Method and apparatus for treating pyrolysis product

Abstract

The application relates to a method and an apparatus for treating a pyrolysis product, in which the pyrolysis product (1) is condensed at a condensation step to form a condensed product phase (3), an aqueous phase and a pyrolysis liquid phase are separated from the condensed product phase, at least a part of the aqueous phase (6) is recirculated to the condensation step to condense the pyrolysis product, and the pyrolysis liquid phase (7) is recovered.

Description

[0001] METHOD AND APPARATUS FOR TREATING PYROLYSIS PRODUCT

[0002] FIELD

[0003] The application relates to a method defined in claim 1 and an apparatus defined in claim 10 for treating a pyrolysis product .

[0004] BACKGROUND

[0005] Different products can be produced from different raw materials in pyrolysis processes and catalytic pyrolysis processes . Further, fluidized bed reactors can be used for producing pyrolysis products .

[0006] OBJECTIVE

[0007] Further, the obj ective is to disclose a new-type method and apparatus for treating a pyrolysis product, such as pyrolysis product vapor, after a pyrolysis . Further, the obj ective is to upgrade the pyrolysis product . Further, the objective is to improve a condensation after the pyrolysis .

[0008] SUMMARY

[0009] The method and apparatus are characterized by what are presented in the claims .

[0010] The method for treating a pyrolysis product comprises condensing the pyrolysis product at a condensation step to form a condensed product phase, separating an aqueous phase and a pyrolysis liquid phase from the condensed product phase, and recirculating at least a part of the aqueous phase to the condensation step to condense the pyrolysis product .

[0011] The apparatus for treating a pyrolysis product comprises at least one condensing apparatus for condensing the pyrolysis product to form a condensed product phase, at least one separating device for separating an aqueous phase and a pyrolysis liquid phase from thecondensed product phase, and at least one recirculation means for recirculating at least a part of the aqueous phase to the condensing apparatus to condense the pyrolysis product .

[0012] BRIEF DESCRIPTION OF THE DRAWING

[0013] The accompanying drawings, which are included to provide a further understanding of the invention and constitute a part of this specification, illustrate some embodiments of the invention and together with the description help to explain the principles of the invention. In the drawings :

[0014] Fig. 1 is a flow chart illustration of a process according to one embodiment, and

[0015] Fig . 2 is a flow chart illustration of a process according to another embodiment .

[0016] DETAILED DESCRIPTION

[0017] In a method for treating a pyrolysis product, the pyrolysis product is condensed at a condensation step to form a condensed product phase, an aqueous phase and a pyrolysis liquid phase are separated from the condensed product phase, at least a part of the aqueous phase is recirculated to the condensation step to condense the pyrolysis product, and the pyrolysis liquid phase is recovered.

[0018] An apparatus for treating a pyrolysis product comprises at least one condensing apparatus for condensing the pyrolysis product to form a condensed product phase, at least one separating device for separating an aqueous phase and a pyrolysis liquid phase from the condensed product phase, and at least one recirculation means for recirculating at least a part of the aqueous phase to the condensing apparatus to condense the pyrolysis product . In one embodiment, the apparatus comprises at least one outlet, pipe, recovery device, othersuitable element or any combination thereof for recovering the pyrolysis liquid phase .

[0019] Some embodiments of the method and the apparatus are shown in Fig. 1.

[0020] In this context, the pyrolysis product means any product which is formed by the pyrolysis . Preferably, the pyrolysis product is in a gaseous form after the reactor. The pyrolysis product can be formed from any suitable raw material .

[0021] In this context, the raw material means any raw material, feed or feed material which is treated in a reactor of the process, e . g. in a pyrolysis, and from which the pyrolysis product can be formed. The raw material may comprise wood-based material, biomass, woody biomass, agrobiomass, waste material, plastic-based material, residual material, side stream material, other suitable material or their combinations . Further, the raw material can comprise also other materials . The raw material may comprise one or more components . The raw material component may be recycled material, residue material, waste material or virgin material or their combinations . In one embodiment, the raw material is formed from recycled material, waste material, residue material and their combinations . In one embodiment, the raw material is biomass . In one embodiment, the pyrolysis product is formed from biobased raw material, e . g. biomass or other biobased material, by the pyrolysis .

