Process for producing hydrocarbon materials from organic feedstocks

Abstract

A method for producing hydrocarbon materials from hydrocarbon material precursors containing free fatty acid materials is provided, comprising: supplying a feed containing the hydrocarbon material precursor to a conversion zone so that the feed containing the hydrocarbon material precursor is converted into a product containing a gaseous hydrocarbon material; condensing a portion of the product containing the gaseous hydrocarbon material to obtain a condensed product containing the hydrocarbon material; and recycling the condensed product containing the hydrocarbon material to the conversion zone as a reflux; wherein the condensation is achieved in response to placing the product containing the gaseous hydrocarbon material in heat transfer communication with a radiator disposed outside the conversion zone.

Description

Technical Field

[0001] This document relates to the conversion of fatty acid materials into hydrocarbon materials. Background Art

[0002] There is increasing social and economic pressure to develop renewable energy sources as well as renewable and biodegradable industrial and consumer products and materials. A new focus is biorefining, which can be described as the processing of agroforestry feedstocks to gain added value by processing them into a variety of products, including biodiesel. However, there is still room for improvement in the conversion of such feedstocks into a variety of products using existing technologies. Summary of the invention

[0003] In one aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0004] supplying a feed of a hydrocarbonaceous material precursor to a conversion zone, causing the feed of the hydrocarbonaceous material precursor to be converted into a product comprising a gaseous hydrocarbon material;

[0005] condensing a portion of the gaseous hydrocarbon material-containing product to obtain a condensed hydrocarbon material-containing product; and

[0006] recycling the condensed hydrocarbonaceous material product to the conversion zone as reflux;

[0007] wherein condensation is achieved in response to placing the product comprising gaseous hydrocarbon material in heat transfer communication with a heat sink disposed external to the conversion zone.

[0008] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances, (i) a feed of the hydrocarbon material precursor is supplied to a conversion zone, (ii) the feed of the hydrocarbon material precursor is converted into a product containing gaseous hydrocarbon material in the conversion zone, and (iii) the product containing gaseous hydrocarbon material is placed in a heat transfer connection with a radiator arranged outside the conversion zone so that a portion of the product containing gaseous hydrocarbon material is condensed, resulting in a condensed hydrocarbon material product being obtained outside the conversion zone: the condensed hydrocarbon material product is recycled to the conversion zone.

[0009] In another aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0010] supplying a feed of a hydrocarbonaceous material precursor to a conversion zone, causing the feed stream of the hydrocarbonaceous material precursor to be converted into a hydrocarbonaceous material product;

[0011] recovering the hydrocarbonaceous material product from the conversion zone; and

[0012] recirculating a portion of the recovered hydrocarbonaceous material product to the conversion zone;

[0013] wherein the proportion of the recovered gaseous hydrocarbon material-containing product being refluxed to the conversion zone defines a reflux ratio, the reflux ratio being based on at least one detected parameter, the at least one detected parameter comprising at least one of: (i) the chain length of hydrocarbon material in the gaseous hydrocarbon material-containing product, and (ii) the chain length of free fatty acid material in the gaseous hydrocarbon material-containing product;

[0014] Such that the method further comprises at least one of: (i) detecting the chain length of hydrocarbon material within the product comprising gaseous hydrocarbon material, and (ii) detecting the chain length of free fatty acid material within the product comprising gaseous hydrocarbon material.

[0015] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances: (i) a feed of the hydrocarbon material precursor is supplied to a conversion zone, (ii) the feed of the hydrocarbon material precursor is converted into a hydrocarbon material product in the conversion zone, (iii) the hydrocarbon material product is being recovered from the conversion zone; (iv) the recovered hydrocarbon material product is being monitored for at least one of the following: (a) the chain length of the hydrocarbon material in the product containing gaseous hydrocarbon material, (b) the chain length of the free fatty acid material in the product containing gaseous hydrocarbon material: at least a portion of the recovered hydrocarbon material product is refluxed to the conversion zone based at least on the monitoring.

[0016] In another aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0017] Converting a hydrocarbon material precursor into an intermediate material mixture in the interior space of the process vessel, wherein the conversion includes subjecting at least a portion of the hydrocarbon material precursor to a reaction conversion in a reaction zone by a reaction process;

[0018] separating the intermediate material mixture into at least a product comprising a gaseous hydrocarbon material and a product comprising a liquid hydrocarbon material in response to at least buoyancy;

[0019] discharging the separated product containing liquid hydrocarbon material from the process vessel to obtain an external product containing liquid hydrocarbon material;

[0020] mixing at least a portion of the externally placed liquid hydrocarbon material-containing product with a feed of a hydrocarbon material precursor to obtain a combined material;

[0021] supplying a combined feed to the reaction zone; and

[0022] The heating source is arranged in a coordinated manner relative to at least a portion of the external product containing liquid hydrocarbon material and the feed of hydrocarbon material precursor, so that before the combined feed is supplied to the reaction zone, at least a portion of the external product containing liquid hydrocarbon material and the feed of hydrocarbon material precursor are heated with the help of the heating source.

[0023] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances: (i) converting the hydrocarbon material precursor into an intermediate material mixture within the internal space of a process container, wherein the conversion comprises reacting and converting at least a portion of the hydrocarbon material precursor through a reaction process within a reaction zone; (ii) separating the intermediate material mixture into at least one product containing a gaseous hydrocarbon material and one product containing a liquid hydrocarbon material in response to at least buoyancy; (iii) discharging the separated product containing the liquid hydrocarbon material from the process container to obtain an external product containing the liquid hydrocarbon material; (iv) mixing at least a portion of the external product containing the liquid hydrocarbon material with a feed of the hydrocarbon material precursor to obtain a combined material; (v) supplying the combined feed to the reaction zone; and cooperatively placing a heating source relative to at least a portion of the external product containing the liquid hydrocarbon material and the feed of the hydrocarbon material precursor, so that at least a portion of the external product containing the liquid hydrocarbon material and the feed of the hydrocarbon material precursor are heated by the heating source before the combined feed is supplied to the reaction zone.

