Processes for controlling afterburn in a reheater and loss of entrained solid particles in reheater flue gas are provided. Carbonaceous biomass feedstock is pyrolyzed using a heat transfer medium forming pyrolysis products and a spent heat transfer medium comprising combustible solid particles. The spent heat transfer medium is introduced into a fluidizing dense bed. The combustible solid particles of the spent heat transfer medium are combusted forming combustion product flue gas in a dilute phase above the fluidizing dense bed. The combustion product flue gas comprises flue gas and solid particles entrained therein. The solid particles are separated from the combustion product flue gas to form separated solid particles. At least a portion of the separated solid particles are returned to the fluidizing dense bed.

The present invention is directed to processing feedstock materials for recovery, recycling and/or reuse of the constituent components of the feedstock materials, and includes adding feedstock materials at a constant temperature to a thermal reactor, heating the feedstock materials at a temperature of 1,100 F. or higher in an anaerobic environment within the thermal reactor to produce cracked and gasified hydrocarbons and residual material, removing cracked and gasified hydrocarbons released from the feedstock materials from the thermal reactor, further processing the residual material to recover one or more constituent component of the feedstock materials, and oxidizing the cracked and gasified hydrocarbons removed from the thermal reactor having five or less carbon atoms in their molecular structure in order to produce heat to obtain the temperature of 1,100 F. or higher for the thermal reactor. The present invention further includes systems, reactors and apparatuses configured to perform the processes of the present invention.

The present invention is directed to processing feedstock materials for recovery, recycling and/or reuse of the constituent components of the feedstock materials, and includes adding feedstock materials at a constant temperature to a thermal reactor, heating the feedstock materials at a temperature of 1,100 F. or higher in an anaerobic environment within the thermal reactor to produce cracked and gasified hydrocarbons and residual material, removing cracked and gasified hydrocarbons released from the feedstock materials from the thermal reactor, further processing the residual material to recover one or more constituent component of the feedstock materials, and oxidizing the cracked and gasified hydrocarbons removed from the thermal reactor having five or less carbon atoms in their molecular structure in order to produce heat to obtain the temperature of 1,100 F. or higher for the thermal reactor. The present invention further includes systems, reactors and apparatuses configured to perform the processes of the present invention.

The present disclosure provides a method for preparing a catalyst for pyrolysis of waste plastics to produce oil, comprising: washing and modifying coal gangue powder with acid, and then placing in an alkaline solution, etching under magnetic stirring for 20-30 minutes, and washing with water until neutral; placing the catalyst washed until neutral in a metal solution, loading the metal by impregnation, and then filtering and washing; then placing the catalyst in the molding machine and adding adhesive and water, to compress into a suitable shape, drying, and finally calcinating to activate to obtain a product. The present disclosure not only solves the problem of waste plastic pollution, but also obtains fuel oil with high valuable products while reducing the cost of waste plastic treatment, and also improves the yield of fuel oil.

The present disclosure provides a method for preparing a catalyst for pyrolysis of waste plastics to produce oil, comprising: washing and modifying coal gangue powder with acid, and then placing in an alkaline solution, etching under magnetic stirring for 20-30 minutes, and washing with water until neutral; placing the catalyst washed until neutral in a metal solution, loading the metal by impregnation, and then filtering and washing; then placing the catalyst in the molding machine and adding adhesive and water, to compress into a suitable shape, drying, and finally calcinating to activate to obtain a product. The present disclosure not only solves the problem of waste plastic pollution, but also obtains fuel oil with high valuable products while reducing the cost of waste plastic treatment, and also improves the yield of fuel oil.

Methods for defoaming in hydrocarbon processes include the steps of providing a defoaming agent, and introducing the agent into a hydrocarbon process to inhibit or control foaming in the hydrocarbon process. These methods may be particularly useful in coking processes, especially as to foaming in coke drums. In certain embodiments, defoaming agents may comprise a plurality of carbon nanoparticles. In some embodiments, drag reducing agents may comprise high-molecular weight alkanes. Advantages include, but are not limited to, more efficient and effective foam inhibition, reduced or eliminated product contamination, reduced or eliminated catalyst poisoning, increased refinery production rate, debottlenecking the coker, and reduced cost and consequences of applying too much antifoam.

Methods for defoaming in hydrocarbon processes include the steps of providing a defoaming agent, and introducing the agent into a hydrocarbon process to inhibit or control foaming in the hydrocarbon process. These methods may be particularly useful in coking processes, especially as to foaming in coke drums. In certain embodiments, defoaming agents may comprise a plurality of carbon nanoparticles. In some embodiments, drag reducing agents may comprise high-molecular weight alkanes. Advantages include, but are not limited to, more efficient and effective foam inhibition, reduced or eliminated product contamination, reduced or eliminated catalyst poisoning, increased refinery production rate, debottlenecking the coker, and reduced cost and consequences of applying too much antifoam.

A process for converting biomass to products is described. Biomasss is contacted with hydrogen in the presence of a fluidized bed of hydropyrolysis catalyst in a reactor vessel under hydropyrolysis conditions; and products and char are removed from the reactor vessel. The products leave the fluidized bed at an exit bed velocity, the char has a settling velocity that is less than the exit bed velocity and hydropyrolysis catalyst has a settling velocity that is greater than the exit bed velocity.

A process for converting biomass to products is described. Biomasss is contacted with hydrogen in the presence of a fluidized bed of hydropyrolysis catalyst in a reactor vessel under hydropyrolysis conditions; and products and char are removed from the reactor vessel. The products leave the fluidized bed at an exit bed velocity, the char has a settling velocity that is less than the exit bed velocity and hydropyrolysis catalyst has a settling velocity that is greater than the exit bed velocity.

An apparatus for supplying additives into a coker drum includes an inlet for supplying a hydrocarbon feed stream into the coker drum and conduits along the circumference of walls of the coker drum. Each conduit has an injection nozzle to supply additives inside the coker drum. An injection control system controls the operation of the injection nozzles such that 1) one or more of the injection nozzles placed within a first distance above a vapour liquid interphase of the hydrocarbon feed stream are configured to supply the additives; and 2) supply of the additive discontinues from a particular injection nozzle when a distance between the injection nozzle and the vapour liquid interphase is less than or equal to a second distance. The apparatus optionally includes a mechanical drive system moving at least one of the conduits based on the level of the vapour liquid interphase in the coker drum.