[0022] Preferably, the raw material may be treated by the pyrolysis in the pyrolysis reactor to form a pyrolysis product . In one embodiment, the pyrolysis is a catalytic pyrolysis, e . g. a catalytic fast pyrolysis . In one embodiment, the pyrolysis reactor comprises a catalyst . Any suitable catalyst may be used in the reactor . In one embodiment, the reactor is a fast pyrolysis reactor . In one embodiment, the reactor is a fluidized bed reactor . In one embodiment, the reactor is a fluidizedbed reactor in which any suitable bed material may be used, e . g. inert fluidizable material, inert granular material, fluidizable material with catalytic properties or other suitable bed material . Any suitable reactor can be used in the process . In one embodiment, the raw material can be fed using a feeder to the reactor . Any suitable feeder can be used in feeding, e . g. a screw feeder, extruder, gravimetric feeder, pneumatic feeder or their combinations .

[0023] In one embodiment, the pyrolysis product is formed by a catalytic pyrolysis in a pyrolysis reactor. In one embodiment, the pyrolysis product is formed by a catalytic fast pyrolysis in the pyrolysis reactor . In one embodiment, the pyrolysis product is formed by the catalytic fast pyrolysis in the pyrolysis reactor, and the pyrolysis product is supplied from the pyrolysis reactor to the condensation step, such as to the condensing apparatus . In one embodiment, the apparatus comprises at least one pyrolysis reactor, in which the pyrolysis product is formed by the catalytic pyrolysis . In one embodiment, the apparatus comprises at least one pyrolysis reactor, in which the pyrolysis product is formed by the catalytic fast pyrolysis . In one embodiment, the apparatus comprises at least one pyrolysis reactor, in which the pyrolysis product is formed by the catalytic fast pyrolysis, and at least one line for supplying the pyrolysis product from the pyrolysis reactor to the condensing apparatus . In one embodiment, the pyrolysis is carried out at temperature of 300 - 600 °C, in one embodiment at temperature of 400 - 580 °C, and in one embodiment at temperature of 450 - 550 °C .

[0024] The pyrolysis product is condensed at the condensation step to form the condensed product phase . In one embodiment, the pyrolysis product is condensed after the pyrolysis reactor . The pyrolysis product is condensed, preferably to form a liquid product, i . e . thecondensed phase . In one embodiment, the pyrolysis product is supplied to at least one condensing apparatus in which the product is cooled and condensed. In one embodiment, the apparatus comprises one condensing apparatus . In one embodiment, the apparatus comprises at least two condensing apparatuses . In one embodiment, the product is supplied from the pyrolysis reactor to the condensing apparatus to form the condensed product phase . In one embodiment, the apparatus comprises at least one nozzle for feeding the pyrolysis product to the condensing apparatus . Any suitable condensing apparatus can be used for condensing the pyrolysis product . In one embodiment, the condensing apparatus is a scrubber, quench, condenser or any combination thereof . In one embodiment, the scrubber is a counterflow scrubber or a concurrent scrubber . In one embodiment, the condensation is carried out in one or more condensing apparatuses, e . g. a scrubber, quench, condenser or any combination thereof .

[0025] In one embodiment, the condensation is carried out in one or more steps . In one embodiment, the condensation is carried out in one step . In one embodiment, the condensation is carried out at least two steps . In one embodiment, the apparatus comprises more than one condensing apparatus, in which the condensation is carried out . In one embodiment, the apparatus comprises one condensing apparatus .

[0026] In one embodiment, the pyrolysis product is condensed using the aqueous phase in a first and / or second condensation step . In one embodiment, the pyrolysis product is condensed using the aqueous phase in the first condensation step . In one embodiment, the pyrolysis product is condensed using the aqueous phase in the second condensation step . In one embodiment, the pyrolysis product is condensed using the aqueous phase in the first and second condensation steps . In one embodiment, the first and / or second condensing apparatus is arrangedto condense the pyrolysis product using the aqueous phase .