[0024] In another aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0025] Converting a hydrocarbon material precursor into an intermediate material mixture within the interior space of the process vessel, wherein the conversion includes converting at least a portion of the hydrocarbon material precursor by a reaction process within the reaction zone;

[0026] separating the intermediate material mixture into at least one product comprising a gaseous hydrocarbon material and one product comprising a liquid hydrocarbon material in response to at least buoyancy;

[0027] discharging the separated product containing liquid hydrocarbon material from the process vessel to obtain an external product containing liquid hydrocarbon material;

[0028] heating at least a portion of the external liquid hydrocarbon material-containing product to obtain a heated external liquid hydrocarbon material-containing product; and

[0029] At least a portion of the heated external liquid hydrocarbon material-containing product is supplied to the reaction zone.

[0030] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances: (i) converting the hydrocarbon material precursor into an intermediate material mixture in the internal space of a process container, wherein the conversion includes reacting and converting at least a portion of the hydrocarbon material precursor through a reaction process in a reaction zone; (ii) separating the intermediate material mixture into at least one product containing gaseous hydrocarbon material and one product containing liquid hydrocarbon material in response to at least buoyancy; (iii) discharging the separated product containing liquid hydrocarbon material from the process container to obtain an external product containing liquid hydrocarbon material; (iv) recycling at least a portion of the external product containing liquid hydrocarbon material to the reaction zone; and heating the recycled external product containing liquid hydrocarbon material.

[0031] In another aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0032] Converting a hydrocarbon material precursor into an intermediate material mixture within the interior space of the process vessel, wherein the conversion includes converting at least a portion of the hydrocarbon material precursor by a reaction process within the reaction zone;

[0033] separating the intermediate material mixture into at least one product comprising a gaseous hydrocarbon material and one product comprising a liquid hydrocarbon material in response to at least buoyancy;

[0034] discharging the separated product containing liquid hydrocarbon material from the process vessel to obtain an external product containing liquid hydrocarbon material;

[0035] removing solid material from at least a portion of the externally disposed liquid hydrocarbon material-containing product to obtain a solids-depleted externally disposed liquid hydrocarbon material-containing product; and

[0036] At least a portion of the solids-depleted external liquid hydrocarbon material-containing product is supplied to the reaction zone.

[0037] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances: (i) converting the hydrocarbon material precursor into an intermediate material mixture within the internal space of a process container, wherein the conversion comprises reacting and converting at least a portion of the hydrocarbon material precursor through a reaction process within a reaction zone; (ii) separating the intermediate material mixture into at least one product containing a gaseous hydrocarbon material and one product containing a liquid hydrocarbon material in response to at least buoyancy; (iii) discharging the separated product containing the liquid hydrocarbon material from the process container to obtain an external product containing the liquid hydrocarbon material; (iv) recycling at least a portion of the external product containing the liquid hydrocarbon material to the reaction zone; removing solid material from at least the recycled external product containing the liquid hydrocarbon material, so that the external product containing the liquid hydrocarbon material recycled to the reaction zone is depleted of solids compared with the external product containing the liquid hydrocarbon material discharged from the process container.

[0038] In another aspect, there is provided a method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising:

[0039] Converting a hydrocarbon material precursor into an intermediate material mixture within the interior space of the process vessel, wherein the conversion includes converting at least a portion of the hydrocarbon material precursor by a reaction process within the reaction zone;

[0040] separating the intermediate material mixture into at least a product comprising a gaseous hydrocarbon material and a product comprising a liquid hydrocarbon material in response to at least buoyancy;

[0041] discharging the separated product containing liquid hydrocarbon material from the process vessel to obtain an external product containing liquid hydrocarbon material;

[0042] fractionating at least a portion of the externally disposed liquid hydrocarbon material-containing product into a recovered gaseous material portion and a discarded residual slurry portion based on volatility differences; and

[0043] The recovered gaseous material portion is supplied to the reaction zone.

[0044] On the other hand, a method for producing hydrocarbon material from a hydrocarbon material precursor containing free fatty acid material is provided, comprising: under the following circumstances: (i) converting the hydrocarbon material precursor into an intermediate material mixture within the internal space of a process container, wherein the conversion comprises reacting and converting at least a portion of the hydrocarbon material precursor through a reaction process within a reaction zone; (ii) separating the intermediate material mixture into at least one product containing a gaseous hydrocarbon material and one product containing a liquid hydrocarbon material in response to at least buoyancy; (iii) discharging the separated product containing the liquid hydrocarbon material from the process container to obtain an external product containing the liquid hydrocarbon material; based on volatility differences, fractionating at least a portion of the external product containing the liquid hydrocarbon material into a recovered gaseous material portion and a discarded residual slurry portion; and supplying the recovered gaseous material portion to the reaction zone.

[0045] Other aspects will become apparent from the description and drawings provided herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Embodiments will now be described with reference to the following drawings, in which:

[0047] Figure 1 is a process flow diagram of a first embodiment of a system in which the methods herein may be employed;

[0048] Figure 2 is a process flow diagram of a second embodiment of a system in which the methods herein may be employed;

[0049] Figure 3 is a process flow diagram of a third embodiment of a system in which the methods herein may be employed;

[0050] Figure 4 is a process flow diagram of a fifth embodiment of a system that can employ the method of the present invention

[0051] Figure 5 is a process flow diagram of a fourth embodiment of a system in which the methods herein may be employed;

[0052] Figure 6 is a process flow diagram of a sixth embodiment of a system in which the methods herein may be employed;

[0053] Figure 7 is a process flow diagram of a seventh embodiment of a system in which the methods herein may be employed;

[0054] Figure 8 is a process flow diagram of a seventh embodiment of a system in which the methods herein may be employed. DETAILED DESCRIPTION

[0055] See also Figure 1-7, a method for producing a hydrocarbon material from a hydrocarbon material (hereinafter referred to as HM) precursor is provided. The HM precursor used to produce the hydrocarbon material is in a liquid state. The HM precursor includes a fatty acid (hereinafter referred to as FA) material.

[0056] The FA material is composed of at least one FA substance. Each of the at least one FA substance is individually defined by a free fatty acid or its corresponding salt. In this regard, in some embodiments, for example, the FA material is composed of a free fatty acid material, and the free fatty acid material is composed of one or more free fatty acid compounds.

[0057] The fatty acid may be a saturated fatty acid or an unsaturated fatty acid. Suitable fatty acids include butyric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, alpha-linolenic acid, docosahexaenoic acid, eicosapentaenoic acid, linoleic acid, arachidonic acid, oleic acid, erucic acid or any fatty acid naturally derived from a plant or animal source.

