Pyrolysis reactor and fluidized bed combustion chamber

Claim 2

In a process for pyrolysis of particulate solid carbonaceous materials in which a particulate solid carbonaceous material is pyrolyzed by heat transferred thereto by a particulate source of heat to yield a particulate carbon containing solid residue as a product of pyrolysis and in which the particulate source of heat is formed by oxidizing at least a portion of the particulate carbon containing solid residue, the improvement which comprises forming the particulate source of heat by the steps of: (a) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material to a fluidized bed around a substantially vertically oriented, open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (b) educting particulate carbon containing solid residue from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit to oxidize carbon in the particulate carbon containing solid residue thereby partially heating the particulate carbon containing solid residue and transporting the particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; and (c) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones being sufficient to generate the particulate source of heat.

Claim 3

The method of claim 1 in which the conduit is spaced apart from the riser, and the particulate carbon containing solid residue is fluidized in the fluidized bed by an upward flow of a fluidizing gas, and wherein fluidizing gas passes into the riser through the space between the riser and the conduit.

Claim 4

The method of claim 1 in which the fluidized bed is fluidized by a fluidizing gas containing oxygen.

Claim 5

A continuous process for pyrolysis of particulate solid carbonaceous materials which comprises, in combination, the steps of: (a) subjecting a particulate solid carbonaceous material to flash pyrolysis by continuously: (i) transporting the particulate solid carbonaceous material contained in a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the particulate solid carbonaceous material to a substantially vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature below about 2000° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material to the pyrolysis reactor at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iii) forming a turbulent mixture of the particulate source of heat, particulate solid carbonaceous material and carrier gas to pyrolyze the particulate solid carbonaceous material and yield a pyrolysis product stream containing as solids, the particulate source of heat and a particulate carbon containing solid residue of pyrolysis, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (b) passing the pyrolysis product stream from the pyrolysis reactor to a first separation zone and separating at least the bulk of the solids from the vapor mixture; and (c) forming the particulate source of heat by: (i) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material and separated from the vapor mixture to a fluidized bed around a substantially vertically oriented open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (ii) educting particulate carbon containing solid residue from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit to oxidize carbon in the particulate carbon containing solid residue thereby heating the particulate carbon containing solid residue and to transport particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; (iii) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones in combination being sufficient to generate the particulate source of heat; and (iv) passing the formed particulate source of heat and the gaseous combustion products from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion products of the particulate carbon containing solid residue and feeding the thusly separated particulate source of heat to the pyrolysis reactor.

Claim 6

A continuous process for pyrolysis of particulate solid carbonaceous materials which comprises, in combination, the steps of: (a) subjecting a particulate solid carbonaceous material to flash pyrolysis by continuously: (i) transporting the particulate solid carbonaceous material contained in a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the particulate solid carbonaceous material to a substantially vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature below about 2000° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material to the pyrolysis reactor at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iii) forming a turbulent mixture of the particulate source of heat, particulate solid carbonaceous material and carrier gas to pyrolyze the particulate solid carbonaceous material and yield a pyrolysis product stream containing as solids, the particulate source of heat and a particulate carbon containing solid residue of pyrolysis, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (b) passing the pyrolysis product stream from the pyrolysis reactor to a first separation zone and separating at least the bulk of the solids from the vapor mixture; and (c) forming the particulate source of heat by: (i) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material and separated from the vapor mixture to a fluidized bed around a substantially vertically oriented open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (ii) educting particulate carbon containing solid residue from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit to oxidize carbon in the particulate carbon containing solid residue thereby heating the particulate carbon containing solid residue and to transport particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; (iii) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones in combination being sufficient to generate the particulate source of heat; and (iv) passing the formed particulate source of heat and the gaseous combustion products from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion products of the particulate carbon containing solid residue and feeding the thusly separated particulate source of heat to the pyrolysis reactor.

Claim 7

A process as claimed in claim 4 in which the first separation zone is a cyclone separation zone.

Claim 8

A process as claimed in claim 4 in which the second separation zone is a cyclone separation zone.

