comprising a capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, under predetermined conditions of temperature and flow rate of capping agent sufficient for substantially simultaneously stabilizing substantially all of said newly formed volatilized hydrocarbon free radicals by the transfer of hydrogen from said capping agent to said newly formed volatilized hydrocarbon free radicals to terminate such free radicals, and substantially simultaneously condensing at least a major portion of said larger hydrocarbons, thereby forming a gaseous residue and a liquid mixture comprising condensed stabilized hydrocarbons, a hydrogen depleted capping agent, and said product agent;
• (d) separating said liquid mixture from said gaseous residue;
• (e) separating said liquid mixture, after separation from said gaseous residue, into at least neutral tar liquids comprising at least a major portion of said hydrogen depleted capping agent and said product agent, and a residue liquid mixture comprising at least a portion of said condensed stabilized hydrocarbons;
• (f) hydrogenating at least a portion of said neutral tar liquids thusly separated to produce hydrogenated neutral tar liquids comprising a hydrogenated capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, at least a major portion of said hydrogenated capping agent being produced from said product agent;
• (g) utilizing at least a portion of said hydrogenated capping agent as at least a major portion of said capping agent contained in said quench fluid used for contacting said substantially solids-free gaseous mixture stream;
• and
• (h) recovering at least a portion of said residue liquid mixture.

A continuous process for producing condensed stabilized hydrocarbons from a solid particulate carbonaceous material comprising:

• (a) pyrolyzing a solid particulate carbonaceous feed material under conditions of time and elevated temperature sufficient to produce therefrom a gas-solids mixture which is a pryolysis product comprising particulate product solids and pyrolytic product vapors which comprise hydrocarbons which comprise newly formed volatilized hydrocarbon free radicals, a portion of said hydrocarbons containing larger hydrocarbons, said larger hydrocarbons being all the hydrocarbon vapors in said pyrolytic product vapors containing four or more carbon atoms, a portion of said hydrocarbons comprising a product agent suitable for use as a capping agent either directly or after hydrotreatment of said product agent;
• (b) separating solids which comprise said particulate product solids from a gaseous mixture which comprises said pyrolytic product vapors to form a substantially solids-free gaseous mixture stream;
• (c) contacting said substantially solids-free gaseous mixture stream with a quench fluid comprising a capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, under predetermined conditions of temperature and flow rate of capping agent sufficient for substantially simultaneously stabilizing substantially all of said newly formed volatilized hydrocarbon free radicals by the transfer of hydrogen from said capping agent to said newly formed volatilized hydrocarbon free radicals to terminate such radicals, and substantially simultaneously condensing at least a major portion of said larger hydrocarbons, thereby forming a gaseous residue and a liquid mixture comprising condensed stabilized hydrocarbons, a hydrogen depleted capping agent, and said product agent;
• (d) separating said liquid mixture from said gaseous residue;
• (e) separating said liquid mixture, after separation from said gaseous residue, into at least neutral tar liquids and a residue liquid mixture, said neutral tar liquids comprising at least a major portion of said hydrogen depleted capping agent, said product agent, and heavy tars of said liquid mixture, said residue liquid mixture comprising at least a portion of said condensed stabilized hydrocarbons;
• (f) hydrogenating at least a portion of said neutral tar liquids thusly separated to produce hydrogenated neutral tar liquids comprising hydrogenated heavy tars and a hydrogenated capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, at least a major portion of said hydrogenated capping agent being produced from said product agent;
• (g) separating said hydrogenated neutral tar liquids into at least a recycle stream comprising at least a major portion of said hydrogenated capping agent, and a heavy tar stream comprising at least a major portion of said hydrogenated heavy tars;
• (h) utilizing at least a portion of said recycle stream as at least a major portion of said capping agent contained in said quench fluid used for contacting said substantially solids-free gaseous mixture stream;
• and
• (i) recovering at least a portion of said residue liquid mixture and said heavy tar stream.

A continuous process for producing condensed stabilized hydrocarbons from a solid particulate carbonaceous material comprising:

• (a) pyrolyzing a solid particulate carbonaceous feed material under conditions of time and elevated temperature sufficient to produce therefrom a gas-solids mixture which is a pyrolysis product comprising particulate product solids and pyrolytic product vapors which comprise hydrocarbons which comprise newly formed volatilized hydrocarbon free radicals, a portion of said hydrocarbons containing larger hydrocarbons, said larger hydrocarbons being all the hydrocarbon vapors in said pyrolytic product vapors containing four or more carbon atoms, a portion of said hydrocarbons comprising a product agent suitable for use as a capping agent either directly or after hydrotreatment of said product agent;
• (b) separating solids which comprise said particulate product solids from a gaseous mixture which comprises said pyrolytic product vapor to form a substantially solids-free gaseous mixture stream;
• (c) contacting said substantially solids-free gaseous mixture stream with a quench fluid comprising a capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, under predetermined conditions of temperature and flow rate of capping agent sufficient for substantially simultaneously stabilizing substantially all of said newly formed volatilized hydrocarbon free radicals by the transfer of hydrogen from said capping agent to said newly formed volatilized hydrocarbon free radicals to terminate such free radicals, and substantially simultaneously condensing at least a major portion of said larger hydrocarbons, thereby forming a gaseous residue and a liquid mixture comprising condensed stabilized hydrocarbons, a hydrogen depleted capping agent, and said product agent;
• (d) separating said liquid mixture from said gaseous residue;
• (e) separating said liquid mixture into:
• (i) light aromatics comprising liquids of from about four to about eight carbon atoms per molecule,
• (ii) tar bases comprising amines,
• (iii) tar acids comprising phenols, and
• (iv) neutral tar liquids comprising at least a major portion of said hydrogen depleted capping agent, said product agent, and heavy tars of said liquid mixture;
• (f) hydrogenating at least a portion of said neutral tar liquids thusly separated to produce hydrogenated neutral tar liquids comprising a hydrogenated capping agent suitable for stabilizing said newly formed volatilized hydrocarbon free radicals, and hydrogenated heavy tars comprising at least a portion of said condensed stabilized hydrocarbons, at least a major portion of said hydrogenated capping agent being produced from said product agent;
• (g) separating said hydrogenated neutral tar liquids into at least a recycle stream comprising at least a major portion of said hydrogenated capping agent, and a heavy tar stream comprising at least a major portion of said hydrogenated heavy tars;
• (h) utilizing at least a portion of said recycle stream as at least a major portion of said capping agent contained in said quench fluid used for contacting said substantially solids-free gaseous mixture stream;
• and
• (i) recovering at least a portion of said light aromatics, said tar bases, said tar acids and said heavy tar stream.