[0058] The FA material of the HM precursor defines a FA material-defining precursor component. In some embodiments, for example, the HM precursor includes at least 80 wt % (such as, for example, at least 85 wt %, such as, for example, at least 90 wt %) of the FA material-defining precursor component based on the total weight of the HM precursor.

[0059] In certain embodiments, for example, at least a portion of the FA material definition precursor component is derived from a FA precursor material. Suitable FA precursor materials include edible vegetable oils, vegetable oils, animal fats, fungal oils, tall oil, animal fats, biosolids, edible oils, used edible oils, waste grease or soap stock or any combination thereof. Suitable edible vegetable oils include corn oil, cottonseed oil, canola oil, rapeseed oil, olive oil, palm oil, peanut oil, groundnut oil, safflower oil, sesame oil, soybean oil, sunflower oil, algae oil, almond oil, apricot oil, argan oil, avocado oil, Ben oil, cashew oil, castor oil, grapeseed oil, hazelnut oil, hempseed oil, linseed oil, mustard oil, neem oil, palm kernel oil, pumpkin seed oil, tall oil, rice bran oil or walnut oil or any combination thereof. Suitable animal fats include whale fat, cod liver oil, ghee, lard, tallow, its derivatives (such as yellow grease, used edible oil, etc.) or any combination thereof.

[0060] The FA precursor material includes at least one FA precursor compound. Exemplary FA precursor compounds include lipids, phospholipids, triglycerides, diglycerides, and monoglycerides.

[0061] In some embodiments, obtaining a FA material-defined precursor component from a FA precursor material is achieved, for example, in response to conversion of at least one FA precursor compound, wherein the conversion forms a product material comprising at least one FA substance. In this regard, in some embodiments, for example, the method includes, prior to generating a hydrocarbon material from a HM precursor, converting at least one FA precursor compound in the FA precursor material into a product material comprising at least one FA substance, such that the FA material-defined precursor component of the HM precursor includes at least one FA substance obtained from the conversion of the at least one FA precursor compound. In some embodiments, for example, the conversion includes a reaction process such as, for example, hydrolysis.

[0062] In some embodiments, the FA precursor material is subjected to pretreatment to remove moisture, metals, gums, proteins and pigments, which may cause emulsification during the hydrolysis process, such as before conversion. In some embodiments, such as the pretreatment includes acid treatment, followed by the addition of an absorbent (bleaching clay or activated carbon). The absorbent is filtered off. Residual moisture in the FA precursor material is removed under vacuum.

[0063] In some embodiments, for example, the method includes converting a feed 12 containing a HM precursor into at least one product 14 containing a gaseous hydrocarbon material in a conversion zone 10. The product 14 containing a gaseous hydrocarbon material includes a gaseous hydrocarbon material (hereinafter referred to as GHM). GHM is composed of one or more hydrocarbon compounds. In some embodiments, for example, GHM contains a gaseous target hydrocarbon material. At least one hydrocarbon of the gaseous target hydrocarbon material independently includes a total number of carbon atoms of at least one (1) and not more than 24. In some embodiments, for example, the gaseous hydrocarbon material includes at least 50% by weight (for example, such as at least 60% by weight, such as at least 70% by weight, such as at least 80% by weight) of the gaseous target hydrocarbon material based on the total weight of the gaseous hydrocarbon material.

[0064] In some embodiments, for example, the conversion of the feed 12 containing the HM precursor includes reacting and converting at least a portion of the feed 12 containing the HM precursor by a reaction process. In some embodiments, for example, at least a portion of the FA material-defined precursor component of the feed 12 containing the HM precursor is reacted and converted into GHM. In some of these embodiments, for example, during the conversion, at least a portion of the FA material-defined precursor component of the feed 12 containing the HM precursor remains unreacted, or is reacted and converted into another material (so that the FA material-defined precursor component is only partially reacted and converted into GHM). In this regard, in addition to GHM, the GHM-containing product 14 includes gaseous FA material, and the gaseous FA material includes unconverted and / or partially converted FA material-defined precursor components. The gaseous FA material of the GHM-containing product 14 is derived from the FA material-defined precursor component. In this regard, in some embodiments, for example, the gaseous FA material includes one or more FA substances in the FA material-defined precursor component, which are gasified during the HM precursor conversion process, and / or include one or more gaseous FA substances, which are obtained from the partial reaction conversion of one or more FA substances of the FA material-defined precursor component. Gaseous FA materials generally include relatively low molecular weight compounds characterized by relatively low boiling points such as short chain fatty acids.

[0065] See also Figure 1-3 In some embodiments, for example, in order to achieve conversion in the conversion zone 10, a feed 12 containing a HM precursor is supplied to the conversion zone 10. In some embodiments, for example, the feed 12 containing a HM precursor is supplied from a feed tank 22 to a feed receiving area 21A in the interior space 21 of a process vessel 20 for conversion in the conversion zone 10 disposed in the process vessel 20.

[0066] In some embodiments, for example, the conversion includes heating the feed 12 containing the HM precursor in the conversion zone 10. In some of these embodiments, for example, the heating includes heating the feed containing the HM precursor in a preheater 121 before supplying the feed 12 to the process vessel. In some embodiments, for example, the heating additionally or alternatively includes heating the feed 12 in the conversion zone 10. In this regard and with reference to Figure 5 In some embodiments, for example, the interior space 21 is placed in heat transfer communication with the heat exchanger 441, so that heat is conducted from the heat exchanger to the interior space 21 to heat the interior space 21 to establish desired temperature conditions within the conversion zone 10. In some embodiments, the conduction is through the walls of the process vessel 21, which define the interior space 21. In embodiments where heating includes "heating within the preheater 12", in some of these embodiments, for example, the conversion zone 10 is defined within both the preheater 12 and the process vessel 20.