[0027] The aqueous phase and the pyrolysis liquid phase are separated from the condensed product phase . The condensed product phase may be a two-phase liquid. In one embodiment, the condensed product phase is supplied to at least one separating device in which the aqueous and pyrolysis liquid phases are separated. In one embodiment, the apparatus comprises one separating device . In one embodiment, the apparatus comprises more than one separating device . Any suitable separating device can be used for separating the aqueous and pyrolysis liquid phases from the condensed product phase . In one embodiment, the separating device is a separator, filter, centrifuge, evaporator, decanter or any combinations thereof . In one embodiment, the aqueous phase and the pyrolysis liquid phase are separated by separating, filtrating, centrifuging, evaporating, decanting or any combinations thereof .

[0028] In one embodiment, the condensed product phase is formed in the condensing apparatus, and the aqueous phase and pyrolysis liquid phase are separated from the condensed product phase in the separating device .

[0029] In this context, the aqueous phase means any aqueous phase or fraction which is separated from the condensed product phase . Preferably the aqueous phase is liquid, e . g. one-phase liquid. In one embodiment, the aqueous phase comprises at least water and water-soluble compounds or components, e . g. hydrocarbons . In one embodiment, pH of the aqueous phase is 2 - 5, e . g. 2.5 -4.5.

[0030] In this context, the pyrolysis liquid phase means any liquid product phase or fraction which is separated from the condensed product phase . In one embodiment, the pyrolysis liquid phase comprises at least hydrocarbons .The aqueous phase is recirculated to the condensation step . Preferably, at least a part of the aqueous phase is recirculated to the condensation step to condense and / or cool the pyrolysis product . Further, the apparatus comprises at least one recirculation means for recirculating the aqueous phase . Any suitable recirculation means can be used in the process . In one embodiment, the recirculation means may comprise pipes, lines, pumps, compressors and other suitable devices and equipments for recirculating the aqueous phase . In one embodiment, the apparatus comprises at least one line, e . g. line, channel or the like, for recirculating the aqueous phase, preferably for recirculating to the condensing apparatus . In one embodiment, a flow rate of the aqueous phase is adjusted, e . g. in the recirculation means, e . g. in the line .

[0031] In one embodiment, the aqueous phase is supplied by at least one nozzle to the condensation step . In one embodiment, the aqueous phase is supplied to the nozzle (s) of the condensation step. In one embodiment, the apparatus comprises at least one nozzle for supplying the aqueous phase to the condensing apparatus . In one embodiment, the apparatus comprises more than one nozzle . In one embodiment, the apparatus comprises one or more nozzles for feeding the agueous phase to the condensing apparatus . In one embodiment, a flow rate of the aqueous phase is adjusted, preferably for adjusting a feed to the nozzle . In one embodiment, a flow rate of the aqueous phase is adjusted to a desired level for supplying the aqueous phase with the desired flow rate to the nozzle . When the aqueous phase, preferably one-phase aqueous phase, is fed to the nozzle (s) throughout the run, less changes take place during the operation . Further, an improved condensation, e . g. scrubbing, coverage can be achieved against the gas stream, becausethere is easier droplet formation at the nozzle ( s) for the aqueous phase .

[0032] In one embodiment, temperature of the aqueous phase is adjusted, preferably before supplying the aqueous phase to the condensation. In one embodiment, the temperature of the aqueous phase is adjusted such that the temperature is suitable for the condensation. In one embodiment, the apparatus comprises at least one heat exchanger to adjust the temperature of the aqueous phase . In one embodiment, the heat exchanger is a part of the condensation step .

[0033] In one embodiment, the aqueous phase is cooled, preferably before supplying to the condensation step . The aqueous phase may be cooled using the cooling device or heat exchanger . Further, the apparatus comprises at least one cooling device or heat exchanger for cooling the aqueous phase . In one embodiment, the cooling device can be a heat exchanger, indirect cooling device, direct heat exchange device, or any combinations thereof .

