A fast pyrolysis heat exchanger system and method for economically and efficiently converting biomass and other combustible materials into bio-oil. The system employs multiple closed loop tubes situated inside the heat exchanger. As heat carrier is deposited at the top of the heat exchanger and caused to move downwardly therethrough, heat is transferred from the tubes to the heat carrier which is then transferred to a reactor where it is placed in contact with the combustible materials. Vapor containing char fines is discharged from the reactor into a vacuum-operated blow back filter. The blow back filter is activated when a drop in vacuum level at the output of the reactor is detected. Thereby, excess char buildup on the blow back filter elements is removed.

Apparatus for the pyrolysis treatment of plastics includes a vertically developing reactor which includes: a first zone, a second zone and a third zone which are in direct communication with each other, the first zone being vertically superimposed on the second zone and the second zone being vertically superimposed on the third zone, an inlet for high temperature particles, the inlet being arranged so that the particles fall by gravity into the second zone first passing through the first zone, a plurality of nozzles which are mounted in correspondence with the second zone for introducing the plastics in the molten state into the second zone, and a mechanical mixing device which is positioned and acts inside the third zone.

Apparatus for the pyrolysis treatment of plastics includes a vertically developing reactor which includes: a first zone, a second zone and a third zone which are in direct communication with each other, the first zone being vertically superimposed on the second zone and the second zone being vertically superimposed on the third zone, an inlet for high temperature particles, the inlet being arranged so that the particles fall by gravity into the second zone first passing through the first zone, a plurality of nozzles which are mounted in correspondence with the second zone for introducing the plastics in the molten state into the second zone, and a mechanical mixing device which is positioned and acts inside the third zone.

The disclosure is generally directed to the field of optimizing feedstock in pyrolysis systems. A method of obtaining pyrolysis oil from a feedstock comprising rubber comprises the steps of: providing a feedstock comprising rubber; milling the feedstock, thereby providing particles; and pyrolyzing the particles in a vessel; wherein the median size of the particles is from about 0.5 mm to about 15 mm, optionally from about 0.5 mm to about 12 mm, optionally from about 0.5 mm to about 9 mm, optionally from about 0.5 mm to about 6 mm, optionally 15 mm or smaller, optionally 12 mm or smaller, optionally 9 mm or smaller, optionally 6 mm or smaller. The feedstock optionally comprises a plurality of tires.

The disclosure is generally directed to the field of optimizing feedstock in pyrolysis systems. A method of obtaining pyrolysis oil from a feedstock comprising rubber comprises the steps of: providing a feedstock comprising rubber; milling the feedstock, thereby providing particles; and pyrolyzing the particles in a vessel; wherein the median size of the particles is from about 0.5 mm to about 15 mm, optionally from about 0.5 mm to about 12 mm, optionally from about 0.5 mm to about 9 mm, optionally from about 0.5 mm to about 6 mm, optionally 15 mm or smaller, optionally 12 mm or smaller, optionally 9 mm or smaller, optionally 6 mm or smaller. The feedstock optionally comprises a plurality of tires.

A dual bed pyrolysis system may include a falling bed reactor employing a heat carrier particulate to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product. The dual bed pyrolysis system may also include a fluidized bed reactor. The fluidized bed reactor may accept the pyrolysis waste product including char and heat carrier particulate from the falling bed reactor. The fluidized bed reactor may combust the char in the presence of the heat carrier particulate. The fluidized bed reactor may combust the char to reheat the heat carrier particulate. The reheated heat carrier particulate may be provided to the falling bed reactor to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product.

A dual bed pyrolysis system may include a falling bed reactor employing a heat carrier particulate to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product. The dual bed pyrolysis system may also include a fluidized bed reactor. The fluidized bed reactor may accept the pyrolysis waste product including char and heat carrier particulate from the falling bed reactor. The fluidized bed reactor may combust the char in the presence of the heat carrier particulate. The fluidized bed reactor may combust the char to reheat the heat carrier particulate. The reheated heat carrier particulate may be provided to the falling bed reactor to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product.

Processes and apparatuses for co-processing pyrolysis effluent and a hydrocarbon stream in which a char produced by the catalytic cracking of the pyrolysis effluent is recovered and utilized to provide energy, such as heat to the catalytic cracking zone. The char can be burned in various combustion zones associated with the catalytic cracking zone. The char is produced from a renewable resource.

A method for pyrolyzing ligneous biomass includes mechanically grinding ligneous biomass into particles with a size of less than 3 cm.sup.3 and conveying the ligneous particles to a dryer. The ligneous particles coming from the dryer is heated in a horizontal-trough pyrolysis reactor having an oxygen level of less than 15%. The reactor includes a first inlet for the ligneous particles and a second inlet for heat-transfer beads. The reactor is configured to make the ligneous particles react so as to have a first output of a mixture of heat-transfer beads and pyrolyzed ligneous particles and a second output of the pyrolysis gas. The residence time in the reactor is at least 20 seconds and the heat-transfer beads are heated in a bead regenerator.

A method for pyrolyzing ligneous biomass includes mechanically grinding ligneous biomass into particles with a size of less than 3 cm.sup.3 and conveying the ligneous particles to a dryer. The ligneous particles coming from the dryer is heated in a horizontal-trough pyrolysis reactor having an oxygen level of less than 15%. The reactor includes a first inlet for the ligneous particles and a second inlet for heat-transfer beads. The reactor is configured to make the ligneous particles react so as to have a first output of a mixture of heat-transfer beads and pyrolyzed ligneous particles and a second output of the pyrolysis gas. The residence time in the reactor is at least 20 seconds and the heat-transfer beads are heated in a bead regenerator.