Claim 9

A process as claimed in claim 4 in which the turbulent mixture in the pyrolysis reactor has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the pyrolysis product stream, and a weight ratio of the particulate source of heat to the particulate solid carbonaceous material of from about 2:1 to about 20:1.

Claim 10

A process as claimed in claim 4 in which the pyrolysis temperature is from about 900° to about 1400° F.

Claim 11

A process as claimed in claim 4 wherein the pyrolysis reactor has a solids feed inlet for the particulate solid carbonaceous material and a vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing zone of the pyrolysis reactor, wherein the step of transporting particulate solid carbonaceous material to the reactor comprises transporting the particulate solid carbonaceous material contained in a carrier gas to the solids feed inlet, wherein the step of feeding a particulate source of heat to the pyrolysis reactor comprises feeding the particulate source of heat to the vertically oriented chamber surrounding the inlet to the pyrolysis reactor, maintaining the particulate source of heat in the vertically oriented chamber in a fluidized state by a flow of a fluidizing gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the particulate solid carbonaceous material, and discharging the fluidized particulate source of heat over said weir and downwardly into said mixing zone, wherein the step of forming the turbulent mixture comprises injecting the particulate solid carbonaceous material contained in a carrier gas from the solids feed inlet into the mixing zone, and wherein the process comprises the additional step of passing the turbulent mixture downward from the mixing zone to the pyrolysis zone of the pyrolysis reactor to pyrolyze the particulate solid carbonaceous material.

Claim 12

The process of claim 9 in which residence time of the carrier gas in the pyrolysis zone of the pyrolysis reactor and the first separation zone in combination is less than about 5 seconds.

Claim 13

The process of claim 4 in which residence time of the carrier gas in the pyrolysis zone of the pyrolysis reactor and the first separation zone in combination is less than about 5 seconds.

Claim 14

The process of claim 4 in which residence time of the carrier gas in the pyrolysis zone of the pyrolysis reactor and the first separation zone in combination is less than about 3 seconds.

Claim 15

A process as claimed in claim 4 in which the particulate solid carbonaceous material is an agglomerative coal substantially of a particle size up to about 250 microns.

Claim 16

A process as claimed in claim 4 in which the pyrolysis temperature is from about 600° to about 2000° F.

Claim 17

A process as claimed in claim 4 in which the pyrolysis temperature is from about 600° to about 1400° F.

Claim 18

A process as claimed in claim 4 in which residence time of the carrier gas in the pyrolysis zone and first separation zone in combination is from about 0.1 to about 3 seconds.

Claim 19

A process as claimed in claim 4 in which the second combustion zone comprises a cyclone oxidation-separation zone.

Claim 20

A process as claimed in claim 17 in which residence time of the particulate carbon containing solid residue in the cyclone oxidation-separation zone is less than about 5 seconds.

Claim 21

A process as claimed in claim 17 in which residence time of the particulate carbon containing solid residue in the cyclone oxidation-separation zone is less than about 3 seconds.

Claim 22

A process as claimed in claim 4 in which a substantial portion of the particulate solid carbonaceous material is particles of a size up to about 1000 microns in diameter.

Claim 23

A process as claimed in claim 4 in which the particulate solid carbonaceous material is an agglomerative coal and substantially composed of particles of a size less than about 250 microns in diameter.

