PYROLYSIS OF BIOMASS TO PRODUCE MAXIMUM LIQUID YIELDS

Abstract: A process for the pyrolysis of biomass can produce liquid yields ranging as high as 90 % by using appropriate reaction conditions in a reactor capable of rapid heat exchange and short gas residence times. In the process, biomass is introduced into the reactor together with a gas and heat and the pyrolysis process is carried out under specific reaction conditions to produce a pyrolysis liquid containing 10 % to 30 % water. The pyrolysis liquid can be further processed to divide it into a water-rich fraction and a water-poor fraction and these fractions can be further processed to obtain desirable products in commercial quantities including hydroxyacetaldehyde, levoglucosan, acetol, glyoxal or methyl glyoxal. In one embodiment, the process can be used to produce a pyrolysis liquid that is suitable for use as a fuel oil. In another embodiment, the process can be used to produce a pyrolysis liquid that is suitable for use as liquid smoke which can be used to flavour food, particularly meat.

Description: PYROLYSIS OF BIOMASS TO PRODUCE MAXIMUM LIQUID YIELDS BACKGROUND OF THE INVENTION FIELD OF THE INVENTION This invention relates to a process for producing maximum liquid yields from the pyrolysis of biomass and in particular to the manner in which the reaction conditions can be controlled to produce such products as fuel oil, hydroxyacetaldehyde, liquid smoke and many other products through the rapid pyrolysis of biomass. DESCRIPTION OF THE PRIOR ART Processes for the rapid pyrolysis of biomass are known. Suitable reactors have been described by Donald S. Scott, et al. in the CANADIAN JOURNAL OF CHEMICAL ENGINEERING, 1984, Volume 62, pp. 404 - 412 and INDUSTRIAL AND ENGINEERING CHEMISTRY PROCESS DESIGN AND DEVELOPMENT, 1985, Volume 24,. pp. 581 - 588. Briefly, the reactor described in these publications is a fluidized bed of inert particulate matter as a heating and reacting medium. Other reaction devices that might be suitable are described in U.S. Patent No. 3,853,498 issued December 10th, 1974 naming R.C. Bailie as inventor and U.S. Patent No. 4,510,021 issued April 9th, 1985 and naming Norman K. Sowards as inventor. With previous pyrolysis processes for biomass, it was not known that valuable chemical products could be obtained readily from the liquid product or that the liquid product could be produced in yields sufficiently high to contain concentrations of desirable chemical products in commercial quantity. SUMMARY OF THE INVENTION It is an object of the present invention to produce in commerical quantities products such as fuel oil, hydroxyacetaldehyde, liquid smoke and numerous other products from the rapid pyrolysis of biomass under controlled conditions that can be easily varied depending on the desired product. A process for producing maximum liquid yields from the pyrolysis of biomass in accordance with the present invention using a reactor capable of rapid heat exchange and short gas residence time comprises introducing the biomass into the reactor, introducing a gas and heat into the reactor and carrying out a pyrolysis process of said biomass under the following conditions: (a) Gas and vapour residence time is less than ten seconds; (b) Solid particle residence time is equal to or greater than the gas and vapour residence time; (c) The solid particle size does not exceed 5 mm; (d) The pyrolysis process is carried out at a temperature ranging from substantially 400oc to substantially 650oc; producing a pyrolysis liquid containing 10% to 30% water with the balance of said liquid being organic compounds including a majority of the lignin type material present in the original biomass together with carbohydrates derived from cellulose. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a graph showing the phase relationships for poplar pyrolysis oil and water; and Figure 2 is a NMR spectra of pyrolitic lignin produced from the process of the present invention. DESCRIPTION OF A PREFERRED EMBODIMENT For the purposes of the present, it is important that the pyrolysis of biomass be conducted rapidly in an appropriate device. Otherwise, the high yields of pyrolysis liquids of the desired composition necessary for economical processing will not be obtained. When the term biomass is used in this specification, it shall be deemed to refer to ligno- cellulosiσ biomass. The gas and vapour residence times should be less than ten seconds and, preferably, equal to or less than approximately two seconds. The solid particle residence time should be equal to or greater than the gas residence time. Particle size should be.less than 5 mm and, preferably, equal to or less than approximately 2 mm. The ter perature of- pyrα-ys±sr should be in the range from substantially 