[0034] In one embodiment, a part of the pyrolysis liquid phase is supplied to the condensation step, preferably to the desired condensation step . In one embodiment, the condensation is carried out in at least two condensation steps, and the pyrolysis liquid phase is supplied to the first condensation step . In one embodiment, the condensation is carried out in at least two condensation steps, and the pyrolysis liquid phase, preferably at least a part of the pyrolysis liquid phase, is supplied to the first condensation step and the aqueous phase, preferably at least a part of the aqueous phase, is supplied to the second condensation step . In one embodiment, the pyrolysis liquid phase is cooled before supplying to the condensation step . In one embodiment, 70 - 99 vol-% of the pyrolysis liquid phase is recirculated to the desired condensation step . In one embodiment, the apparatus comprises at least twocondensing apparatuses, in which the condensation is carried out using the pyrolysis liquid phase in a first condensing apparatus and using the aqueous phase in a second condensing apparatus .

[0035] In one embodiment, the apparatus comprises an adjusting device or a control device for adjusting temperature . In one embodiment, the apparatus comprises a control device . In one embodiment, the apparatus comprises a control device comprising the adjusting device for adjusting the temperature .

[0036] In one embodiment, a second part of the aqueous phase is stored, e . g. in a tank or container . Then the stored aqueous phase may be used later in the condensation step and / or other process steps . In one embodiment, the stored aqueous phase is used to start the condensation in the condensation step and / or in the condensing apparatus . Alternatively, a desired component or components may be recovered from the aqueous phase .

[0037] The pyrolysis liquid phase may be recovered. In one embodiment, the pyrolysis liquid phase is stored. Then one-phase pyrolysis liquid can be produced and / or stored for downstream operations or transport . When the pyrolysis liquid phase is recovered without contact with the warm pyrolysis product gas, an effect of heat can be decreased in the pyrolysis liquid phase, and thus undesired problems, e . g . ageing, may be avoided in the product composition.

[0038] In one embodiment, a remaining pyrolysis gas is recovered in the condensation step and / or supplied from the condensation step to a next process step . In one embodiment, the remaining pyrolysis gas is recovered in the condensation step . The remaining pyrolysis gas after the condensation step may be conveyed to the next process step . In one embodiment, the remaining gas is condensed in an additional condensation step, such as in the second condensation step . In one embodiment, theremaining pyrolysis gas is recovered in the condensation step and supplied from the condensation step to the next process step . In one the apparatus comprises at least one outlet, line or any combination thereof for recovering the remaining pyrolysis gas from the condensing apparatus and / or supplying remaining pyrolysis gas from the condensing apparatus to a next device . In one the apparatus comprises at least one outlet, line or any combination thereof for recovering the remaining pyrolysis gas from the condensing apparatus .

[0039] In one embodiment, the method and apparatus are based on a continuous process .

[0040] Thanks to the invention, the pyrolysis product can be treated effectively after the pyrolysis . By means of the invention, the condensation of the pyrolysis product and controllability of the condensation can be improved, when only the aqueous phase is recirculated. The aqueous phase washes the inlet area of the condensation, such as nozzle (s) , and decreases coking and / or tar forming in the condensation, e . g. in the first condensation step . If the whole condensed product phase would be recirculated to the condensation, tar forming and blockage risk increase in the condensation step, especially at the inlet of the condensing apparatus, and further quality of the product decreases . Further, the blockages cause breaks and stopping in the process and increase need for maintenance . By means of the invention, the condensation may be performed easily and effectively. Further, heat exposure of the pyrolysis liquid can be minimized, and thereby ageing risk can be decreased. This increases efficiency in the whole process, and problems can be avoided in the process .

[0041] The method and apparatus offer a possibility to treat the pyrolysis product easily, and energy- and cost-effectively in the pyrolysis process . The present invention provides an industrially applicable, simpleand affordable way to produce the treated pyrolysis product with good properties from different raw materials . The method and apparatus are easy and simple to realize in connection with production processes .

[0042] EXAMPLES

[0043] Fig. 1 presents some embodiments of the process for treating a pyrolysis product and for producing a treated pyrolysis product . The pyrolysis product is formed by a catalytic pyrolysis, e . g. by a catalytic fast pyrolysis, in a pyrolysis reactor . A raw material, e . g. biomass, is fed to the pyrolysis reactor . The raw material is pyrolyzed to form the pyrolysis product . The pyrolysis product is condensed to form a condensed product .

