Process for converting oxygenated hydrocarbons into hydrocarbons

Claim 2

A process for converting organic waste to hydrocarbons, which comprises the steps of: (a) pyrolyzing said organic waste in an inert atmosphere at conditions sufficient to convert such waste into pyrolytic oils and gases, wherein said pyrolytic oils and gases comprise oxygenated hydrocarbons, and (b) contacting said oxygenated hydrocarbons with a catalyst comprising a crystalline aluminosilicate zeolite at conditions sufficient to convert said oxygenated hydrocarbons into hydrocarbons.

Claim 3

The process of claim 1 wherein said crystalline aluminosilicate zeolite catalyst has a silica to alumina molar ratio of at least about 12.

Claim 4

The process of claim 2 wherein said catalyst includes a low surface area diluent in admixture with said crystalline aluminosilicate zeolite.

Claim 5

The process of claim 3 wherein said diluent has a surface area of less than about 25 m 2 /gm.

Claim 6

The process of claim 4 wherein said diluent is silica.

Claim 7

The process of claim 3 wherein said crystalline aluminosilicate zeolite has a pore size of from about 5.3 to about 6.0 A.

Claim 8

The process of claim 3 wherein the ratio of crystalline aluminosilicate zeolite to low surface area diluent varies from about 0.01 to about 0.50 by weight.

Claim 9

The process of claim 3 wherein said oxygenated hydrocarbons have a carbon to oxygen atomic ratio of from about 2.5 to about 3.0.

Claim 10

The process of claim 3 wherein said oxygenated hydrocarbons are derived from the pyrolysis of the cellulosic fraction of organic waste.

Claim 11

The process of claim 3 wherein said crystalline aluminosilicate zeolite is supported on said low surface area diluent.

Claim 12

The process of claim 3 in which said deoxygenating step is conducted at a temperature from about 350° to about 400° C.

Claim 13

A process for converting solid waste into hydrocarbons, wherein said solid waste includes an organic fraction and an inorganic fraction, which comprises the steps of: (a) separating said solid waste into an inorganic fraction and an organic fraction comprising entrained particulate inorganic constituents; (b) comminuting and drying said separated organic fraction; (c) pyrolyzing said comminuted and dried organic fraction in the presence of a carrier gas which is nondeleteriously reactive with the pyrolysis products, and a solid heat source selected from the group consisting of a carbon-containing residue of pyrolysis and a particulate inorganic solid heat source derived from the decarbonization of the carbon-containing residue of pyrolysis, under transport turbulent flow conditions in a pyrolysis zone maintained at a temperature from about 300° C. to less than the sintering temperature of the particulate inorganic solid heat source for a residence time sufficient to form from the comminuted and dried organic fraction a carbon-containing solid residue of pyrolysis and condensable pyrolytic oils and gases; said condensable pyrolytic oils and gases including oxygenated hydrocarbons; (d) separating the carbon containing solid residue of pyrolysis from the condensable pyrolytic oils and gases; and (e) deoxygenating said oxygenated hydrocarbons by contacting said separated condensable pyrolytic oils and gases with a catalyst comprising a crystalline aluminosilicate zeolite at conditions sufficient to convert said oxygenated hydrocarbons into hydrocarbons.

Claim 14

A process for converting solid waste into hydrocarbons, wherein said solid waste includes an organic fraction and an inorganic fraction, which comprises the steps of: (a) separating said solid waste into an inorganic fraction and an organic fraction comprising entrained particulate inorganic constituents; (b) comminuting and drying said separated organic fraction; (c) pyrolyzing said comminuted and dried organic fraction in the presence of a carrier gas which is nondeleteriously reactive with the pyrolysis products, and a solid heat source selected from the group consisting of a carbon-containing residue of pyrolysis and a particulate inorganic solid heat source derived from the decarbonization of the carbon-containing residue of pyrolysis, under transport turbulent flow conditions in a pyrolysis zone maintained at a temperature from about 300° C. to less than the sintering temperature of the particulate inorganic solid heat source for a residence time sufficient to form from the comminuted and dried organic fraction a carbon-containing solid residue of pyrolysis and condensable pyrolytic oils and gases; said condensable pyrolytic oils and gases including oxygenated hydrocarbons; (d) separating the carbon containing solid residue of pyrolysis from the condensable pyrolytic oils and gases; and (e) deoxygenating said oxygenated hydrocarbons by contacting said separated condensable pyrolytic oils and gases with a catalyst comprising a crystalline aluminosilicate zeolite at conditions sufficient to convert said oxygenated hydrocarbons into hydrocarbons.

Claim 15

The process of claim 12 wherein said temperature maintained in said pyrolysis zone is from about 300° to about 800° C.

Claim 16

The process of claim 12 in which the residence time of said comminuted and dried organic fraction in the pyrolysis zone is from 0.1 to about 2 seconds.

Claim 17

The process of claim 12 in which the comminuted and dried organic fraction is of a particle size less than about 8 mesh.

Claim 18

The process of claim 12 in which the particle size of the particulate inorganic solid heat source is from about 20 to about 2000 microns.

Claim 19

The process of claim 12 in which the crystalline aluminosilicate zeolite has a silica to alumina ratio of at least about 12.

Claim 20

The process of claim 12 in which the crystalline aluminosilicate zeolite is admixed with a low surface area diluent.

Claim 21

The process of claim 18 in which the diluent has a Hammet acid function value of about 3 or more.

Claim 22

The process of claim 12 in which the separated carbon-containing solid residue of pyrolysis is decarbonized by high temperature oxidation in the presence of a source of oxygen at a temperature below the fusion temperature of the inorganic solid heat source derived therefrom.

Claim 23

The process of claim 20 in which the source of oxygen is air.

Claim 24

The process of claim 12 in which the weight ratio of the solid heat source to the comminuted and dried organic fraction fed to said pyrolysis zone is from about 2 to 1 to about 20 to 1.

Claim 25

The process of claim 4 wherein said diluent is characterized as having a Hammet acid function value of at least about 3.