Claim 24

A continuous process for pyrolysis of agglomerative coals which comprises the steps of: (a) providing a particulate agglomerative coal feed containing agglomerative coal particles of a size less than about 250 microns in diameter; (b) subjecting the particulate coal feed to flash pyrolysis by continuously: (i) transporting the particulate agglomerative coal feed contained in a carrier gas which is nondeleteriously reactive with respect to products of pyrolysis of the particulate agglomerative feed to a solids feed inlet of a vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature above about 600° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated char resulting from pyrolysis of the particulate agglomerative coal feed to a vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing zone of the pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therethrough of a fluidizing gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the particulate agglomerative coal feed; (iii) discharging the particulate source of heat over said overflow weir and downwardly into said mixing zone at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iv) injecting the particulate agglomerative coal feed and carrier gas from the solids feed inlet into the mixing zone to form a turbulent mixture of the particulate source of heat, the particulate agglomerative coal feed and carrier gas; (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate agglomerative coal feed and yield a pyrolysis product stream containing as solids, the particulate source of heat and char, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (c) passing the pyrolysis product stream from said pyrolysis reactor to a first cyclone separation zone and separating at least the bulk of the solids from the vapor mixture; (d) forming the particulate source of heat by: (i) transporting at least a portion of the separated solids from the first cyclone separation zone to a fluidized bed around a substantially vertically oriented open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (ii) educting solids from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit to oxidize carbon in the solids thereby partially heating the solids and transporting partially heated solids and gaseous combustion products of the solids, including carbon monoxide, to a second combustion zone; (iii) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones being sufficient to generate the particulate source of heat; and (iv) passing the formed particulate source of heat and gaseous combustion products from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion products of the solids for feed of the formed particulate source of heat to the vertically oriented chamber of the pyrolysis reactor; (e) passing the formed particulate source of heat thusly separated 48 heat to the vertically oriented chamber surrounding the upper portion of the pyrolysis reactor.

Claim 25

A continuous process for pyrolysis of agglomerative coals which comprises the steps of: (a) providing a particulate agglomerative coal feed containing agglomerative coal particles of a size less than about 250 microns in diameter; (b) subjecting the particulate coal feed to flash pyrolysis by continuously: (i) transporting the particulate agglomerative coal feed contained in a carrier gas which is nondeleteriously reactive with respect to products of pyrolysis of the particulate agglomerative feed to a solids feed inlet of a vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature above about 600° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated char resulting from pyrolysis of the particulate agglomerative coal feed to a vertically oriented chamber surrounding the upper portion of the pyrolysis reactor, the chamber having an inner peripheral wall forming an overflow weir to a vertically oriented mixing zone of the pyrolysis reactor, the particulate heat source in said chamber being maintained in a fluidized state by the flow therethrough of a fluidizing gas substantially nondeleteriously reactive with respect to the products of pyrolysis of the particulate agglomerative coal feed; (iii) discharging the particulate source of heat over said overflow weir and downwardly into said mixing zone at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iv) injecting the particulate agglomerative coal feed and carrier gas from the solids feed inlet into the mixing zone to form a turbulent mixture of the particulate source of heat, the particulate agglomerative coal feed and carrier gas; (v) passing the resultant turbulent mixture downwardly from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate agglomerative coal feed and yield a pyrolysis product stream containing as solids, the particulate source of heat and char, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (c) passing the pyrolysis product stream from said pyrolysis reactor to a first cyclone separation zone and separating at least the bulk of the solids from the vapor mixture; (d) forming the particulate source of heat by: (i) transporting at least a portion of the separated solids from the first cyclone separation zone to a fluidized bed around a substantially vertically oriented open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (ii) educting solids from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit to oxidize carbon in the solids thereby partially heating the solids and transporting partially heated solids and gaseous combustion products of the solids, including carbon monoxide, to a second combustion zone; (iii) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones being sufficient to generate the particulate source of heat; and (iv) passing the formed particulate source of heat and gaseous combustion products from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion products of the solids for feed of the formed particulate source of heat to the vertically oriented chamber of the pyrolysis reactor; (e) passing the formed particulate source of heat thusly separated 48 heat to the vertically oriented chamber surrounding the upper portion of the pyrolysis reactor.

Claim 26

The process of claim 22 in which the particulate source of heat is passed from the second separation zone to the vertically oriented chamber surrounding the upper portion of the pyrolysis reactor through a vertically oriented standpipe fluidized with a gas which is nondeleteriously reactive with respect to products of pyrolysis of the particulate agglomerative coal feed.

Claim 27

The process of claim 22 in which carrier gas residence time in the pyrolysis zone of the pyrolysis reactor and the first cyclone separation zone in combination is less than about 5 seconds.

Claim 28

A process as claimed in claim 22 in which the turbulent mixture in the pyrolysis reactor has a solids content ranging from about 0.1 to about 10% by volume based on the total volume of the turbulent mixture and a weight ratio of the particulate source of heat to particulate agglomerative coal feed from about 2:1 to about 20:1.