[0067] The reaction conversion of at least a portion of the feed 12 containing HM precursors is achieved in the reaction zone 18 of the conversion zone 10 by a reaction process. An exemplary reaction process is pyrolysis (pyrolysis). Exemplary reaction processes occurring during pyrolysis include decarbonylation, decarboxylation and thermal cracking and condensation or any combination thereof. During the pyrolysis process, long-chain hydrocarbons are cracked into smaller chain molecules, including naphtha and diesel, by removing oxygen groups through decarboxylation and decarbonylation. The pyrolysis products include a product 14 containing GHM and a product 42 containing liquid hydrocarbon materials. In some embodiments, for example, the product 14 containing GHM includes GHM, FA materials, carbon monoxide, carbon dioxide and diatomic hydrogen. In some embodiments, for example, the product 42 containing liquid hydrocarbon materials includes liquid hydrocarbon compounds, such as liquid hydrocarbon compounds containing a total of six (6) to 16 carbon atoms, free fatty acid compounds containing a total of four (4) to 18 carbon atoms, water and solid carbon byproducts consisting of high molecular weight substances such as large-size polycyclic aromatic hydrocarbons. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst. In some embodiments, for example, the reaction process is carried out in the absence of added diatomic hydrogen. In some embodiments, for example, the reaction process is carried out in the absence of added diatomic oxygen. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst and added diatomic hydrogen. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst, added diatomic hydrogen, and added diatomic oxygen. In some embodiments, for example, the conversion zone and the feed supply of the hydrocarbon-containing material precursor to the conversion zone 10 cooperate so that the space time defined by "the time required for the supplied feed of the hydrocarbon-containing material precursor to occupy the entire conversion zone 10" is at least 10 minutes, for example, at least 15 minutes. In some embodiments, for example, the conversion zone and the feed supply of the hydrocarbon-containing material precursor to the conversion zone 10 cooperate so that the space time defined by "the time required for the supplied feed of the hydrocarbon-containing material precursor to occupy the entire conversion zone 10" is ten (10) minutes to 120 minutes, such as ten (10) minutes to 90 minutes. In some embodiments, for example, the temperature in the reaction zone 18 is 350 degrees Celsius to 500 degrees Celsius, for example, from 360 degrees Celsius to 450 degrees Celsius. In some embodiments, for example, the pressure within reaction zone 18 is from 100 psig to 250 psig.

[0068] In some embodiments, for example, the process is a continuous process, and in this regard, the process includes: (i) a feed 12 containing a HM precursor is supplied to a conversion zone 10, and (ii) the feed 12 containing a HM precursor is converted into a product 14 containing GHM within the conversion zone under the following circumstances: the product 14 containing GHM is recovered from the conversion zone 10.

[0069] After recovering the GHM-containing product 14, a portion of the recovered GHM-containing product 14 is condensed to obtain a condensed HM-containing product 28, and the condensed HM-containing product 28 (liquid) is recycled to the conversion zone 10 to at least achieve further conversion of the GHM-containing product 28 (such as, for example, through a reaction process in the reaction zone 19A of the conversion zone 19). In this regard, the HM-containing product 28 is used as a reflux 28. In some embodiments, for example, the reflux 28 returns longer chain fatty acid materials for further conversion in the conversion zone 10, and also returns longer chain hydrocarbon materials for further conversion in the conversion zone 10. In some embodiments, for example, the HM-containing product 28 returned to the conversion zone 10 defines a reflux ratio. An increased reflux ratio promotes achieving a greater proportion of shorter chain hydrocarbon materials and a lesser proportion of longer chain FA materials in the recovered GHM-containing product 14.

[0070] In some embodiments, for example, the reflux ratio is based on at least one parameter, and the at least one parameter includes at least one of: (i) the chain length of the hydrocarbon material within the product (14 or 28) containing the hydrocarbon material, and (ii) the chain length of the FA material (e.g., such as free fatty acid material) within the product (14 or 28) containing the hydrocarbon material.

[0071] In some embodiments, for example, the method further includes detecting the chain length of the hydrocarbon material within the HM-containing product (14 or 28), and in some of these embodiments, for example, the method further includes adjusting the reflux ratio based at least on the detection of the chain length of the hydrocarbon material within the hydrocarbon-containing product (14 or 28). In some embodiments, for example, the method further includes detecting the chain length of the FA material (e.g., free fatty acid material) within the hydrocarbon-containing product (14 or 28), and in some of these embodiments, for example, the method further includes adjusting the reflux ratio based at least on the detection of the chain length of the FA material within the hydrocarbon-containing product (14 or 28). In some embodiments, for example, the method further includes (i) detecting the product (14 or 28) of the hydrocarbon-containing material to obtain the chain length of the hydrocarbon material within the product (14 or 28) of the hydrocarbon-containing material, and (ii) detecting the product (14 or 28) of the hydrocarbon-containing material to obtain the chain length of the free fatty acid material within the product (14 or 28) of the hydrocarbon-containing material, and in some of these embodiments, for example, the method further includes adjusting the reflux ratio, the adjustment being based at least on: (i) detection of the chain length of the hydrocarbon material within the product (14 or 28) of the hydrocarbon-containing material; (ii) detection of the chain length of the free fatty acid material within the product (14 or 28) of the hydrocarbon-containing material; or (iii) detection of the chain length of the hydrocarbon material within the product (28) of the hydrocarbon-containing material and detection of the chain length of the free fatty acid material within the product (28) of the hydrocarbon-containing material.

[0072] In some embodiments, for example, a portion of the GHM-containing product 14 is condensed by cooling the GHM-containing product 14 in response to placing the GHM-containing product 14 in heat transfer communication with a heat sink. In some embodiments, for example, the heat sink is a cooling fluid and the heat transfer communication is an indirect heat transfer communication. In some embodiments, for example, the indirect heat transfer communication is achieved through a heat exchanger 30.

[0073] In some of these embodiments, for example, the process is a continuous process, and in this regard, the process includes: in the following cases, (i) supplying a feed 12 containing a HM precursor to a conversion zone 10, causing the feed 12 containing the HM precursor to be converted into at least one GHM-containing product 14, and (ii) recovering the GHM-containing product 14 from the conversion zone 10: condensing a portion of the GHM-containing product 14 to obtain a condensed HM-containing product 28 and recycling it to the conversion zone 10.

[0074] See also Figure 2 and 3 In some embodiments, for example, the conversion includes intermediate conversion and fractionation. The intermediate conversion is performed in the intermediate conversion zone 19, and the fractionation is performed in the fractionation zone 26. In this regard, the conversion zone 10 includes the intermediate conversion zone 19 and the fractionation zone 26.

