Pyrolysis device of solid hydrocarbon material and process method thereof

Abstract

The application relates to a pyrolysis device and a process method thereof. The device is composed of one or more tubular pyrolysis reactors arranged in a column tube mode. The heated section is arranged in a heating chamber. The pyrolysis gas obtained by pyrolysis of raw materials or externally supplied fuel gas is combusted in the heating chamber through a heat storage combustion mode to provide heat for the pyrolysis reaction. A gas collection inner member is arranged in the center of each tubular pyrolysis reactor to control the radial flow of the pyrolysis gas phase product through the moving particle bed, realize in-situ filtration and dust removal and selective cracking and upgrading, and thus solve the problems of poor quality of pyrolysis oil (high content of heavy components and large dust content) and low oil yield of the existing pyrolysis technology. The application has the advantages of easy industrial expansion. The method of only expanding the number of pyrolysis units is used to realize the scale application of the industrial reactor and the pyrolysis technology, and solve the problems of difficult expansion of the existing pyrolysis technology and increased operation difficulty and declined operation effect of the industrial reactor.

Description

Technical Field

[0001] This invention relates to a pyrolysis apparatus and its process, and particularly to a pyrolysis apparatus and its process for solid hydrocarbon feedstock. Background Technology

[0002] Solid hydrocarbon feedstocks include coal, oil shale, waste tires, biomass, oil sands, and urban organic solid waste. Through pyrolysis, products such as oil, gas, and char can be obtained. Pyrolysis oil can be used as a fuel to replace fossil fuel oil or as a chemical raw material to produce high-value-added chemicals. Pyrolysis gas can be used as fuel gas to provide energy or as feedstock gas. Pyrolysis char is applied according to its characteristics and properties, such as biochar for soil improvement and remediation, waste tire pyrolysis char for carbon black preparation, coal semi-coke for power generation and metallurgy, and specially processed carbon materials for battery anodes.

[0003] Currently reported representative solid hydrocarbon feedstock pyrolysis technologies include the Fushun rotary distillation furnace in China, the Toscoal rotary distillation furnace in the United States, the Galoter rotary distillation furnace in Estonia, the ATP rotary furnace process in Canada, the Lurgi-Ruhr moving bed pyrolysis technology in Germany, and the Dagong new method of distillation in China. Among these, pyrolysis technologies for large-scale industrial application are currently limited to using lumpy feedstocks, resulting in the accumulation and discarding of large quantities of small particles (over 40%). Furthermore, existing lumpy feedstock pyrolysis technologies yield low oil yields. The development of corresponding pyrolysis technologies for small-particle solid hydrocarbon feedstocks has been ongoing for decades, with most technologies conducting demonstrations of hundreds to thousands of tons per day, but none have yet achieved long-term stable industrial operation. The main problems facing these technologies are low pyrolysis oil yields, high content of heavy components in the oil, poor oil quality, and severe dust contamination, leading to pipeline blockage, difficulties in continuous operation, and poor economic efficiency. In addition, the traditional method of industrial scale-up by increasing the size of the reactor not only increases the difficulty of equipment operation, but also easily causes problems such as uneven heat transfer, reduced heat and mass transfer efficiency, and significantly lower operating performance compared to the small reactor.

[0004] The pyrolysis process can be broadly divided into two stages: First, the organic matter in the solid hydrocarbon feedstock decomposes upon heating, producing primary pyrolysis products. These primary pyrolysis products are released from the particles into the particle bed and reactor. During the process of exiting the reactor, secondary reactions of the pyrolysis oil and gas occur, including reactions between pyrolysis gaseous products and between these products and the solid particles. Finally, pyrolysis oil and pyrolysis gas are separated and collected. In principle, to obtain high-yield and high-quality pyrolysis oil, it is necessary to maximize the primary pyrolysis products while controlling the secondary reactions of these products to improve the quality of the pyrolysis oil. Regarding dust transport, small particles or powdery feedstocks move violently within the reactor during pyrolysis, such as in fluidized beds and rotary kilns. Dust raised within the reactor is carried out with the pyrolysis gaseous products, ultimately resulting in a high dust content in the pyrolysis oil. Typically, dust removal operations, such as cyclone dust collectors and particle bed dust collectors, are required during the collection and separation of pyrolysis gaseous products. However, these devices not only complicate the process and increase operational difficulty but also have poor dust removal effects. Furthermore, the secondary reactions of the pyrolysis oil and gas significantly reduce the oil yield. Therefore, in order to solve the common problems faced by small particulate feedstock pyrolysis technology, such as low product oil yield, high content of heavy components, high dust content, and difficulty in technology scale-up. Summary of the Invention

