Bio-propylene Production via Hydrotreated Feed Catalytic Cracking
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Solution Overview
Problem
Current methods for producing propylene from bio-based materials are inefficient, resulting in low yields of high-quality products, reactor fouling, and catalyst deactivation, due to the high oxygen content in bio-based feeds, which requires multi-step processing and co-processing with petroleum feedstocks, limiting the production of 100% bio-based fuels and chemicals.
Innovation Solution
A process involving hydrotreating an oxygen-containing bio-based feedstock to reduce oxygen content, followed by catalytic cracking using a moving solid catalyst at elevated temperatures to produce a bio-propylene composition, with a focus on minimizing gaseous compounds in the feed to enhance propylene productivity and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct catalytic cracking of oxygenated bio-based feedstocks is used, then bio-based hydrocarbon production is achieved, but reactor fouling and catalyst deactivation occur due to high oxygen content
Solution Approach 1:
The patent applies preliminary action by performing hydrotreatment before catalytic cracking to remove oxygen from bio-based feedstocks. This pre-processing step converts oxygenated compounds into hydrocarbons, preventing reactor fouling and catalyst deactivation during the subsequent cracking process while maintaining high bio-based hydrocarbon production
2Object-generated harmful factors
If multi-step processing is used to handle high oxygen content, then oxygen removal is achieved, but process complexity increases and 100% bio-based fuel production is limited
Solution Approach 1:
The patent merges multiple functions into a single catalytic cracking step that simultaneously handles cracking and oxygen removal. By using a moving bed catalyst system with specific catalyst compositions, the process achieves both feedstock conversion and oxygen elimination in one integrated operation, reducing process complexity while enabling 100% bio-based fuel production
3Productivity
If steam cracking is used for propylene production, then propylene is produced, but energy consumption is extremely high and it is one of the most energy-intensive industrial processes
Solution Approach 1:
The patent replaces the thermal steam cracking process with a catalytic cracking process using a moving bed catalyst system. This substitution uses catalyst-mediated reactions instead of high-temperature thermal decomposition, significantly reducing energy consumption while maintaining high propylene production rates from bio-based feedstocks
4Ease of manufacture
If co-processing with petroleum feedstocks is used, then processing of oxygenated biomass is enabled, but production of 100% bio-based fuels and chemicals is limited
Solution Approach 1:
The patent extracts and removes oxygen from bio-based feedstocks through hydrotreatment, producing pure hydrocarbon streams that can be processed independently without petroleum co-feedstocks. This extraction of oxygen enables 100% bio-based fuel production while simplifying the manufacturing process
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 achieves high propylene productivity with a favorable propylene to ethylene ratio, low energy consumption, and the production of high-quality bio-propylene and bio-gasoline components, while minimizing reactor fouling and catalyst deactivation, thus improving the sustainability and efficiency of propylene production from bio-based materials.
Implementation Method 1
catalytically cracking the catalytic cracking feed in a catalytic cracking reactor at a temperature of at least 450° C. using a moving solid catalyst
Implementation Method 2
hydrotreating an oxygen-containing bio-based feedstock to obtain a hydrotreatment effluent comprising oxygen-depleted hydrocarbons
Data Source
AI summary
The present disclosure relates to a process for manufacturing bio-based hydrocarbons, such as bio-propylene and optionally bio-gasoline, and to a bio-propylene composition, a bio-gasoline component and to a method of producing a (co)polymer composition. The process can include hydrotreating an oxygen-containing bio-based feedstock, followed by gas-liquid separation and optionally fractionation, to provide a hydrotreated bio-based hydrocarbon feed containing less than 1 wt.-% of gaseous compounds (NTP), providing a catalytic cracking feed containing the hydrotreated bio-based hydrocarbon feed; catalytically cracking the catalytic cracking feed in a catalytic cracking reactor at a temperature of at least 450° C. using a moving solid catalyst to obtain a cracking effluent; and recovering from the cracking effluent a fraction rich in bio-propylene.