Fluidized-Bed Pyrolysis Coke Particles for Carbon Deposition Control
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Solution Overview
Problem
Existing hydrocarbon pyrolysis methods face challenges in efficiently producing larger pyrolysis coke particles with controlled size distributions and high commercial value, leading to carbon deposition on reactor surfaces and operational inefficiencies.
Innovation Solution
A method involving a fluidized bed pyrolysis process with controlled conditions, including seed particle introduction and gas/solids separation, to form pyrolysis coke particles with a targeted size distribution and composition, minimizing deposition on reactor surfaces and maximizing hydrogen generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pyrolysis methods are used, then hydrogen is produced, but carbon deposits on reactor surfaces causing operational inefficiencies
Solution Approach 1:
The patent converts the harmful carbon byproduct into a valuable product by introducing seed particles that serve as carriers for carbon deposition. The carbon that would otherwise deposit on reactor surfaces is redirected to deposit on seed particles, forming pyrolysis coke particles with controlled size distributions suitable for commercial applications.
Solution Approach 2:
Seed particles act as intermediaries between the hydrocarbon feed and the reactor surfaces. They provide alternative deposition sites for carbon, preventing direct carbon deposition on reactor surfaces while enabling controlled formation of pyrolysis coke particles with desired properties.
2Manufacturing precision
If pyrolysis methods forming carbon black are used, then small particles (1.0 μm or smaller) are produced, but larger particles with higher commercial value cannot be obtained
Solution Approach 1:
The patent changes key parameters including seed particle size (ranging from fine to coarse), pyrolysis temperature, and residence time to produce pyrolysis coke particles with controlled size distributions. By adjusting these parameters, particles in various size ranges can be produced to meet different application requirements.
Solution Approach 2:
The patent segments the particle formation process by using seed particles of different sizes and introducing them at different rates. This allows independent control of particle size distribution characteristics, enabling production of particles suitable for multiple applications simultaneously.
3Stability of the object's composition
If batch mode fluidized bed pyrolysis is used, then uniform particles are formed, but continuous production and operational stability are compromised
Solution Approach 1:
The patent implements continuous operation by continuously introducing seed particles, hydrocarbon feed, and heating the fluidized bed. This maintains steady-state conditions that ensure both particle uniformity and continuous production capability, eliminating the interruptions inherent in batch processing.
Solution Approach 2:
The patent employs feedback control mechanisms to monitor and adjust operating parameters such as seed particle addition rate, hydrocarbon feed rate, and heating power. This maintains stable fluidized bed conditions and consistent particle properties during continuous operation.
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
The method produces pyrolysis coke particles with desirable properties for various applications, such as proppants and carbon electrodes, while reducing carbon deposition on reactor surfaces, enhancing operational stability, and enabling continuous hydrogen production.
Implementation Method 1
Pyrolysis of hydrocarbons is a technology that provides a potential pathway for producing large volumes of H2 while reducing or minimizing the amount of carbon oxides that are generated
Implementation Method 2
a desired particle size distribution can be achieved by controlling one or more parameters for the fluidized bed process
Implementation Method 3
U.S. Patent Application Publication 2021/0331918 describes pyrolysis of hydrocarbons (such as methane) using stacked fluidized beds to improve conversion during pyrolysis
Data Source
AI summary
Compositions for pyrolysis coke particles are provided. The pyrolysis coke particles can have at least an outer shell of pyrolysis coke. In some aspects, the pyrolysis coke particles can be based on a homogeneous seed, so that the entire particle corresponds to pyrolysis coke. In other aspects, the particle can be based on a heterogeneous seed, so that a different type of carbon-containing material serves as the core of a particle. Systems and methods for forming such particles are also provided.