[0075] Regarding the intermediate conversion, the feed 12 containing the HM precursor is converted into the intermediate product 16 containing GHM in the intermediate conversion zone 19. In this regard, the conversion includes converting the feed 12 containing the HM precursor into the intermediate product 16 containing GHM in the intermediate conversion zone 19. "Converting the feed 12 containing the HM precursor into the intermediate product 16 containing GHM" includes: the reaction conversion of at least a portion of the feed 12 containing the HM precursor. The reaction conversion of at least a portion of the feed 12 containing the HM precursor is achieved by a reaction process in the reaction zone 19A of the intermediate conversion zone 19. In this regard, the intermediate conversion includes: reacting and converting at least a portion of the feed 12 containing the HM precursor in the reaction zone 19A of the intermediate conversion zone 19 by means of a reaction process. An exemplary reaction process is pyrolysis (high temperature decomposition). Exemplary reaction processes occurring during pyrolysis include decarbonylation, decarboxylation, thermal cracking and condensation or any combination thereof. During pyrolysis, oxygen groups are removed by decarboxylation and decarbonylation, and long-chain hydrocarbons are cracked into smaller chain molecules, which include naphtha and diesel. The pyrolysis products include a product 14 containing GHM and a product 42 containing liquid hydrocarbon materials. In some embodiments, for example, the product 14 containing GHM includes GHM, FA materials, carbon monoxide, carbon dioxide, methane, ethane, propane and diatomic hydrogen. In some embodiments, for example, the product 42 containing liquid hydrocarbon materials includes liquid hydrocarbon compounds, such as liquid hydrocarbon compounds containing a total of six (6) to 16 carbon atoms, free fatty acid compounds containing a total of four (4) to 18 carbon atoms, water, and solid carbon byproducts composed of high molecular weight substances such as large-sized polycyclic aromatic hydrocarbons. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst. In some embodiments, for example, the reaction process is carried out in the absence of added diatomic hydrogen. In some embodiments, for example, the reaction process is carried out in the absence of added diatomic oxygen. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst and added diatomic hydrogen. In some embodiments, for example, the reaction process is carried out in the absence of a catalyst, added diatomic hydrogen and added diatomic oxygen. In some embodiments, for example, the conversion zone is coordinated with the supply of the feed of the hydrocarbonaceous material precursor to the reaction zone 19A, so that the space time defined by the time required for the supplied feed of the hydrocarbonaceous material precursor to occupy the entire reaction zone 19A is at least 10 minutes, for example at least 15 minutes. In some embodiments, for example, the reaction zone 19A is coordinated with the supply of the feed of the hydrocarbonaceous material precursor to the conversion zone 10, so that the space time defined by the time required for the supplied feed of the hydrocarbonaceous material precursor to occupy the entire reaction zone 19A is ten (10) minutes to 120 minutes, for example from ten (10) minutes to 90 minutes. In some embodiments, for example, the temperature in the reaction zone 18 is 350 degrees Celsius to 500 degrees Celsius, for example from 360 degrees Celsius to 450 degrees Celsius. In some embodiments, for example, the pressure in the reaction zone 18 is 100 to 250 psig.

[0076] With respect to fractionation, the GHM-containing intermediate product 16 is fractionated in the fractionation zone 26 to obtain the GHM-containing product 14. In this regard, the conversion includes fractionating the GHM-containing intermediate product 16 in the fractionation zone 26 to obtain the GHM-containing product 14. In some embodiments, for example, the fractionation is achieved in response to contacting the GHM-containing intermediate product 16 with the reflux 28 described above in the fractionation zone 26. In some embodiments, during the contact between the reflux 28 and the GHM-containing intermediate product 16, the reflux 28 flows in a direction opposite to the flow of the GHM-containing intermediate product 16. In this regard, in some embodiments, for example, the fractionation is achieved in response to contacting the reflux 28 with the GHM-containing intermediate product 16, while the reflux 28 flows in a countercurrent manner to the flow of the GHM-containing intermediate product 16. In some embodiments, for example, the flow of the GHM-containing intermediate product 16 is upward, while the flow of the reflux 28 is downward. In some of these embodiments, contact between the GHM-containing intermediate product 16 and the reflux 28 is facilitated, for example, by a contact medium disposed within the fractionation zone 26. Suitable contact media include trays, plates, and packing.

[0077] In some of the embodiments, for example, the process is a continuous process, and in this regard, the process includes, under the following circumstances, (i) supplying a feed 12 containing a HM precursor to an intermediate conversion zone 19, causing the feed 12 containing a HM precursor to be converted into at least one intermediate product 16 containing GHM, (ii) placing the intermediate product 16 containing GHM in a fractionation zone 26, (iii) condensing a portion of the product 14 containing GHM to obtain a condensed HM-containing product 28, and (iv) recycling the condensed HM-containing product 28 to the fractionation zone 26: contacting the intermediate product 16 containing GHM with the condensed HM-containing product 28 in the fractionation zone 26, causing the intermediate product containing GHM to be fractionated to obtain the product 14 containing GHM.

[0078] See also Figure 3 , since a portion of the GHM-containing product 14 is condensed, the condensed portion is separated from the GHM-containing product 14, thereby obtaining a product 32 rich in short-chain hydrocarbons. The product 32 rich in shorter-chain hydrocarbons is cooled in a heat exchanger 34, thereby producing a condensed liquid material 36 containing a liquid hydrocarbon material product 66 and water 67. The condensed liquid material 36 is supplied to a decanter 38, where the water 67 is separated from the liquid hydrocarbon material 66. In some embodiments, for example, uncondensed gas 40 from the product 32 rich in shorter-chain hydrocarbons is discharged or burned.

[0079] As described above, in some embodiments, the product 42 containing liquid hydrocarbon material is obtained, for example, by conversion of the HM-containing precursor feed 12. Figure 4-7, in some embodiments, for example, a product 42 containing liquid hydrocarbon materials is recovered from the conversion zone 10. In this regard, in some embodiments, for example, the method includes: converting a feed 12 containing a HM precursor into at least a product 14 containing GHMs and a product 42 containing liquid hydrocarbon materials in the conversion zone 10, and separating the product 14 containing GHMs from the product 42 containing liquid hydrocarbon materials. In some embodiments, for example, the separation of the product 14 containing GHMs from the product 42 containing liquid hydrocarbon materials includes gravity separation and is achieved at least in response to buoyancy.