[0005] The purpose of this invention is to provide a pyrolysis device and process method for solid hydrocarbon feedstocks. This invention utilizes the pyrolysis gas produced by the system and adopts a regenerative combustion method for direct combustion heating. One heating unit can accommodate multiple tubular pyrolysis reactors, achieving rapid and efficient heat and mass transfer, which is more energy-efficient and simpler. It solves the problems of low oil yield, heavy oil, and high dust content in the pyrolysis of small-particle-size solid hydrocarbon feedstocks, and overcomes the difficulties in the industrial scale-up application of pyrolysis reactors and pyrolysis technology.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] The present invention discloses a solid hydrocarbon feedstock pyrolysis device, comprising: a feeder, a tubular pyrolysis reactor, a regenerative burner, a heating chamber, a solid product unloader, a gas collecting internal component, a gas product collecting pipe, and a gas product condenser.

[0008] The tubular pyrolysis reactor is formed by combining one or more tubular pyrolysis reactors. The tubular pyrolysis reactor is usually cylindrical in shape, and each reactor has a gas collecting internal component at its center.

[0009] This invention is based on a method of scaling up the number of reactors. It constructs a tubular pyrolysis reactor by combining tubular pyrolysis reactors, making it easier to scale up industrial reactors. The size of the tubular pyrolysis reactor is not significantly different from that of the verified small-scale pyrolysis reactors. It is simple to operate and has good heat and mass transfer effects, solving problems such as difficulty in industrial scale-up of reactors, poor operation of scaled-up reactors, and high operating difficulty.

[0010] The gas collecting internal component is typically cylindrical in shape and has channels or pores that allow gaseous products to pass through. The lower end of the internal component opens into the material layer of the pyrolysis reactor, while the upper end is closed and connected to the gaseous product collection pipe, thus exporting the pyrolysis gaseous products out of the pyrolysis reactor and into the gaseous product condenser.

[0011] This invention features a gas-collecting internal component at the center of the pyrolysis reactor, offering the following advantages: It regulates the radial flow of pyrolysis gaseous products through the moving particle bed, directing them from the high-temperature zone on the outer wall of the reactor to the low-temperature zone at the center, achieving selective pyrolysis of heavy components and suppressing excessive secondary reactions; it enhances heat transfer within the reactor, significantly improving heat transfer efficiency and increasing the throughput per unit time of the pyrolysis unit; it avoids the counter-current flow of pyrolysis gaseous products (from bottom to top) and materials (from top to bottom), greatly reducing dust carryover from the gaseous products, while utilizing the moving particle bed for in-situ filtration and dust removal. Compared to reactors without a gas-collecting internal component, the pyrolysis reactor and pyrolysis unit of this invention significantly improve the yield and quality of the product oil, achieve faster heat transfer rates, and significantly reduce the dust content of the product oil.

[0012] The heating section of the tubular pyrolysis reactor is located in the heating chamber, and the tubular pyrolysis reactors are arranged in a tubular manner in the heating chamber.

[0013] The heating chamber is an indoor combustion chamber that provides heat for the pyrolysis reaction through the combustion of combustible gas. One or more tubular pyrolysis reactors can be arranged in the heating chamber.

[0014] The regenerative burners are distributed symmetrically on the upper and lower surfaces or sides of the heating chamber.

[0015] Preferably, the regenerative burner uses combustible gas as fuel, selected from one or more combinations of pyrolysis gas, natural gas, gasified coal gas, and petroleum gas. Preferably, it uses pyrolysis gas obtained by separating gas phase product condenser as gaseous fuel.