Claim 29

A process as claimed in claim 22, in which the pyrolysis temperature is from about 900° to about 1400° F.

Claim 30

A process as claimed in claim 22 in which the pyrolysis temperature is from about 600° to about 2000° F.

Claim 31

A process as claimed in claim 22 in which the pyrolysis temperature is from about 600° to about 1400° F.

Claim 32

A continuous process for pyrolysis of solid carbonaceous materials comprising the steps of: (a) subjecting a particulate solid carbonaceous material to flash pyrolysis by continuously: (i) transporting particulate solid carbonaceous material contained in a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the particulate solid carbonaceous material to a vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature from about 600° to about 2000° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material to the pyrolysis reactor at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iii) forming a turbulent mixture of the particulate source of heat, particulate solid carbonaceous material and carrier gas and pyrolyzing the particulate solid carbonaceous material to form a pyrolysis product stream containing as solids, the particulate source of heat and a particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (b) passing the pyrolysis product stream from the pyrolysis reactor to a first separation zone and separating at least the bulk of the solids from the vapor mixture; (c) forming the particulate source of heat by: (i) transporting at least a portion of the separated solids from the first separation zone to a fluidized bed around a substantially vertically oriented riser, the riser and conduit comprising a first combustion zone; (ii) fluidizing the solids in the fluidizing bed with an upward flow of a fluidizing gas which then passes into the riser through the space between the conduit and the riser; (iii) educting particulate carbon containing solid residue from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit and oxidizing carbon in the particulate carbon containing solid residue thereby partially heating the particulate carbon containing solid residue and transporting particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; and (iv) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones in combination being sufficient to generate the particulate source of heat; (d) passing the formed particulate source of heat and combustion gases from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion product and feeding the separated particulate source of heat to the pyrolysis reactor.

Claim 33

A continuous process for pyrolysis of solid carbonaceous materials comprising the steps of: (a) subjecting a particulate solid carbonaceous material to flash pyrolysis by continuously: (i) transporting particulate solid carbonaceous material contained in a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the particulate solid carbonaceous material to a vertically oriented, descending flow pyrolysis reactor containing a pyrolysis zone operated at a pyrolysis temperature from about 600° to about 2000° F.; (ii) feeding a particulate source of heat at a temperature above the pyrolysis temperature and comprising heated particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material to the pyrolysis reactor at a rate sufficient to maintain said pyrolysis zone at the pyrolysis temperature; (iii) forming a turbulent mixture of the particulate source of heat, particulate solid carbonaceous material and carrier gas and pyrolyzing the particulate solid carbonaceous material to form a pyrolysis product stream containing as solids, the particulate source of heat and a particulate carbon containing solid residue of pyrolysis of the particulate solid carbonaceous material, and a vapor mixture of carrier gas and pyrolytic vapors comprising hydrocarbons; (b) passing the pyrolysis product stream from the pyrolysis reactor to a first separation zone and separating at least the bulk of the solids from the vapor mixture; (c) forming the particulate source of heat by: (i) transporting at least a portion of the separated solids from the first separation zone to a fluidized bed around a substantially vertically oriented riser, the riser and conduit comprising a first combustion zone; (ii) fluidizing the solids in the fluidizing bed with an upward flow of a fluidizing gas which then passes into the riser through the space between the conduit and the riser; (iii) educting particulate carbon containing solid residue from the fluidized bed upwards into the first combustion zone by injecting a gaseous source of oxygen upwardly into the conduit and oxidizing carbon in the particulate carbon containing solid residue thereby partially heating the particulate carbon containing solid residue and transporting particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; and (iv) introducing a source of oxygen into the second combustion zone in an amount at least equal to 50% of the molar feed of carbon monoxide to the second combustion zone for oxidation of such carbon monoxide in the second combustion zone, the total oxygen fed to the first and second combustion zones in combination being sufficient to generate the particulate source of heat; (d) passing the formed particulate source of heat and combustion gases from the second combustion zone to a second separation zone and separating the particulate source of heat from the gaseous combustion product and feeding the separated particulate source of heat to the pyrolysis reactor.