[0080] In some embodiments, the conversion includes an intermediate conversion, where the feed 12 containing the HM precursor is converted into at least one intermediate product 16 containing GHM in the intermediate conversion zone 19, and the conversion also includes a second conversion, where the intermediate product 16 containing GHM is fractionated in the fractionation zone 26 to obtain the product 14 containing GHM, and in some embodiments, for example, the intermediate conversion results in the production of a product 42 containing liquid hydrocarbon materials. In this regard, in some embodiments, the method further includes separating the intermediate product 16 containing GHM from the product 42 containing liquid hydrocarbon materials. In some embodiments, for example, "separating the intermediate product 16 containing GHM from the product 42 containing liquid hydrocarbon materials" includes gravity separation and is achieved in response to at least buoyancy.

[0081] In some embodiments, for example, the intermediate material mixture 24 is disposed in the intermediate conversion zone 19 and includes reaction products (from the reaction conversion) and unreacted HM precursor-containing feed 12. As described above, at least a portion of the unreacted HM precursor-containing feed 12 can be converted into reaction products.

[0082] In embodiments where the GHM-containing intermediate product 16 is separated from the liquid hydrocarbon material-containing product 42, in some of these embodiments, the separation is achieved, for example, by separating the intermediate material mixture 24 into at least the GHM-containing intermediate product 16 and the liquid hydrocarbon material-containing product 42, the separation comprising gravity separation and being achieved at least in response to buoyancy.

[0083] In some of these embodiments, for example, the process is a continuous process, and in this regard, the process includes: (i) the intermediate material mixture 24 is disposed in the intermediate conversion zone 19, and (ii) the feed 12 containing the HM precursor is supplied separately to the intermediate conversion zone 10, under the following circumstances: the intermediate material mixture 24 is separated into at least an intermediate product 16 containing GHM and a product 42 containing liquid hydrocarbon material.

[0084] In some embodiments, for example, the separated product 42 containing liquid hydrocarbon materials is discharged from the process vessel 20. At least a portion of the discharged product 42 containing liquid hydrocarbon materials is recycled outside the internal space 21 by a pump 60. In this regard, in some embodiments, for example, a recycling loop 62 is provided to recycle at least a portion of the discharged product 42 containing liquid hydrocarbon materials outside the internal space 21, so that the discharged product 42 containing liquid hydrocarbon materials is returned to the internal space 21 of the process vessel 20, so that the conversion of the feed containing the HM precursor is achieved in the internal space 21 of the process vessel 20, as described above. In this regard, in some embodiments, the intermediate conversion zone 19 includes a recycling loop 62. The residual liquid material product 58 that is not recycled can be further processed.

[0085] See also Figure 4 , Figure 5 , Figure 7 and Figure 8 In some embodiments, for example, the recirculation loop 62 includes a heat exchanger 44 for heating the material (e.g., at least a portion of the product 42 containing liquid hydrocarbon material) recycled in the recirculation loop 62 to obtain a recycled heated material 50. In some embodiments, for example, the heat exchanger 44 includes a molten salt bath. In some embodiments, for example, in embodiments where the feed receiving area 21A is disposed within the process vessel 20, the heated recirculated material 50 provides heat to promote the conversion of the feed 12 containing the HM precursor. By connecting the product 42 containing liquid hydrocarbon material that is recycled outside the interior space 21 through the recirculation loop 62 to the heating source, the degree of wall scaling is reduced compared to the heat transfer connection between the product 42 containing liquid hydrocarbon material disposed in the interior space 21 and the heating source via the wall of the process vessel 20. In some of the embodiments, for example, the feed 12 containing the HM precursor is supplied to the recirculation loop 62 instead of to the internal space 21 of the process vessel 20, so that the feed receiving area 21A of the intermediate conversion zone 19 is confined within the recirculation loop 62 instead of the internal space 21 of the process vessel 20 in a manner such that conversion of the feed 12 containing the HM precursor is achieved in the internal space 21, as described above.

[0086] In some embodiments, for example, the process including "recycling of the discharged product 42 containing liquid hydrocarbon materials" is continuous. In this regard, in some embodiments, for example, the method includes: in the following cases, (i) converting the HM precursor into the intermediate material mixture 24 in the internal space 21 of the process container 20, wherein the conversion includes reacting at least a portion of the HM precursor in the reaction zone 18 by means of a reaction process; (ii) separating the intermediate material mixture 24 into the product 14 containing GHM and the product 42 containing liquid hydrocarbon materials in response to at least buoyancy; (iii) discharging the separated product 42 containing liquid hydrocarbon materials from the process container 20 to obtain the external product 42 containing liquid hydrocarbon materials; and (iv) recycling at least a portion 50 of the external product 42 containing liquid hydrocarbon materials to the internal space 21 of the process container 20: heating the recycled external product 50 containing liquid hydrocarbon materials.

[0087] See also Figure 6 In some embodiments, for example, the recycle loop 62 includes a solids removal unit operation 56 for removing at least a portion of solid material entrained in the discharged liquid hydrocarbon material-containing product 42 that is recycled in the recycle loop 62, thereby producing a solids-depleted liquid material 52. Exemplary solids removal unit operations include one or more of filtration, hydrocyclone separation, and centrifugation.

[0088] See also Figure 7 In some embodiments where the recirculation loop includes the heat exchanger 44, at least a portion of the solid material entrained in the recirculating liquid material product is removed from the recirculating liquid material product prior to directing the recirculating liquid material product through the heat exchanger 44, thereby obtaining a solids-depleted recirculating material 52. In this regard, the solids-depleted recirculating material 52 is circulated through the heat exchanger 44 such that the heated recirculating material 50 is defined by the heated solids-depleted liquid material product.

[0089] See also Figure 8 In some embodiments, for example, the residual liquid material product 58 is separated into a recoverable gaseous material portion 64 and a discardable residual slurry portion 66. The recoverable gaseous material portion 64 is recovered and supplied to a recirculation loop 62 upstream of the pump 60 to supply the interior space 21 of the process container 20.

[0090] With regard to separation, in some embodiments, for example, in response to heating of the residual liquid material product 58, the residual liquid material product 58 is fractionated into a recoverable gaseous material portion 64 and a discardable residual slurry portion 66. In this regard, the fractionation is based on volatility differences, and at least a portion of the external liquid hydrocarbon material-containing product is fractionated into a recoverable gaseous material portion and a discarded residual slurry portion. In some embodiments, for example, the heating is performed under vacuum conditions. In this regard, in some embodiments, for example, the heating is performed in a heating zone 68, which is placed at a temperature of from 250 degrees Celsius to 350 degrees Celsius and a pressure below atmospheric pressure, for example, at a pressure of from 0.0725 psia (0.5 kPa) to 0.725 psia (5 kPa).