[0016] The regenerative combustion method used in this invention can effectively utilize the heat of the flue gas after combustion, thereby improving the system's energy utilization efficiency. By using indoor combustion gaseous fuel to directly provide energy for the pyrolysis reaction, the problems of difficult switching to outdoor combustion high-temperature flue gas and large heat loss are avoided.

[0017] The gas phase product collection pipe connects the outlet of the gas collection internal components of the tubular pyrolysis reactors in the same row, and introduces the pyrolysis gas phase products into the gas phase product condenser.

[0018] The present invention also provides a method for pyrolyzing solid hydrocarbon feedstocks, comprising the following steps:

[0019] Solid hydrocarbon feedstocks are fed into the tubular pyrolysis reactor via feeders. As the feedstocks move downwards within the reactor, they are heated and undergo pyrolysis, releasing gaseous pyrolysis products. These gaseous products flow radially through the moving particle bed, entering the gas collection internals through pores or channels, and then are collected in the gaseous product condenser for cooling and separation. The separated pyrolysis gas and / or external fuel gas are mixed with air and introduced through a regenerative burner for combustion in the heating chamber, providing heat to the pyrolysis reactor. After cooling and heat exchange, the solid products from the pyrolysis reaction are discharged from the reactor via a solid product unloader and enter the downstream processing section. The entire process is continuous.

[0020] The present invention has the following beneficial effects:

[0021] 1. This invention applies the method of "number scaling up" of tubular pyrolysis reactors to the scale-up of industrial reactors. By arranging and combining tubular reactors in a column-and-tube manner to form a column-and-tube pyrolysis reactor, it avoids the problems caused by traditional reactor scale-up methods based on reactor size scaling up, such as decreased heat / mass transfer efficiency, increased operation difficulty, and reduced scale-up effect. Industrial scale-up is easier and operation is simpler.

[0022] 2. The tubular pyrolysis reactor used in this invention is equipped with gas-collecting internal components. This allows for the radial flow of pyrolysis gaseous products through a moving particle bed, moving from the outer high-temperature zone to the inner low-temperature zone. This helps reduce secondary reactions of the gaseous products and achieves selective cracking primarily of heavy components, ultimately improving the yield and quality of the pyrolysis oil. Furthermore, the flow of gaseous products from the high-temperature zone to the low-temperature zone also significantly improves the heat transfer rate.

[0023] 3. The tubular pyrolysis reactor with gas collecting internal components used in this invention realizes radial flow of pyrolysis gaseous products, which can realize the interception of dust in pyrolysis gaseous products by the moving particle bed, realize in-situ filtration and dust removal, and solve the problem of high dust content and easy clogging of pipelines in the oil of pyrolysis products of small particle size solid hydrocarbon feedstocks.

[0024] 4. This invention can utilize the pyrolysis gas produced by the system itself and directly burn and heat it using a regenerative combustion method. Moreover, one heating unit can accommodate multiple tubular pyrolysis reactors. Compared with traditional coke ovens, it can achieve rapid and efficient heat and mass transfer, is more energy-efficient, and has a simpler heating unit. Attached Figure Description

[0025] Figure 1 This is a diagram of the solid hydrocarbon feedstock pyrolysis apparatus for Example 1;

[0026] Figure 2 This is a diagram of the solid hydrocarbon feedstock pyrolysis apparatus for Example 2;

[0027] Figure 3The diagram shows a top view of the pyrolysis apparatus and a layout diagram of the regenerative burner in Example 2.

[0028] Figure 4 The diagram shows a top view of the pyrolysis apparatus and a layout diagram of the regenerative burner in Example 3. Detailed Implementation

[0029] The technical solution of the present invention will be further illustrated below through specific embodiments. Those skilled in the art should understand that the embodiments described are merely illustrative of the present invention and should not be construed as limiting the invention in any way.

