Staged heating by oxidation of carbonaceous material

Claim 2

In a continuous process for pyrolyzing a carbonaceous material in which heat for pyrolysis is obtained by partially oxidizing a carbon containing solid residue of said pyrolysis in the presence of oxygen in a combustion zone to form a particulate source of heat which is combined with the carbonaceous material in a pyrolysis reaction zone to initiate pyrolysis of the carbonaceous material, the improvement comprising the steps of: a. at least partially oxidizing in the combustion zone a portion of a preheated carbon containing solid residue in the presence of oxygen to yield the particulate source of heat and gaseous combustion products including carbon monoxide; b. separating the particulate source of heat from the gaseous combustion products of the preheated carbon containing solid residue in a first cyclone separation zone; c. passing the particulate source of heat to the pyrolysis reaction zone to provide at least a portion of the heat required for pyrolysis of the carbonaceous material to produce the carbon containing solid residue; d. preheating said carbon containing solid residue by combining in direct contact, in a heating zone maintained at a temperature less than the temperature in the combustion zone, the carbon containing solid residue, at least a portion of the carbon monoxide containing gaseous combustion products formed by combustion of the preheated carbon containing solid residue and a source of oxygen in an amount sufficient to completely oxidize the carbon monoxide in the gaseous combustion products; and e. separating in a second cyclone separation zone the preheated carbon containing solid residue from at least the bulk of the gases present in the heating zone for feed to the combustion zone.

Claim 3

A process as claimed in claim 1 in which the step of preheating comprises directly contacting carbon containing solid residue with at least a portion of the gaseous combustion products of the carbon containing solid residue and then directly contacting the combined stream of the carbon containing solid and gaseous combustion products with the source of oxygen.

Claim 4

The process of claim 2 in which the carbon containing solid residue is maintained at a temperature less than about 1800° F.

Claim 5

A process as claimed in claim 1 in which the step of preheating the carbon containing solid residue and the step of separating preheated carbon containing solid residue from the gases present in the heating zone occur simultaneously in a cyclone heating-separation zone.

Claim 6

The process of claim 4 in which the residence time of solids in the cyclone heating-separation zone is less than about 5 seconds.

Claim 7

The process of claim 4 in which a combined stream containing a portion of the gases present in the heating-separation zone and the preheated carbon containing solid residue is withdrawn from the cyclone heating-separation zone.

Claim 8

The process of claim 4 in which the residence time of solids in the cyclone heating-separation zone is less than about 3 seconds.

Claim 9

A process as claimed in claim 1 in which the step of partially oxidizing the preheated carbon containing solid residue and the step of separating particulate source of heat from gaseous combustion products occur simultaneously in a cyclone combustion-separation zone.

Claim 10

The process of claim 8 in which the residence time of solids in the cyclone combustion-separation zone is less than about 5 seconds.

Claim 11

The process of claim 8 in which the residence time of solids in the cyclone combustion-separation zone is less than about 3 seconds.

Claim 12

The process of claim 1 in which a combined stream containing preheated carbon containing solid residue and a portion of the gases present in the heating zone is withdrawn from the second cyclone separation zone.

Claim 13

A process as claimed in claim 1 in which the step of combining gaseous combustion products of the carbon containing solids residue with a source of oxygen comprises combining gaseous combustion products of the carbon containing solid residue with greater than a stoichiometric amount of an oxygen to completely oxidize the carbon monoxide in the gaseous combustion products so that at least a portion of the carbon containing solid residue in the heating zone is partially oxidized with the excess oxygen.

Claim 14

The process of claim 1 in which the heating zone is maintained at a temperature less than about 1800° F.

Claim 15

A process as claimed in claim 1 in which the step of preheating comprises combining a source of oxygen with carbon containing solid residue and then combining the combined stream of the carbon containing solid residue and source of oxygen with the gaseous combustion products.

Claim 16

A process as claimed in claim 1 in which the carbonaceous material is coal.

Claim 17

A process as claimed in claim 1 in which the carbonaceous material is the organic portion of solid waste.

Claim 18

In a continuous process for pyrolyzing a carbonaceous material in which heat for pyrolysis is obtained by partially oxidizing a carbon containing solid residue of pyrolysis in the presence of oxygen to form a particulate source of heat which is combined with the carbonaceous material in a pyrolysis reaction zone to initiate pyrolysis of the carbonaceous material, the improvement comprising the steps of: a. at least partially oxidizing in a cyclone combustion-separation zone a portion of a preheated carbon containing solid residue in the presence of oxygen to yield gaseous combustion products including carbon monoxide and form the particulate source of heat while simultaneously separating the particulate source of heat from the gaseous combustion products in the combustion-separation zone b. passing the particulate source of heat to the pyrolysis reaction zone to provide at least a portion of the heat required for pyrolysis of the carbonaceous material to produce the carbon containing solid residue; c. preheating the carbon containing solid residue of pyrolysis, in a heating stage, by directly contacting the carbon containing solid residue of pyrolysis with at least a portion of the gaseous combustion products formed in the combustion-separation zone from combustion of the preheated carbon containing solid residue; and d. further heating the preheated carbon containing solid residue of pyrolysis from the heating stage by combining, in a cyclone heating-separation zone maintained at a temperature less than the temperature of the combustion-separation zone, the preheated carbon containing solid residue of pyrolysis and gases from the heating stage with a sufficient amount of oxygen to completely oxidize the carbon monoxide in the gases present in said heating stage while simultaneously separating the further heated carbon containing solid residue of pyrolysis from gases present in the cyclone heating-separation zone for feed to the cyclone combustion-separation zone.