[0091] In some embodiments, a product mixture 70 is generated within the conversion zone 68, for example in response to heating of the residual liquid material product 58 within the heating zone 68, such that the product mixture 70 is disposed within the heating zone 68. The product mixture 70 includes a recoverable gaseous material portion 64 and a discardable residual slurry portion 66. When the product mixture 70 is disposed within the conversion zone 68, the product mixture 70 is separated into the recoverable gaseous material portion 64 and the discardable residual slurry portion 66 in response to buoyancy.

[0092] In some embodiments, for example, the heating zone 68 is disposed within the process vessel 72 such that: (i) the recoverable gaseous material portion 64 accumulates in the upper portion 74 of the process vessel 72 and is discharged as the recovered gaseous material portion 64A, and (ii) the discardable residual slurry portion 66 accumulates in the bottom portion 76 of the process vessel 74 and is discharged as the discarded residual slurry portion 66A. In some embodiments, for example, the discharge of the recovered gaseous material portion 64A is achieved by a vacuum pump 78 in fluid communication with the upper portion 74 of the process vessel 70.

[0093] In some embodiments, for example, process vessel 70 is a thin film evaporator.

[0094] In some embodiments, the residual liquid material product 58 is cooled within a heat exchanger 86 to further mitigate coke formation, for example, prior to supplying the residual liquid material product 58 to the heating zone 68 .

[0095] In some embodiments, coke formation within the system is mitigated, for example, by separating the discarded residual slurry portion 66A from the recovered gaseous material portion 64A. In this regard, the discarded residual slurry portion 66A includes materials that are susceptible to forming coke in response to high temperature exposure, such as long chain hydrocarbons and solids, and its removal helps reduce coke formation.

[0096] With respect to the discharged recovered gaseous material portion 64A, in some embodiments, for example, the discharged recovered gaseous material portion 64A is condensed within the condensation zone 82 of the condenser 80 to produce a condensed recovered residual material 64B. In some embodiments, for example, the condensation within the condensation zone 82 causes the condensed recovered residual material 64B to be subjected to a temperature of from 150 degrees Celsius to 200 degrees Celsius and a pressure of from 100 psig to 250 psig (e.g., to match the pressure conditions within the process vessel 20 to which the condensed recovered residual material 64B is supplied, see below).

[0097] Regarding the condensed recovery residue material 64B, the condensed recovery residue material 64B is supplied to the inner space 21 of the process vessel 20, thereby achieving conversion of the condensed recovery residue material 64B in the inner space 21, as described above.

[0098] In some embodiments, for example, the condensed recycled residue material 64B is heated prior to supplying the condensed recycled residue material 64B to the interior space 21 of the process vessel 20, such that the condensed recycled residue material 64B is placed at a temperature of from 300 degrees Celsius to 400 degrees Celsius. In some embodiments, the heating includes placing the condensed recycled residue material 64B in heat transfer communication with the residual liquid material product 58 (such as, for example, through a heat exchanger), such that heat is transferred from the residual liquid material product 58 to the condensed recycled residue material 64B. In some embodiments, for example, the heating includes placing the condensed recycled residue material 64B in heat transfer communication with a heating fluid, such as through a heat exchanger 84.

[0099] In some embodiments, the condensed recycled residual material 64B is mixed with the material in the recirculation loop 62 before the condensed recycled residual material 64B is supplied to the interior space 21 of the process vessel 20. In some of these embodiments, for example, the condensed recycled residual material 64B is heated (as described above) before mixing, so that the condensed recycled residual material 64B is exposed to a temperature of from 300 degrees Celsius to 400 degrees Celsius. In some of these embodiments, for example, the material recycled in the recirculation loop 62 includes the feed 12 containing the HM precursor.

[0100] In the above description, many details are set forth for the purpose of explanation in order to provide a thorough understanding of this article. However, it is apparent to those skilled in the art that these specific details are not necessary for practicing this article. Although certain dimensions and materials are described in order to implement the disclosed embodiments, other suitable dimensions and / or materials may be used within the scope of this article. All such modifications and changes, including all suitable current and future technological changes, are considered to be covered within the scope of this article. The full texts of all references mentioned are hereby incorporated by reference into this article.

Claims

1. A method for producing a hydrocarbon material from a feed of a hydrocarbon material precursor comprising a free fatty acid material, comprising: Supplying a reaction material including a feed of a hydrocarbonaceous material precursor to an intermediate conversion zone so that the feed of the hydrocarbonaceous material precursor is converted into an intermediate product containing a gaseous hydrocarbon material through a reaction process; contacting the intermediate product containing gaseous hydrocarbon material with a reflux in a fractionation zone to effect fractionation of the intermediate product containing gaseous hydrocarbon material to obtain the product containing gaseous hydrocarbon material and to obtain a fractionated product comprising free fatty acid material and hydrocarbon material; condensing a portion of the gaseous hydrocarbon material-containing product to obtain a condensed hydrocarbon material-containing product; recycling said condensed hydrocarbonaceous material product to the conversion zone, whereby said reflux comprises said condensed hydrocarbonaceous material product; and supplying the fractionated product to the intermediate conversion zone, so that the reaction material includes the fractionated product; in, said condensing being effected in response to placing said product comprising gaseous hydrocarbon material in heat transfer communication with a heat sink disposed outside of said conversion zone, The feed of hydrocarbonaceous material precursor comprises at least 80 wt% free fatty acid material based on the total weight of the feed of hydrocarbonaceous material precursor.

2. The method of claim 1, wherein: The intermediate conversion zone and the fractionation zone are disposed in a process vessel; and The "placing the product containing gaseous hydrocarbon materials in heat transfer communication with a heat sink located outside the conversion zone" includes: discharging the product containing gaseous hydrocarbon materials from the process container.

3. The method according to claim 1 or 2, wherein: The conversion includes reactively converting at least a portion of the feed of the hydrocarbonaceous material precursor by a reaction process in a reaction zone of the intermediate conversion zone.

4. The method of claim 1, wherein: The fractionation zone includes a contact medium for promoting contact between the intermediate product comprising gaseous hydrocarbon material and the reflux.