Claim 34

The process of claim 29 in which the fluidizing gas contains oxygen to partially oxidize carbon in the separated solids to heat the separated solids in the fluidized bed.

Claim 35

A process as claimed in claim 29 in which the pyrolysis temperature is from about 900° to about 1400° F.

Claim 36

The process as claimed in claim 29 in which the pyrolysis temperature is from about 600° to about 1400° F.

Claim 37

A process as claimed in claim 29 in which a substantial portion of the particulate solid carbonaceous material is particles in the range up to about 1000 microns in diameter.

Claim 38

A process as claimed in claim 29 in which the particulate solid carbonaceous material is a particulate agglomerative coal and substantially composed of particles of a size less than about 250 microns in diameter.

Claim 41

An apparatus as claimed in claim 35 in which the conduit is separated from the vertical riser.

Claim 44

The apparatus of claim 37 in which the conduit is spaced apart from the riser.

Claim 45

The apparatus of claim 37 in which the first separator is a cyclone separator.

Claim 46

The apparatus of claim 37 in which the second separator is a cyclone separator.

Claim 47

An apparatus as claimed in claim 37 in which the pyrolysis reactor contains a substantially vertically oriented mixing section and a substantially vertically oriented pyrolysis section, and the reactor has a solids feed inlet and a substantially vertically oriented chamber surrounding the upper portion of the reactor, wherein the inner peripheral wall of the chamber forms an overflow weir to the vertically oriented mixing section, and the means for forming a turbulent mixture comprises: (a) means for feeding particulate source of heat to the vertically oriented chamber; (b) means for introducing a fluidizing gas into the vertically oriented chamber to maintain the particulate source of heat therein in a fluidized state; and (c) means for injecting the particulate solid carbonaceous material contained in the carrier gas from the solids feed inlet into the mixing section to form the turbulent mixture.

Claim 50

In a process for pyrolysis of particulate solid carbonaceous materials in which a particulate solid carbonaceous material is pyrolyzed by heat transferred thereto by a particulate source of heat to yield a particulate carbon containing solid residue as a product of pyrolysis and in which the particulate source of heat is formed by oxidizing at least a portion of the particulate carbon containing solid residue, the improvement which comprises forming the particulate source of heat by the steps of: (a) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material to a fluidized bed around a substantially vertically oriented, open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (b) educting particulate carbon containing solid residue upward from the fluidized bed directly into the first combustion zone by injecting a transport gas upwardly into the conduit to transport particulate carbon containing solid residue to a second combustion zone; and (c) generating the particulate source of heat by combustion of the particulate carbon containing solid residue in a combustion zone in the presence of oxygen.

Claim 51

In a process for pyrolysis of particulate solid carbonaceous materials in which a particulate solid carbonaceous material is pyrolyzed by heat transferred thereto by a particulate source of heat to yield a particulate carbon containing solid residue as a product of pyrolysis and in which the particulate source of heat is formed by oxidizing at least a portion of the particulate carbon containing solid residue, the improvement which comprises forming the particulate source of heat by the steps of: (a) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material to a fluidized bed around a substantially vertically oriented, open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (b) educting particulate carbon containing solid residue upward from the fluidized bed directly into the first combustion zone by injecting a transport gas upwardly into the conduit to transport particulate carbon containing solid residue to a second combustion zone; and (c) generating the particulate source of heat by combustion of the particulate carbon containing solid residue in a combustion zone in the presence of oxygen.

Claim 52

The method of claim 43 in which the conduit is spaced apart from the riser, and the particulate carbon containing solid residue is fluidized in the fluidized bed by an upward flow of a fluidizing gas, and wherein fluidizing gas passes into the riser through the space between the riser and the conduit.

Claim 53

The method of claim 43 in which the fluidized bed is fluidized by a fluidizing gas containing oxygen.

Claim 54

The method of claim 43 wherein the second combustion zone comprises a cyclone oxidation-separation zone in which carbon in the particulate carbon containing solid residue is oxidized to generate the particulate source of heat and gaseous combustion products of the particulate carbon containing solid residue and simultaneously therewith generated particulate source of heat is separated from such gaseous combustion products.

