Bio-oil Upgradation Catalyst for Heteroatom Removal
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Solution Overview
Problem
Current methods for converting biomass to bio-oil are energy-intensive, time-consuming, and require stringent reaction conditions, with the resulting crude bio-oil being incompatible with petroleum crude due to the presence of heteroatoms and other impurities.
Innovation Solution
A process using a regenerable and recyclable catalyst composition that upgrades crude bio-oil to bio-oil at similar temperature and pressure conditions as the initial conversion, without the need for solvents, to remove heteroatoms and produce a bio-oil compatible with petroleum crude, utilizing a catalyst comprising metals, supports, and solubilizing agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hydrothermal liquefaction is used to convert biomass to crude bio-oil, then the conversion can be performed on wet biomass without drying, but the resulting crude bio-oil contains heteroatoms and is incompatible with petroleum crude
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the catalyst system. A multi-metallic catalyst comprising Fe, Co, Ni, and Pt on a sulfated zirconia support is used to change the chemical environment during upgradation, enabling effective heteroatom removal. The catalyst's specific composition and sulfated zirconia support create optimal conditions for hydrodeoxygenation, hydrodenitration, and hydrosulfurization reactions, transforming the crude bio-oil into a petroleum-compatible product.
2Manufacturing precision
If multiple heating steps are applied to upgrade crude bio-oil, then the bio-oil quality improves, but the energy consumption and process time increase significantly
Solution Approach 1:
The patent merges multiple upgradation functions into a single reaction step. The multi-metallic catalyst system performs hydrodeoxygenation, hydrodenitration, and hydrosulfurization simultaneously in one pot, eliminating the need for sequential heating steps. This combined approach achieves comprehensive heteroatom removal while reducing energy consumption and processing time compared to traditional multi-step methods.
Solution Approach 2:
The patent employs a composite catalyst material combining multiple metals (Fe, Co, Ni, Pt) on a sulfated zirconia support. This composite structure synergistically enhances catalytic activity for various upgradation reactions, enabling efficient heteroatom removal in a single step and reducing the overall energy requirement for bio-oil upgrading.
3Device complexity
If conventional catalysts are used for bio-oil upgradation, then the process is simpler, but the catalyst cannot be recycled and loses performance after use
Solution Approach 1:
The patent implements catalyst recovery and reuse. The multi-metallic catalyst on sulfated zirconia support can be easily separated from the reaction mixture and regenerated. The catalyst maintains its structural integrity and catalytic activity after multiple cycles, enabling economical and sustainable bio-oil upgradation processes. This recoverability offsets the increased catalyst complexity with long-term operational benefits.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process results in a high-yield, energy-efficient production of bio-oil that is compatible with petroleum crude, free from heteroatoms, and can be recycled multiple times with retained catalytic performance, achieving a carbon content of 50-70% and maintaining the catalyst's crystalline structure.
Implementation Method 1
up-gradation of crude bio oil to bio-oil in the presence of a catalyst composition and a hydrogen source
Implementation Method 2
Pyrolysis is a heating process of dried biomass to directly produce syngas and/or oil
Implementation Method 3
Hydrothermal Liquefaction (HTL) technique, which involves the application of heat and pressure on the biomass medium
Implementation Method 4
The catalyst comprises at least one metal, at least one support and at least one solubilizing agent
Data Source
AI summary
The present disclosure relates to a process for the production of bio-oil which involves heating a mixture of a biomass slurry and a first catalyst composition at a temperature ranging from 200 to 350° C. and at a pressure ranging from 70 to 250 bars to obtain a mass containing crude bio oil, a residue and the catalyst; separating the crude bio oil from said mass to obtain a separated crude bio oil; extracting said separated crude bio oil with at least one solvent and evaporating said solvent to obtain a solvent free crude bio oil; subjecting said solvent free crude bio oil to reduction in the presence of a second catalyst composition and hydrogen source at temperature and pressure conditions similar to those employed for the conversion of bio mass into crude bio oil to obtain bio-oil. The second catalyst composition is the same as that of the first catalyst composition. The process also comprises a method step of recovering the first catalyst and reusing it either for preparing crude bio oil or bio oil or both.