Bio-propane Purification via Hydrotreatment and Catalyst Optimization
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Solution Overview
Problem
Current methods for producing bio-based polypropylene, propylene oxide, and acrylic acid face limitations in industrial-scale production due to challenges in processing bio-based materials, including high hydrogen consumption, carbon oxide generation, and contamination issues with carbonyl sulphide, which affect the quality and yield of bio-propane and its derivatives.
Innovation Solution
A method involving hydrotreatment of bio-renewable oils and fats with a sulphided metal catalyst, followed by gas-liquid separation, fractionation, and purification to produce high-purity bio-propane, which can be further processed into bio-propylene and bio-polymers, utilizing a diluent to control temperature and reduce decarb-reactions, and recycling hydrogen to minimize energy consumption and impurity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional hydrotreatment methods are used to produce bio-propane from bio-based materials, then the process can proceed with established technology, but high amounts of hydrogen are consumed and significant carbon oxides are generated
Solution Approach 1:
The patent changes the chemical parameters of the hydrotreatment process by using a bifunctional catalyst system (metal function + acid function) and optimizing reaction conditions (temperature 200-400°C, pressure 10-100 bar, LHSV 0.1-5.0 h⁻¹) to promote hydrodeoxygenation while minimizing decarboxylation and decarbonylation reactions, thereby reducing CO and CO2 generation
Solution Approach 2:
The patent converts the harmful effect of oxygen-containing compounds in bio-based materials into a beneficial process feature by using the oxygenates as in-situ hydrogen donors through hydrodeoxygenation reactions, reducing the need for external hydrogen supply while producing high-quality paraffinic hydrocarbons
2Use of energy by moving object
If decarb-reactions are promoted to reduce hydrogen consumption, then hydrogen usage decreases, but carbon oxides (CO and CO2) are generated in high amounts
Solution Approach 1:
The patent carefully controls reaction parameters (temperature, pressure, catalyst composition) to favor hydrodeoxygenation over decarboxylation and decarbonylation, achieving a balance where oxygen is removed as water rather than CO/CO2, thus minimizing carbon oxide generation while maintaining reasonable hydrogen consumption
Solution Approach 2:
The bifunctional catalyst acts as an intermediary that facilitates hydrodeoxygenation through a mechanism involving metal sites for hydrogen activation and acid sites for oxygen removal, providing an alternative pathway that avoids CO and CO2 formation
3Productivity
If thermal cracking is used to produce propylene from bio-naphtha, then propylene can be obtained, but the process generates significant impurities including carbonyl sulphide that contaminate the bio-propane
Solution Approach 1:
The patent extracts and removes impurities including carbonyl sulphide, H2S, CO2, and CO from the reaction product stream through a series of purification steps (washing, adsorption, distillation) to produce high-purity bio-propane suitable for catalytic applications
Solution Approach 2:
The patent introduces an intermediate purification stage between production and final application, using multiple separation techniques to remove contaminants, thereby mediating between the impure thermal cracking output and the purity requirements for catalytic dehydrogenation
4Manufacturing precision
If bio-propane is produced with high purity through extensive purification, then the quality for catalytic applications improves, but the process complexity and energy consumption increase
Solution Approach 1:
The patent performs preliminary purification steps early in the process flow, removing major impurities (H2S, CO2, carbonyl sulphide) before subsequent processing stages, thereby simplifying downstream operations and reducing overall process complexity while achieving high final purity
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 method enhances the yield of high-quality liquid and gaseous hydrocarbon products, reduces hydrogen consumption, and minimizes impurities, enabling the production of bio-propane with high purity suitable for high-value applications such as catalytic dehydrogenation to bio-propylene, ultimately facilitating the production of bio-based polymers.
Implementation Method 1
Upon hydrogenation, this glycerol backbone is usually converted into bio-propane
Implementation Method 2
H2O cleaved by hydrotreatment (HDO) from the organic oxygenates present in the bio-based fresh feed material
Implementation Method 3
CO and CO2 cleaved by decarbonylation and decarboxylation (in the following sometimes simply referred to as decarb reactions) of C3+ organic oxygenates
Implementation Method 4
CO and CO2 cleaved by decarbonylation and decarboxylation (in the following sometimes simply referred to as decarb reactions) of C3+ organic oxygenates
Implementation Method 5
subjecting the hydrotreated effluent to gas-liquid separation so as to provide a gaseous hydrotreated material comprising H2, bio-propane, H2O, H2S, CO2, and CO, and a liquid hydrotreated material comprising paraffinic hydrocarbons
Implementation Method 6
fractionating the dried H2S, CO2 and H2 depleted gaseous stream to recover a bio-propane gas composition
Data Source
AI summary
Provided is a method for upgrading a bio-based material, the method including the steps of pre-treating bio-renewable oil(s) and/or fat(s) to provide a bio-based fresh feed material, hydrotreating the bio-based fresh feed material, followed by separation, to provide a bio-propane composition.