5. The method of claim 1, wherein: Including at least one of the following: (i) the concentration of gaseous hydrocarbon material in the product containing gaseous hydrocarbon material is greater than the concentration of gaseous hydrocarbon material in the intermediate product containing gaseous hydrocarbon material, and (ii) the ratio of gaseous hydrocarbon material to hydrocarbon material precursor in the product containing gaseous hydrocarbon material is greater than the ratio of gaseous hydrocarbon material to hydrocarbon material precursor in the intermediate product containing gaseous hydrocarbon material.

6. The method of claim 1, wherein: The reaction zone of the conversion zone is set at a temperature from 350 degrees Celsius to 500 degrees Celsius.

7. The method according to claim 1 or 6, wherein: The reaction zone of the conversion zone is set at a pressure of from 150 psig to 250 psig.

8. The method of claim 7, wherein: There is no added diatomic oxygen in the reaction zone.

9. The method of claim 8, wherein: No externally added diatomic hydrogen is present in the reaction zone.

10. The method of claim 9, wherein: No decarboxylation catalyst is present in the reaction zone.

11. The method of claim 10, wherein: The reaction process includes thermal cracking.

12. The method of claim 11, wherein: The reaction zone and the supply of the hydrocarbonaceous material precursor feed to the reaction zone are coordinated so that the space time is at least ten (10) minutes, and the space time is defined by the time required for the supplied hydrocarbonaceous material precursor feed to occupy the entire reaction zone.

13. The method of claim 1, wherein: The fraction of the product containing gaseous hydrocarbon material which is condensed and returned to the conversion zone defines the reflux ratio, and The reflux ratio is based at least on the chain length of the hydrocarbon material in the product comprising gaseous hydrocarbon material.

14. The method of claim 1, wherein: The fraction of the product containing gaseous hydrocarbon material which is condensed and returned to the conversion zone defines the reflux ratio, and The reflux ratio is based at least on the chain length of the free fatty acid material in the condensed hydrocarbonaceous material product.

15. The method of claim 1, wherein: The method is continuous.

16. A method for producing a hydrocarbon material from a hydrocarbon material precursor comprising a free fatty acid material, comprising: In the following cases, (i) reaction materials, including a feed of a hydrocarbonaceous material precursor, are supplied to an intermediate conversion zone, (ii) the feed of the hydrocarbonaceous material precursor is converted into an intermediate product containing a gaseous hydrocarbon material by a reaction process in the intermediate conversion zone, (iii) the intermediate product containing a gaseous hydrocarbon material is contacted with a reflux in a fractionation zone to effect fractionation of the intermediate product containing a gaseous hydrocarbon material, thereby obtaining a product containing a gaseous hydrocarbon material, and obtaining a fractionated product comprising a free fatty acid material and a hydrocarbon material, and (iv) the product containing a gaseous hydrocarbon material is placed in heat transfer communication with a heat sink so that a portion of the product containing a gaseous hydrocarbon material is condensed, thereby obtaining a condensed product containing a hydrocarbon material, recycling the condensed hydrocarbonaceous material product to the fractionation zone, whereby the reflux comprises the condensed hydrocarbonaceous material product; and supplying the fractionated product comprising free fatty acid material and hydrocarbon material to the intermediate conversion zone, whereby the reaction material comprises the fractionated product, Wherein, based on the total weight of the feed of hydrocarbon-containing material precursor, the feed of hydrocarbon-containing material precursor comprises at least 80 wt % of free fatty acid material.

17. The method of claim 16, wherein: The intermediate conversion zone and the fractionation zone are disposed in a process vessel; and "Placing the product containing gaseous hydrocarbon material in heat transfer communication with a heat sink" includes: discharging the product containing gaseous hydrocarbon material from the process container.

18. The method according to claim 16 or 17, wherein: The conversion includes reacting and converting at least a portion of the feed of the hydrocarbonaceous material precursor in a reaction zone of the intermediate conversion zone through a reaction process.

19. The method of claim 16, wherein: Conversion of the hydrocarbonaceous material precursor feed is achieved upon contacting the gaseous hydrocarbonaceous material-containing intermediate product with the reflux.

20. The method of claim 16, wherein: The fractionation zone includes a contact medium for promoting contact between the intermediate product comprising gaseous hydrocarbon material and the reflux.

21. The method of claim 16, wherein: Include at least one of the following: (i) the concentration of gaseous hydrocarbon material in the product containing gaseous hydrocarbon material is greater than the concentration of gaseous hydrocarbon material in the intermediate product containing gaseous hydrocarbon material, and (ii) the ratio of gaseous hydrocarbon material to hydrocarbon material precursor in the product containing gaseous hydrocarbon material is greater than the ratio of gaseous hydrocarbon material to hydrocarbon material precursor in the intermediate product containing gaseous hydrocarbon material.

22. The method of claim 16, wherein: The reaction zone of the intermediate conversion zone is set at a temperature from 350 degrees Celsius to 500 degrees Celsius.

23. The method of claim 22, wherein: The reaction zone is set at a pressure of from 150 psig to 250 psig.

24. The method of claim 23, wherein: There is no added diatomic oxygen in the reaction zone.

25. The method of claim 24, wherein: No externally added diatomic hydrogen is present in the reaction zone.

26. The method of claim 25, wherein: No decarboxylation catalyst is present in the reaction zone.

27. The method of claim 16 or 26, wherein: The reaction process includes thermal cracking.

28. The method of claim 16, wherein: The reaction zone of the intermediate conversion zone and the supply of the feed of the hydrocarbonaceous material precursor to the reaction zone of the intermediate conversion zone are coordinated so that the space time defined by the time required for the supplied feed of the hydrocarbonaceous material precursor to occupy the entire reaction zone is at least ten (10) minutes.

29. The method of claim 16, wherein: The portion of the product containing gaseous hydrocarbon material that is condensed and recycled to the fractionation zone defines the reflux ratio, and The reflux ratio is based on at least one parameter comprising at least one of: (i) the chain length of hydrocarbon material in the product comprising gaseous hydrocarbon material, and (ii) the chain length of free fatty acid material in the product comprising gaseous hydrocarbon material.

30. The method of claim 1 or 16, wherein: The feed of hydrocarbonaceous material precursor comprises at least 85 wt% free fatty acid material based on the total weight of the feed of hydrocarbonaceous material precursor.

31. The method of claim 1 or 16, wherein: The feed of hydrocarbonaceous material precursor comprises at least 90 wt% free fatty acid material, based on the total weight of the feed of hydrocarbonaceous material precursor.

Images