Claim 19

In a continuous process for pyrolyzing a carbonaceous material in which heat for pyrolysis is obtained by partially oxidizing a carbon containing solid residue of pyrolysis in the presence of oxygen to form a particulate source of heat which is combined with the carbonaceous material in a pyrolysis reaction zone to initiate pyrolysis of the carbonaceous material, the improvement comprising the steps of: a. at least partially oxidizing in a cyclone combustion-separation zone a portion of a preheated carbon containing solid residue in the presence of oxygen to yield gaseous combustion products including carbon monoxide and form the particulate source of heat while simultaneously separating the particulate source of heat from the gaseous combustion products in the combustion-separation zone b. passing the particulate source of heat to the pyrolysis reaction zone to provide at least a portion of the heat required for pyrolysis of the carbonaceous material to produce the carbon containing solid residue; c. preheating the carbon containing solid residue of pyrolysis, in a heating stage, by directly contacting the carbon containing solid residue of pyrolysis with at least a portion of the gaseous combustion products formed in the combustion-separation zone from combustion of the preheated carbon containing solid residue; and d. further heating the preheated carbon containing solid residue of pyrolysis from the heating stage by combining, in a cyclone heating-separation zone maintained at a temperature less than the temperature of the combustion-separation zone, the preheated carbon containing solid residue of pyrolysis and gases from the heating stage with a sufficient amount of oxygen to completely oxidize the carbon monoxide in the gases present in said heating stage while simultaneously separating the further heated carbon containing solid residue of pyrolysis from gases present in the cyclone heating-separation zone for feed to the cyclone combustion-separation zone.

Claim 20

The process of claim 17 in which the residence time of solids in the cyclone heating-separation zone is less than about 5 seconds.

Claim 21

The process of claim 17 in which the residence time of solids in the cyclone combustion-separation zone is less than about 5 seconds.

Claim 22

The process of claim 17 in which the residence time of solids in the cyclone combustion-separation zone is less than about 3 seconds.

Claim 23

The process of claim 17 in which the temperature in the cyclone heating-separation zone is less than about 1800° F.

Claim 24

A process as claimed in claim 17 in which the carbonaceous material is coal.

Claim 25

A process as claimed in claim 17 in which the carbonaceous material is the organic portion of solid waste.

Claim 26

A continuous process for pyrolyzing carbonaceous material comprising the steps of: a. directly contacting carbonaceous material with a particulate source of heat comprising carbon containing solid residue in a pyrolysis reaction zone maintained at a temperature greater than about 600° F to yield as products of pyrolysis a pyrolytic vapor and carbon containing solid residue b. separating carbon containing solid residue from the pyrolytic vapor; c. preheating in a heating zone the separated carbon containing solid residue by: i. combining the separated carbon containing solid residue with carbon monoxide containing gaseous combustion products of carbon containing solid residue; and ii. substantially completely oxidizing the carbon monoxide contained in the gaseous combustion products in the presence at least a stoichiometric amount of oxygen; d. separating from at least the bulk of the gases present in the heating zone carbon containing solid residue for feed to a combustion zone; e. at least partially oxidizing in the combination zone, a portion of the preheated carbon containing solid residue in the presence of oxygen to yield carbon monoxide containing gaseous combustion products of carbon containing solid residue and form a particulate source of heat; f. separating the particulate source of heat from the carbon monoxide containing gaseous combustion products; and g. recycling at least a portion of the formed particulate source of heat to the pyrolysis zone.

Claim 27

A continuous process for pyrolyzing carbonaceous material comprising the steps of: a. directly contacting carbonaceous material with a particulate source of heat comprising carbon containing solid residue in a pyrolysis reaction zone maintained at a temperature greater than about 600° F to yield as products of pyrolysis a pyrolytic vapor and carbon containing solid residue b. separating carbon containing solid residue from the pyrolytic vapor; c. preheating in a heating zone the separated carbon containing solid residue by: i. combining the separated carbon containing solid residue with carbon monoxide containing gaseous combustion products of carbon containing solid residue; and ii. substantially completely oxidizing the carbon monoxide contained in the gaseous combustion products in the presence at least a stoichiometric amount of oxygen; d. separating from at least the bulk of the gases present in the heating zone carbon containing solid residue for feed to a combustion zone; e. at least partially oxidizing in the combination zone, a portion of the preheated carbon containing solid residue in the presence of oxygen to yield carbon monoxide containing gaseous combustion products of carbon containing solid residue and form a particulate source of heat; f. separating the particulate source of heat from the carbon monoxide containing gaseous combustion products; and g. recycling at least a portion of the formed particulate source of heat to the pyrolysis zone.

Claim 28

A process as claimed in claim 24 in which the carbonaceous material is coal.

Claim 29

A process as claimed in claim 24 in which the carbonaceous material is the organic portion of solid waste.