[0044] The apparatus of Fig. 1 comprises condensing apparatus (2 ) , separating device (5) and recirculation means . Further, the apparatus comprises one or more nozzles for feeding the pyrolysis product ( 1 ) and / or an agueous phase ( 6) to the condensing apparatus . Further, according to an example, the apparatus may comprise outlet, pipe, recovery device, other suitable recovery element or any combination thereof for recovering the pyrolysis liquid phase (7 ) and / or a remaining pyrolysis gas (4 ) from the condensing apparatus .

[0045] The pyrolysis product vapor ( 1 ) is supplied to the condensing apparatus (2 ) , which is scrubber, quench or condenser, in which the pyrolysis product vapor is cooled and condensed to form a condensed product phase (3) , preferably a two-phase liquid. An aqueous phase and a pyrolysis liquid phase are separated in the separating device (5) . At least a part of the aqueous phase ( 6) , preferably one-phase liquid, is recirculated using the recirculation means from the separating device back to the condensing apparatus, preferably to the nozzles of the condensing apparatus . The separated pyrolysis liquidphase (7 ) can be recovered. A temperature of the aqueous phase may be adjusted, preferably before supplying the aqueous phase to the condensation, e . g. using a heat exchanger . A remaining pyrolysis gas (4 ) from the condensing apparatus may be recovered and / or supplied to a next process step or device .

[0046] Example 1

[0047] In this example, a pyrolysis product is formed by a catalytic fast pyrolysis in a pyrolysis reactor and the pyrolysis product is treated after the pyrolysis reactor according to Fig. 1.

[0048] A raw material, which is lignocellulose-based biomass, is fed to the catalytic pyrolysis reactor . The raw material is pyrolyzed at temperature of 450 - 550 °C to form the pyrolysis product vapor .

[0049] The pyrolysis product vapor ( 1 ) is supplied to a condensing apparatus (2 ) , which is scrubber, in which the pyrolysis product vapor is cooled and condensed to form a condensed product phase (3) . The condensed product phase is a two-phase liquid. An aqueous phase and a pyrolysis liquid phase are separated in a separator (5) . At least a part of the aqueous phase ( 6) may be recirculated from the separator back to the condensing apparatus to condense the pyrolysis product vapor .

[0050] According to the example, pH of the aqueous phase is between 2.8 - 4, and water content of the aqueous phase is 75 - 95 wt% . Further, the aqueous phase may comprise organic acids, phenols, alcohols, aldehydes, aromatic hydrocarbons and / or other hydrocarbons .

[0051] Example 2

[0052] In this example, a pyrolysis product is treated after a pyrolysis reactor according to Fig. 2. The pyrolysis product vapor ( 1 ) is supplied to the condensation stage comprising two condensing apparatuses (2a,2b) , which may be scrubber or other condensing apparatus and in which the pyrolysis product vapor is cooled and condensed to form a condensed product phase (3) . A pyrolysis gas (4 ) from the condensing apparatus is recovered and / or supplied to a next process step or device . The condensed product phase (3) is a two-phase liquid. An aqueous phase ( 6) and a pyrolysis liquid phase (7 ) are separated from the condensed product phase in a separator (5) . At least a part of the aqueous phase ( 6) is recirculated from the separator to the second condensing apparatus (2b) . Further, a part of the pyrolysis liquid phase, e . g. 70 - 99 vol-%, of the pyrolysis liquid phase is supplied to the first condensation apparatus (2a) . The condensation is carried out using the pyrolysis liquid phase in the first condensation step and using the aqueous phase in the second condensation step .

[0053] According to one example, the pyrolysis liquid phase is cooled before supplying to the condensation step .

[0054] The reactors, condensing apparatuses, separating devices, recirculation means, heat exchangers, and other devices and equipment of the process used in Fig.

[0055] 1 are known per se in the art, and therefore they are not described in any more detail in this context .