Claim 55

The method of claim 46 in which the source of oxygen is introduced directly into the cyclone oxidation-separation zone.

Claim 56

A process as claimed in claim 46 in which residence time of the carbon containing solid residue in the cyclone oxidation-separation zone is less than about 5 seconds.

Claim 57

A process as claimed in claim 46 in which residence time of the carbon containing solid residue in the cyclone oxidation-separation zone is less than about 3 seconds.

Claim 58

In a process for pyrolysis of particulate solid carbonaceous materials in which a particulate solid carbonaceous material is pyrolyzed by heat transferred thereto by a particulate source of heat to yield a particulate carbon containing solid residue as a product of pyrolysis and in which the particulate source of heat is formed by oxidizing at least a portion of the particulate carbon containing solid residue, the improvement which comprises forming the particulate source of heat by the steps of: (a) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material to a fluidized bed around a substantially vertically oriented, open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (b) educting particulate carbon containing solid residue upward from the fluidized bed directly into the first combustion zone by injecting a transport gas comprising oxygen upwardly into the conduit to oxidize carbon in the particulate carbon containing solid residue and partially heating the particulate carbon containing solid residue and transporting the particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; and (c) introducing a source of oxygen into the second combustion zone for oxidation of such carbon monoxide in the second combustion zone to form carbon dioxide, the total oxygen fed to the first and second combustion zones being sufficient to generate the particulate source of heat.

Claim 59

In a process for pyrolysis of particulate solid carbonaceous materials in which a particulate solid carbonaceous material is pyrolyzed by heat transferred thereto by a particulate source of heat to yield a particulate carbon containing solid residue as a product of pyrolysis and in which the particulate source of heat is formed by oxidizing at least a portion of the particulate carbon containing solid residue, the improvement which comprises forming the particulate source of heat by the steps of: (a) transporting at least a portion of the particulate carbon containing solid residue formed by pyrolysis of the particulate solid carbonaceous material to a fluidized bed around a substantially vertically oriented, open conduit in open communication with a substantially vertically oriented riser, the conduit and riser comprising a first combustion zone; (b) educting particulate carbon containing solid residue upward from the fluidized bed directly into the first combustion zone by injecting a transport gas comprising oxygen upwardly into the conduit to oxidize carbon in the particulate carbon containing solid residue and partially heating the particulate carbon containing solid residue and transporting the particulate carbon containing solid residue and gaseous combustion products of the particulate carbon containing solid residue, including carbon monoxide, to a second combustion zone; and (c) introducing a source of oxygen into the second combustion zone for oxidation of such carbon monoxide in the second combustion zone to form carbon dioxide, the total oxygen fed to the first and second combustion zones being sufficient to generate the particulate source of heat.

Claim 60

The method of claim 50 in which the conduit is spaced apart from the riser, and the particulate carbon containing solid residue is fluidized in the fluidized bed by an upward flow of a fluidizing gas, wherein fludizing gas passes into the riser through the space between the riser and the conduit.

Claim 61

The method of claim 50 in which the fluidized bed is fluidized by a fluidizing gas containing oxygen.

Claim 62

The method of claim 50 wherein the second combustion zone comprises a cyclone oxidation-separation zone in which carbon monoxide is oxidized to carbon dioxide and simultaneously therewith generated particulate source of heat is separated from such formed carbon dioxide.

Claim 63

The method of claim 53 in which the source of oxygen is introduced directly into the cyclone oxidation-separation zone.

Claim 64

A process as claimed in claim 53 in which residence time of the particulate carbon containing solid residue in the cyclone oxidation-separation zone is less than about 5 seconds.

Claim 65

A process as claimed in claim 53 in which residence time of the particulate carbon containing solid residue in the cyclone oxidation-separation zone is less than about 3 seconds.

Claim 68

An apparatus as claimed in claim 57 in which the conduit is separated from the vertical riser.

Claim 69

The apparatus of claim 57 in which the combustion chamber is a cyclone for separating formed particulate source of heat from such formed combustion gas.

Claim 70

The apparatus of claim 57 in which the means for introducing oxygen comprises means for introducing oxygen directly into the combustion chamber.