[0030] Example 1

[0031] like Figure 1 As shown, a solid hydrocarbon feedstock pyrolysis device includes: a feeder 1, a tubular pyrolysis reactor 2, a regenerative burner 3, a heating chamber 4, a solid product unloader 5, a gas collecting internal component 6, a gas product collecting pipe 7, and a gas product condenser 8. The tubular pyrolysis reactor 2 is formed by combining one tubular pyrolysis reactor, and the tubular pyrolysis reactor is cylindrical in shape, with the gas collecting internal component 6 located at the center of the reactor.

[0032] The gas collecting internal component 6 is cylindrical in shape and has a channel on it that allows gaseous products to pass through. The lower end of the internal component opens into the material layer of the pyrolysis reactor, and the upper end is closed and connected to the gaseous product collection pipe 7, so as to discharge the pyrolysis gaseous products out of the pyrolysis reactor and send them into the gaseous product condenser 8.

[0033] The heating section of the tubular pyrolysis reactor 2 is placed inside the heating chamber 4.

[0034] Heating chamber 4 is an indoor combustion chamber that provides heat for the pyrolysis reaction through the combustion of pyrolysis gas. A tubular pyrolysis reactor is arranged in the heating chamber.

[0035] The regenerative burners 3 are distributed symmetrically on the upper and lower surfaces of the heating chamber 4; the regenerative burners 3 use pyrolysis gas obtained by separating gas phase product condenser 8 as fuel.

[0036] The gas phase product collection pipe 7 is connected to the outlet of the gas collection internal component 6 of the tubular pyrolysis reactor, and introduces the pyrolysis gas phase product into the gas phase product condenser 8.

[0037] Example 2

[0038] like Figure 2 As shown, a solid hydrocarbon feedstock pyrolysis device is provided, the device comprising: a feeder 1, a tubular pyrolysis reactor 2, a regenerative burner 3, a heating chamber 4, a solid product unloader 5, a gas collecting internal component 6, a gas product collecting pipe 7, and a gas product condenser 8.

[0039] The tubular pyrolysis reactor 2 is formed by combining 8 tubular pyrolysis reactors. The tubular pyrolysis reactors are cylindrical in shape, and each reactor has a gas collecting internal component 6 at its center.

[0040] The gas collecting internal component 6 is cylindrical in shape and has a channel on it that allows gaseous products to pass through. The lower end of the internal component opens into the material layer of the pyrolysis reactor, and the upper end is closed and connected to the gaseous product collection pipe 7, so as to discharge the pyrolysis gaseous products out of the pyrolysis reactor and send them into the gaseous product condenser 8.

[0041] The heating section of the tubular pyrolysis reactor 2 is located inside the heating chamber 4, and eight tubular pyrolysis reactors are arranged in a tubular configuration within the heating chamber 4. Figure 3 As shown, four tubular pyrolysis reactors form one row, and two rows are staggered in the heating chamber.

[0042] Heating chamber 4 is an indoor combustion chamber that provides heat for the pyrolysis reaction through natural gas combustion. Eight tubular pyrolysis reactors can be arranged in the heating chamber.

[0043] like Figure 3 As shown, the regenerative burners 3 are distributed symmetrically above and below the heating chamber 4, and use natural gas as fuel.

[0044] The gas phase product collection pipe 7 connects the outlets of the gas collection internal components 6 of the four tubular pyrolysis reactors in the same row, and introduces the pyrolysis gas phase products into the gas phase product condenser 8.

[0045] Example 3

[0046] like Figure 2 As shown, a solid hydrocarbon feedstock pyrolysis device is provided, the device comprising: a feeder 1, a tubular pyrolysis reactor 2, a regenerative burner 3, a heating chamber 4, a solid product unloader 5, a gas collecting internal component 6, a gas product collecting pipe 7, and a gas product condenser 8.

[0047] The tubular pyrolysis reactor 2 is formed by combining 8 tubular pyrolysis reactors. The tubular pyrolysis reactors are cylindrical in shape, and each reactor has a gas collecting internal component 6 at its center.

