Carbon Conversion Process with Rapid Catalyst Separation
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Solution Overview
Problem
Existing processes for converting carbon-based energy carrier materials to liquid or gaseous fuels require high reaction temperatures, leading to deterioration of products and reduced yield, with bio-oil of poor quality necessitating extensive treatment.
Innovation Solution
A process involving contacting carbon-based energy carrier materials with a particulate catalyst at temperatures between 200° C. and 450° C., preferably between 250° C. and 350° C., followed by rapid separation of vapor phase reaction products and quenching to below 200° C. to minimize degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high reaction temperatures are used to convert carbon-based energy carrier material, then the conversion reaction proceeds, but the reaction products deteriorate and are converted to gas, char and coke
Solution Approach 1:
The invention changes the temperature parameter from conventional high temperatures (>450°C) to lower temperatures (200-450°C, preferably 250-350°C). This parameter change allows the conversion reaction to proceed while minimizing the formation of gas, char and coke, thereby improving bio-oil quality without sacrificing conversion efficiency
Solution Approach 2:
The invention implements rapid separation of reaction products from the catalyst within 10 seconds after reaction. This rushing through the process prevents prolonged exposure of products to high temperatures and catalyst surfaces, thereby avoiding further degradation and coke formation
2Productivity
If high reaction temperatures are used, then the conversion reaction proceeds, but the exposure time of reaction products to elevated temperatures reduces yield
Solution Approach 1:
The invention changes the temperature parameter to a lower range (200-450°C) that maintains adequate conversion rate while significantly reducing thermal degradation of products, thereby preserving yield
Solution Approach 2:
The invention implements preliminary rapid separation of reaction products from the catalyst within 10 seconds after reaction completion. This preliminary action prevents further unwanted reactions and minimizes product loss before the products can degrade
3Productivity
If conventional processes are used, then conversion occurs, but bio-oil quality is poor and requires extensive costly treatment
Solution Approach 1:
The invention changes the temperature parameter from conventional high temperatures to lower temperatures (250-350°C), which fundamentally alters the reaction pathway to produce higher quality bio-oil with fewer contaminants, reducing subsequent treatment requirements
Solution Approach 2:
The invention implements rapid quenching of reaction products to below 200°C within 10 seconds after reaction. This rapid cooling freezes the reaction products in their desired state, preventing further degradation and coke formation that would otherwise require extensive treatment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces product degradation, improves the quality of bio-oil, and increases the yield of the reaction process by maintaining reaction conditions at lower temperatures and short exposure times.
Implementation Method 1
contacting the carbon-based energy carrier material with a particulate catalyst material converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C.
Implementation Method 2
separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed
Implementation Method 3
quenching the reaction products to a temperature below 200° C.
Data Source
AI summary
A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.