Improved process for converting carbon-based energy carrier material

Abstract

A catalytic process is disclosed for converting solid or high viscosity carbon-based energy carrier materials, such as heavy crudes, oil sands, synthetic polymeric wastes and cellulosic or aquatic biomass. The conversion temperature is less than 450° C. The reaction products are separated from the catalyst within 10 seconds after being formed. The temperature of the reaction products is lowered to less than 200° C. within 10 seconds after being formed. The process results in less deterioration of the reaction products.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to a catalytic process of converting a carbon-based energy carrier material to a liquid or gaseous fuel.[0003]2. Description of the Related Art[0004]As the supply of light crude diminishes, alternate materials are being developed as a source of liquid and gaseous fuels. Alternate materials being considered include mineral energy carriers, such as heavy crudes, shale oils, tars (e.g., from tar sands) and bitumen.[0005]Alternate materials further include waste supplies of synthetic resins. These synthetic resins may be virgin materials, for example rejects from molding and drawing operations, and used materials, such as recycled packaging materials.[0006]Yet another, and potentially the most important, source of alternate carbon-based energy carrier material includes biomass, in particular biomass containing cellulose, lignin, and lignocellulose.[0007]Processes have been developed for convert...

AI Technical Summary

Problems solved by technology

Even when catalysts are used, however, the conversion reaction requires relatively high reaction temperatures, often in excess of 450° C. Exposure of the reaction products to these reaction conditions results in a significant deterioration of the reaction products.

As a result, valuable materials are converted to undesirable materials such as gas, char and coke, which foul and deactivate the catalyst particles and reduce the yield of the reaction process.