Process for the Catalytic Conversion of Solid-like Hydrocarbons

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This invention describes a method for catalytically transforming solid-like hydrocarbons, such as brown coal, biomass, plastics, oil coke, oil sands, or oil shale, into valuable chemical products. The process involves simultaneously grinding, drying, and catalytically reacting the solid feedstock using specially designed catalyst-coated grinding bodies. As the solids are broken down, they react with the catalyst surface both physically and chemically, generating lighter hydrocarbons and other useful chemical products in a single, integrated process. The catalyst bodies can be regenerated and reused, making the process more efficient.

Use CasesContent extracted from patent full text and abstract with AI.

• Chemical processing of lignite (brown coal) into higher-value chemicals and fuels.
• Recycling of plastics and transforming waste polymers into hydrocarbon feedstocks.
• Conversion of biomass into chemical products or synthetic fuels in biorefineries.
• Processing of oil coke, oil shale, or oil sands to extract useful hydrocarbons in refining plants.
• Reduction of solid hydrocarbon waste in industrial plants through catalytic valorization.

BenefitsContent extracted from patent full text and abstract with AI.

• Combines grinding, drying, and chemical reaction into a single step, increasing process efficiency.
• Enables the catalytic conversion of solid materials, which are typically more difficult to process than liquids or gases.
• Facilitates the production of valuable hydrocarbons from low-grade or waste feedstocks, improving resource utilization.
• The catalyst bodies can be separated, regenerated, and reused, lowering operational costs.
• Reduces the need for high-cost chemicals (e.g., hydrogen) and minimizes waste generation compared to traditional methods.
• Can be adapted for different solid carbon sources, including renewable and non-renewable feedstocks, increasing process flexibility.

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Patent Abstract

The invention relates to a method for the catalytic conversion of solid-like hydrocarbons, wherein the solid-like hydrocarbons pass through grinding, drying, and primary and secondary reaction processes. The grinding bodies are molded bodies having a carrier material which forms a molded body core and to which the catalyst material is applied. The solid-like hydrocarbons to be converted and the catalytically active material, which is present in the form of the molded bodies, are brought into contact with each other. According to the invention, the grinding, drying, and primary and secondary reaction processes take place simultaneously in that the solid matter is dried and ground simultaneously, a solid-solid reaction of organic solid matter of the solid-like hydrocarbons and solid catalyst is carried out, and the developing gaseous or liquid products are further cleaved and/or converted in secondary reactions on the catalyst surface. The invention is used in particular for the material use of brown coals and/or biomass and/or plastics, such as thermoset materials and thermoplastics, and/or oil coke and/or oil sands and/or oil shale in refining plants.