4Q0θc tα substantially 650OC and, preferably, in. he- range frσπr substantially 450oc to substantially 550©C " . Atmospheric pressure is satisfactory but pressure significantly above atmospheric can be. used. also. The process of the present invention can be used to produce a pyrolysis liquid containing..10% to 30% water with the balance of said liquid being organic compounds including a majority of the lignin type material present in the original biomass together with carbohydrates derived from cellulose. Preferably, the moisture content of the biomass feed ranges from 5% to 15% and the total liquid yield ranges from 50% to 90% and, still more preferably, from 60% to 90%. If rapid pyrolysis of biomass is carried out in accordance with the present invention, a maximum yield of liquid products can be obtained and the liquid can be separated into two fractions. These two fractions can then be further processed to yield valuable products. For example, a pyrolysis liquid can be produced in accordance with the present invention having properties that make it suitable for use as a fuel oil. The two fractions are created by diluting the pyrolysis liquid obtained by the process with water to a water content of at least 50% and, preferably, at least 55%, at temperatures near ambient. This causes the two fractions to separate and the water-poor fraction can then be filtered off from the water-rich fraction. As an example of a pyrolysis liquid that can be used as a substitute for fuel oil, such a liquid can be obtained from the rapid pyrolysis of a hardwood, for example, poplar wood. The poplar wood preferably contains 5% to 10% moisture although moisture contents as ~ .fed-.up: to 30% can be used. The pyrolysis liquid σ3-it_a:__ned- xll typically have a composition of agpx.α_-α- * -t * ate * -C[r 75% to 85% organic liquid and 15% to 25% water-depending * on the. operating conditions. The yield of: * pyrσiysis liquid will..be..65% to 75% of the dry wood fed. The liquid will typically have a density ranging from 1,150 kg/m3 to 1,200 kg/m3 and a pH ranging from 2.3 to 3.5. The pyrolysis liquid is a single phase homogeneous liquid in which the water is dissolved in the organic phase. The liquid will have certain significant quantities of chemicals or classes of chemicals if the liquid has been prepared in accordance with the process of the present invention. in Figure 1, there is shown a typical solubility diagram for a liquid obtained from poplar wood. Pyrolytic liquids prepared by other methods from wood, which do not meet the process requirements of rapid pyrolysis for maximum liquid production will not show similar solubility behaviour because their chemical composition will be quite different. The phase diagram of Figure 1 shows that if the pyrolysis liquid as produced is diluted with water to a water content of 55% or more at temperatures near ambient, with no further treatment, a water-poor phase will separate and can be filtered off from a water-rich phase. The water-poor phase contains insoluble material that can be dried at temperatures preferably not exceeding IIO O Q and then easily ground to give a fine free ' -'-'ing material. The crude pyrolysis liquid can also be heated for a period if desired, before or after dilution with water, in order to cause acid hydrolysis of oligiosaccharides or of anhydrosaccharides to occur to increase the yield of onomeric sugar-related carbohydrates. However, this step is not essential to the separation. The water-poor fraction is primarily derived from the lignin content of the biomass and is largely aromatic in character. Depending on the biomass feed, the water-poor fraction will be 10% to 30% of the dry wood fed, or 15% to 40% of the pyrolysis liquid. Further, it is only under the previously described conditions of rapid pyrolysis that these yields of lignin related materials can be recovered in the pyrolysis liquid and can be readily separated from this liquid• The water-rich fraction contains a high proportion of hydroxy carbonyl compounds related to sugars. The water-rich fraction can be further treated so that acids are first removed by any suitable method. Primarily formic and acetic acids will be removed through distillation, neutralization, solvent extraction or ion exchange. However, because yields of these acids are substantial, methods such as distillation or solvent extraction are preferred if the acid is to be recovered as a commercial product. If desirable, treatment with charcoal, or other adsorbent, or extraction with a suitable solvent will largely remove residual amounts of aromatic or furanoid compounds from the aqueous solution. The treated aqueous solution can then be used as a source of carbohydrates for fermentation processes. It can also be used as a feed stock for the