[0056] The method and apparatus are suitable in different embodiments for treating different pyrolysis products and for producing desired final products from different raw materials .

[0057] The invention is not limited merely to the examples referred to above; instead many variations are possible within the scope of the inventive idea defined by the claims .

Claims

CLAIMS1. A method for treating a pyrolysis product, characterized in that the method comprises- condensing the pyrolysis product ( 1 ) at a condensation step to form a condensed product phase (3) , - separating an aqueous phase and a pyrolysis liquid phase from the condensed product phase,- recirculating at least a part of the aqueous phase ( 6) to the condensation step to condense the pyrolysis product, and- recovering the pyrolysis liquid phase (7 ) .

2. The method according to claim 1, characterized in that the aqueous phase ( 6) is supplied by at least one nozzle to the condensation step .

3. The method according to claim 1 or 2, characterized in that the condensation is carried out in a scrubber, quench, condenser or any combination thereof .

4. The method according to any one of claims 1 to 3, characterized in that the condensation is carried out in one or more steps .

5. The method according to any one of claims 1 to 4, characterized in that the pyrolysis product ( 1 ) is condensed using the aqueous phase ( 6) in a first and / or second condensation step .

6. The method according to any one of claims 1 to 5, characterized in that the condensation is carried out in at least two condensation steps, and at least a part the pyrolysis liquid phase (7 ) is supplied to a first condensation step and at least a part of the aqueous phase ( 6) is supplied to a second condensation step .

7. The method according to any one of claims 1 to 6, characterized in that the pyrolysis product ( 1 ) is formed by a catalytic fast pyrolysis in a pyrolysis reactor, and the pyrolysis product is supplied from the pyrolysis reactor to the condensation step .8 . The method according any one of claims 1 to 7, characterized in that the pyrolysis product ( 1 ) is formed from biobased raw material by a pyrolysis .

9. The method according to any one of claims 1 to 8, characterized in that a remaining pyrolysis gas (4 ) is recovered in the condensation step and / or supplied from the condensation step to a next process step .

10. An apparatus for treating a pyrolysis product, characterized in that the apparatus comprises- at least one condensing apparatus (2 ) for condensing the pyrolysis product ( 1 ) to form a condensed product phase (3) ,- at least one separating device (5) for separating an aqueous phase and a pyrolysis liquid phase from the condensed product phase (3) , and- at least one recirculation means for recirculating at least a part of the aqueous phase ( 6) to the condensing apparatus (2 ) to condense the pyrolysis product .

11. The apparatus according to claim 10, characterized in that the apparatus comprises at least one nozzle for supplying the aqueous phase ( 6) to the condensing apparatus (2) .

12. The apparatus according to claim 10 or 11, characterized in that the condensing apparatus (2 ) is a scrubber, quench, condenser or any combination thereof .

13. The apparatus according to any one of claims 10 to 12, characterized in that the apparatus comprises more than one condensing apparatus (2 ) , in which the condensation is carried out .

14. The apparatus according to any one of claims 10 to 13, characterized in that the first and / or second condensing apparatus (2 ) is arranged to condense the pyrolysis product ( 1 ) using the aqueous phase ( 6) .

15. The apparatus according to any one of claims 10 to 14, characterized in that the apparatus comprises at least two condensing apparatuses (2a, 2b) ,in which the condensation is carried out using the pyrolysis liquid phase (7 ) in a first condensing apparatus (2a) and using the aqueous phase ( 6) in a second condensing apparatus (2b) .

16. The apparatus according to any one of claims 10 to 15, characterized in that the apparatus comprises at least one pyrolysis reactor, in which the pyrolysis product (1 ) is formed by a catalytic fast pyrolysis, and at least one line for supplying the py-rolysis product from the pyrolysis reactor to the condensing apparatus (2) .

17. The apparatus according to any one of claims 10 to 16, characterized in that the apparatus comprises at least one outlet, line or any combination thereof for recovering a remaining pyrolysis gas (4 ) from the condensing apparatus (2 ) and / or supplying the remaining pyrolysis gas from the condensing apparatus to a next device .

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