[0048] The gas collecting internal component 6 is cylindrical in shape and has pores that allow gaseous products to pass through. The lower end of the internal component opens into the material layer of the pyrolysis reactor, and the upper end is closed and connected to the gaseous product collection pipe 7 to guide the pyrolysis gaseous products out of the pyrolysis reactor and into the gaseous product condenser 8.

[0049] The heating section of the tubular pyrolysis reactor 2 is located inside the heating chamber 4, and eight tubular pyrolysis reactors are arranged in a tubular configuration within the heating chamber 4. Figure 4 As shown, four tubular pyrolysis reactors form one row, and two rows are staggered in the heating chamber.

[0050] Heating chamber 4 is an indoor combustion chamber that provides heat for the pyrolysis reaction through the combustion of gasified coal gas. Eight tubular pyrolysis reactors can be arranged in the heating chamber.

[0051] like Figure 4 As shown, the regenerative burners 3 are distributed symmetrically on the side of the heating chamber 4, using gasified coal gas as fuel.

[0052] The gas phase product collection pipe 7 connects the outlets of the gas collection internal components 6 of the four tubular pyrolysis reactors in the same row, and introduces the pyrolysis gas phase products into the gas phase product condenser 8.

[0053] Example 4

[0054] A solid hydrocarbon feedstock pyrolysis apparatus, the apparatus comprising: a feeder 1, a tubular pyrolysis reactor 2, a regenerative burner 3, a heating chamber 4, a solid product unloader 5, a gas collecting internal component 6, a gas product collecting pipe 7, and a gas product condenser 8.

[0055] The tubular pyrolysis reactor 2 is formed by combining 16 tubular pyrolysis reactors. The tubular pyrolysis reactors are cylindrical in shape, and each reactor has a gas collecting internal component 6 at its center.

[0056] The gas collecting internal component 6 is cylindrical in shape and has pores that allow gaseous products to pass through. The lower end of the internal component opens into the material layer of the pyrolysis reactor, and the upper end is closed and connected to the gaseous product collection pipe 7 to guide the pyrolysis gaseous products out of the pyrolysis reactor and into the gaseous product condenser 8.

[0057] The heating section of the tubular pyrolysis reactor 2 is placed inside the heating chamber 4, and 16 tubular pyrolysis reactors are arranged in a tubular manner in the heating chamber 4.

[0058] Heating chamber 4 is an indoor combustion chamber that provides heat for the pyrolysis reaction through the combustion of pyrolysis gas. Up to 16 tubular pyrolysis reactors can be arranged in the heating chamber.

[0059] The regenerative burners 3 are distributed symmetrically on the upper and lower surfaces of the heating chamber 4; the regenerative burners 3 use pyrolysis gas obtained by separating gas phase product condenser 8 as fuel.

[0060] The gas phase product collection pipe 7 connects to the outlet of the gas collection internal component 6 of the tubular pyrolysis reactor in the same row, and introduces the pyrolysis gas phase product into the gas phase product condenser 8.

[0061] Example 5

[0062] A pyrolysis method based on a solid hydrocarbon feedstock pyrolysis device, the method comprising the following steps:

[0063] Solid hydrocarbon feedstock is fed into eight tubular pyrolysis reactors via eight feeders 1. As the feedstock moves downwards within the tubular pyrolysis reactors 2, it is heated and undergoes a pyrolysis reaction, releasing pyrolysis gaseous products. These gaseous products flow radially through the moving particle bed and enter the gas collection internals 6 through pores. The outlets of the gas collection internals of each of the four parallel tubular pyrolysis reactors are then connected to the gaseous product collection pipes 7. The pyrolysis gaseous products are collected in the gaseous product condenser 8 for cooling and separation. The separated pyrolysis gas is mixed with air and introduced through a regenerative burner 3, where it is burned as fuel in the heating chamber 4 to heat the pyrolysis reactors. After cooling and heat exchange, the solid products from the pyrolysis reaction are discharged from the pyrolysis reactors via a solid product unloader 5 and enter the downstream processing section. The entire process is continuous.

[0064] In this embodiment, compared with the pyrolysis device without gas collection internal components in the tubular pyrolysis reactor, the heat transfer rate of the present invention is increased by more than 1 times, the pyrolysis oil yield is increased by more than 1 times, and the dust content is reduced to below 0.2%.