recovery of specific chemicals, in particular, the product hydroxyacetaldehyde (glycolaldehyde or 3-hydroxy ethanal), as V Ώ 11 as other components present, for example, levoglucosan, acetol, glyoxal, methyl glyoxal and numerous other components. In some processes, the amount of a particular component will not be sufficient to justify its recovery. However, usually the reaction conditions can be varied so that the yield of a particular desirable component will be increased. In Table 1, there is shown the results for a typical pyrolysis process in an atmospheric pressure fluidized bed reactor of the type described in the papers by Donald S. Scott, et al referred to previously. In Table 2, there are set out typical yields of the more important compounds present in the water-rich fraction at a particular temperature. The yield of any given component can be maximized by the variation of temperature and residence time in the reactor. Of course, the yield can also -be varied with the type of feed stock. It is to be noted particularly in Table 2 the high yield of hydroxyacetaldehyde. Similarly, liquid smoke can be produced as part of the water-rich phase in sufficient quantity for recovery. Liquid smoke is used for the preparation of food and in meat flavouring. When it is desired to produce a pyrolysis liquid that can be used as a fuel oil, the water content must be adjusted to between 10% and 30% and, preferably, between 15% and 25%. This amount of water, when referring to the phase diagram of Figure 1, dissolves in the organic material. Also, this concentration of water reduces the viscosity of the liquid so that it remains fluid and pumpable (i.e. 40 centipoises at 40oc) . The water content also gives the liquid a very low pour point (-24θc for liquid from poplar wood) . Further, the water content stabilizes the liquid in storage and storage of liquid in sealed containers shows 3 ' .le change over eighteen months at room temperature. If the water content is too low, the TABLE 1 PILOT PLANT TEST RESULTS IEA Standard Poplar-Aspen, -595uin, 6.25% moisture, 0.44% Ash tn.f. C (mf) 48.39%, H ( f) 5.89%, N - .068% Run No. 30_ 28 ^ 27 25 26 34* Vapor Res. Time,sees 0.616 0.584 0.550 0.539 0.520 0.53 Temp, in Bed, C 425 465 500 541 625 541 Feed Rate, kg/hr 2.391 1.709 2.238 1.281 1.001 1.29 Yields, % of Wood mf. * Organic Liquids 55.88 67.17 65.76 63.65 40.27 62.05 Water (K.F.) 3.8 5.5 9.3 7.4 4.1 7.7 Char 30.51 18.88 12.15 8.99 7.81 9.72 Gas 5.95 8.53 12.45 21.22 36.65 19.11 H 2 .004 .009 .019 .064 .235 .04 CO 2.06 3.27 5.32 10.47 22.88 9.13 C0 3.72 4.86 6.30 8.64 8.44 8.25 CH 4 .091 .20 .48 1.28 3.51 .89 C 2 H 4 .038 .085 .20 .49 1.09 .36 C 2 H 6 .010 .021 .043 .12 .23 .15 c 3+ .031 .085 .085 .16 .27 .31 Overall Recovery, % 96.14 100.08 99.66 101.26 88.83 98.58 Liquid Condensate, gms/ l 1.145 1.171 1.172 1.130 0.992 1.15 Table 2 Typical Yields of Some Organic Components of Pyrolysis Oil from Fast Pyrolysis of Poplar Wood at 504°C % 1by weight of dry wood Cellobiosan and other anhydrodi saccharides 1.11 Glucose 0.55 . Fructose 1.34 Glyoxal 1.42 Levoglucosan + ethylglyoxal 2.52 Hydroxyacetaldehyde 6.47 Formic acid 5.40 Acetic acid 6.30 Ethylene glycol 0.87 Acetol (1-hydroxy propanone) 1.70 foregoing advantages disappear. Similarly, if the water content is too high, the heating value of the liquid becomes insignificant and sustained combusj-ion is difficult. In the preferred range of water content, the pyrolysis liquid from wood can be burned with appropriate ignition devices in the same combustion equipment as that used for fuel oils with either pressure atomizing or gas atomizing burners. As a further advantage, the fuel oil obtained from the process of the present invention contains essentially no ash and is very low in sulfur content. From hardwoods or softwoods, it is possible to obtain a yield of pyrolytic liquids ranging from 70% to 75%. The water-poor fraction is essentially identical in chemical functionalities to that produced in steam explosion processes. Steam explosion processes are very different and less economical than the process of the present invention. Comparison of the water-poor fraction of the present invention with the lignin derived material from steam explosion processes using nuclear magnetic resonance spectra, shows the two materials are similar. While the process has been specifically described in the examples using poplar wood, numerous other woods can be used in the process and the conditions can be varied to produce maximum yields of particular components. Variations, within the scope of the attached claims, will be readily apparent to those skilled in the art. Figure 2 is a NMR spectra of pyrolytic lignin resulting from fast pyrolysis of poplar wood in accordance with the process of the present invention.

