Hydroprocessing Biocomponent Feedstocks via Phase Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hydroprocessing of biocomponent feeds for diesel fuel production is costly due to high hydrogen consumption and generates CO and CO2, which pose challenges for hydrogen recycling and catalyst poisoning.
Innovation Solution
A method involving multiple hydrotreating stages with a continuous gas phase environment, followed by a hydroprocessing stage with a continuous liquid phase, where hydrogen is partially dissolved in recycled product streams, reducing overall hydrogen consumption and minimizing CO and CO2 production, allowing for integration of dewaxing and aromatic saturation stages while minimizing catalyst poisoning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing is used for biocomponent feeds, then the diesel fuel can be produced, but hydrogen consumption becomes excessively high (over 1000 scf/bbl)
Solution Approach 1:
The hydroprocessing process is divided into multiple stages with different phase environments. The first stage uses gas phase conditions for initial hydrodeoxygenation, while subsequent stages transition to liquid phase conditions for final processing. This segmentation allows each stage to operate under optimized conditions, reducing overall hydrogen consumption compared to single-stage conventional processing.
Solution Approach 2:
The patent changes the physical state parameter of the reaction medium from purely gas phase to liquid phase in subsequent stages. This parameter change enables better hydrogen utilization and reduces excessive hydrogen consumption by matching the hydrogen delivery method to the specific processing requirements of each stage.
2Object-generated harmful factors
If conventional hydroprocessing is used for biocomponent feeds, then hydrogen is consumed for processing, but CO and CO2 are generated which complicate hydrogen recycling
Solution Approach 1:
The patent extracts and removes CO and CO2 from the reaction system by designing the process to minimize their generation in the first place. By using controlled hydrodeoxygenation conditions and transitioning to liquid phase processing, the system reduces the formation of these harmful byproducts, thereby simplifying hydrogen recycling operations.
Solution Approach 2:
The patent converts the potential harm of CO and CO2 generation into a benefit by controlling the hydrodeoxygenation process to produce these gases in manageable quantities that can be integrated into the fuel product or handled more easily in subsequent processing stages, rather than requiring complex scrubbing systems.
3Loss of energy
If high hydrogen consumption is used for biocomponent processing, then the feed can be processed, but the operating cost increases significantly
Solution Approach 1:
The patent implements self-service by using the liquid phase product stream itself as the hydrogen delivery medium in subsequent stages. The liquid phase naturally carries dissolved hydrogen, eliminating the need for separate hydrogen injection systems and reducing overall hydrogen consumption costs while maintaining productive processing rates.
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 approach reduces hydrogen consumption, eliminates the need for hydrogen recycling, and minimizes CO and CO2 contaminants, resulting in a deoxygenated diesel fuel with low sulfur content and improved catalyst performance.
Implementation Method 1
hydrogen at least partially dissolved in a liquid phase feedstock
Implementation Method 2
contacting a feedstock with a hydrotreating catalyst in a plurality of hydrotreating stages
Implementation Method 3
hydrotreating stages under effective hydrotreating conditions
Implementation Method 4
contacting the liquid phase effluent portion with a catalyst in a hydroprocessing stage
Implementation Method 5
hydroprocessing stage under effective hydroprocessing conditions to form a diesel fuel product, the diesel fuel product being substantially deoxygenated
Data Source
AI summary
Diesel fuel is produced from a feedstock that is at least partially biocomponent in origin. A feedstock is treated in a reactor including one or more hydrotreating zones having a continuous gas phase. The liquid effluent from the hydrotreating zones is then hydroprocessed in a hydroprocessing zone having a continuous liquid phase, such as a hydroprocessing zone in the same reactor. The hydroprocessing zone can be operated under effective catalytic dewaxing conditions.