[0065] Example 6

[0066] A pyrolysis method based on a solid hydrocarbon feedstock pyrolysis device, the method comprising the following steps:

[0067] Solid hydrocarbon feedstock is fed into 16 tubular pyrolysis reactors via 16 feeders 1. As the feedstock moves downwards within the tubular pyrolysis reactors 2, it is heated and undergoes a pyrolysis reaction, releasing pyrolysis gaseous products. These gaseous products flow radially through the moving particle bed and enter the gas collection internals 6 through pores. The outlets of the gas collection internals of each of the eight parallel tubular pyrolysis reactors are then connected to the gaseous product collection pipes 7. The pyrolysis gaseous products are collected in the gaseous product condenser 8 for cooling and separation. The separated pyrolysis gas and externally supplied natural gas are mixed with air and introduced through a regenerative burner 3, burning as fuel in the heating chamber 4 to heat the pyrolysis reactors. After cooling and heat exchange, the solid products from the pyrolysis reaction are discharged from the pyrolysis reactors through the solid product unloader 5 and enter the downstream processing section. The entire process operates continuously.

[0068] In this embodiment, compared with the pyrolysis device without gas collection internal components in the tubular pyrolysis reactor, the heat transfer rate of the present invention is increased by more than 1.5 times, the pyrolysis oil yield is increased by more than 1 times, and the dust content is reduced to below 0.1%.

[0069] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. For those skilled in the art, other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A pyrolysis apparatus for solid hydrocarbon feedstock, characterized in that, The device includes a feeder (1), a tubular pyrolysis reactor (2), a regenerative burner (3), a heating chamber (4), a solid product unloader (5), a gas collecting internal component (6), a gas product collecting pipe (7), and a gas product condenser (8); the tubular pyrolysis reactor (2) is formed by combining 8 tubular pyrolysis reactors, the tubular pyrolysis reactors are cylindrical in shape, and a gas collecting internal component (6) is set in the center of each reactor. The gas collecting internal component (6) is cylindrical in shape. The gas collecting internal component is provided with pores that allow gaseous products to pass through. The lower end of the gas collecting internal component is open in the material layer of the pyrolysis reactor, and the upper end is closed and connected to the gaseous product collection pipe (7) to export the pyrolysis gaseous products out of the pyrolysis reactor and send them into the gaseous product condenser (8). The heating section of the tubular pyrolysis reactor (2) is placed in the heating chamber (4). Eight tubular pyrolysis reactors are arranged in the heating chamber (4) in a tubular manner; every four tubular pyrolysis reactors form one row, and two rows are staggered in the heating chamber. The regenerative burners (3) are distributed symmetrically on the upper and lower surfaces of the heating chamber (4); The gas phase product collection pipe (7) connects the outlets of the gas collection internal components (6) of the four tubular pyrolysis reactors in the same row, and introduces the pyrolysis gas phase products into the gas phase product condenser (8).

2. The process method of a solid hydrocarbon feedstock pyrolysis device according to claim 1, characterized in that, The process includes the following steps: solid hydrocarbon feedstock is fed into eight tubular pyrolysis reactors through eight feeders (1). The feedstock is heated and undergoes pyrolysis reaction as it moves downward in the tubular pyrolysis reactor (2), releasing pyrolysis gaseous products. The gaseous products flow radially through the moving particle bed and enter the gas collection internal component (6) through the pores. Then, the outlet of the gas collection internal component of each of the four parallel tubular pyrolysis reactors is connected to the gaseous product collection pipe (7). The pyrolysis gaseous products are collected in the gaseous product condenser (8) for cooling and separation. The pyrolysis gas obtained by separation is mixed with air and introduced through the regenerative burner (3) to burn as fuel in the heating chamber (4) to heat the pyrolysis reactor. The solid products after the pyrolysis reaction are cooled and heat exchanged and then discharged from the pyrolysis reactor through the solid product unloader (5) and enter the downstream processing section. The whole process is continuous.

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