Claims: I CLAIM: 1. A process for producing maximum liquid yields °frσm the pyrolysis of biomass by using a reactor capable of rapid heat exchange and short gas residence times, said process comprising introducing said biomass into said reactor, introducing a gas into said reactor, introducing heat into said reactor and carrying out a pyrolysis process of said biomass under the following conditions: (a) Gas and vapour residence time is less than ten seconds; (b) Solid particle residence time is equal to or greater than the gas and vapour residence time; (c) The solid particle size does not exceed 5 mm; (d) The pyrolysis process is carried out at a temperature ' ranging from substantially 400θc to substantially 650OC; producing a pyrolysis liquid containing 10% to 30% water with the balance of said liquid being organic compounds including a majority of the lignin type material present in the original biomass together with carbohydrates derived from cellulose. 2. A process as claimed in Claim 1 wherein the moisture content of the biomass ranges from 5% to 15% and the total liquid yield ranges from 50% to 90%. 3. A process as claimed in Claim 2 wherein the gas residence time does not exceed approximately two seconds. 4. A process as claimed in Claim 3 wherein the particle size of the biomass does not exceed approximately 2 mm. 5. A process as claimed in Claim 4 wherein the process is carried out at a te mp erature ranging from substantially 450 O Q to substantially 550oc. 6. A process as claimed in Claim 5 wherein the pressure is near one atmosphere. 7. A process as claimed in Claim 5 -wherein the pyrolysis liquid is divided into two fractions, a water-rich fraction and a water-poor fraction. 8. A process as claimed in Claim 7 wherein the two fractions are created by diluting the pyrolysis liquid obtained from the process with water to a water content of at least 50%, at temperatures near ambient, causing the two fractions to separate, filtering off the water-poor fraction from the water-rich fraction. 9. A process as claimed in Claim 7 wherein the two fractions are created by diluting the pyrolysis liquid obtained from the process with water to a water content of at least 55%, at temperatures near ambient, causing the two fractions to separate, filtering off the water-poor fraction from the water-rich fraction. i 10. A process as claimed in Claim 7 wherein the water-poor fraction ranges from 10% to 30% of dry wood fed and 15% to 40% of the pyrolysis liquid. 11. A process as claimed in any one of Claims 8 or 9 wherein recovering the water-poor phases by filtration, washing and drying to yield a lignin- derived material. 12. A process as claimed in Claim 10 wherein the reaction conditions are such that the water-rich fraction contains a high proportion of hydroxy carbonyl compounds related to sugars. 13. A process as claimed in Claim 12 wherein the water-rich fraction is further processed to remove acids, the fraction is then further treated to remove residual amounts of aromatic or furanoid compounds, the product so formed being a source of carbohydrates. 14. A process as claimed in Claim 13 wherein the aromatic or furanoid compounds are removed using adsorption. 15. A process as claimed in Claim 13 wherein the aromatic or furanoid compounds are removed using extraction. 16. A process as claimed in Claim 13 wherein one or more of the following products are recovered from the remaining product of the water-rich phase, being hydroxyacetaldehyde, levoglucosan, acetol, glyoxal or methyl glyoxal. 17. A process as claimed in any one of Claims 8, 9 or 14 wherein hydroxyacetaldehyde is recovered from the water-rich phase. 18. A process as claimed in Claim 16 wherein the yield of a particular chemical component is maximized by varying the reaction conditions. 19. process as claimed in Claim 5 wherein the pyrolysis liquid resulting from the pyrolysis process is diluted with water so that the water content ranges between 10% and 30%, said pyrolysis liquid being suitable for use as a fuel oil. 20. A process as claimed in Claim 5 wherein the pyrolysis liquid is diluted with water so that the water content ranges from 15% to 25%, making the pyrolysis suitable for use as a fuel oil. 21. A process as claimed in Claim 5 wherein the biomass is a hardwood or softwood and the yield of pyrolysis liquid ranges from 70% to 75%. 22. A process as claimed in any one of Claims 1, 2 or 3 wherein a chemical referred to generiσally as liquid smoke that can be used in the preparation of a food or in meat flavouring is recovered from the water- rich phase. 23. A process as claimed in any one of Claims 4, 5 or 6 wherein a chemical referred to generically as liquid smoke that can be used in the preparation of a food or meat flavouring is recovered from the water- rich phase. 24. A process as claimed in any one of Claims 8, 9 or 14 wherein a chemical referred to generically as liquid smoke that can be used in the preparation of a food or meat flavouring is recovered from the water- rich phase.

Inventors: SCOTT DONALD S, SCOTT, DONALD, S.
Applicants: SCOTT DONALD S, WHISENHUNT FRED S, SCOTT, DONALD, S., WHISENHUNT, FRED, S.
Application year: 1987
Main classification: C07C1
IPC codes: A23B4, C07C45, C10C5