Fluid Catalytic Cracking Biocrude Deoxygenation

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Solution Overview

Problem

Conventional processes for converting biomass into hydrocarbon products face challenges such as high oxygen content in bio-oil, leading to costly and inefficient upgrading due to high hydrogen consumption, particularly in hydroprocessing methods.

Innovation Solution

A fluid catalytic cracking system is employed, which includes a riser with a catalyst, where biomass-derived liquid and hydrocarbon feeds react to produce hydrocarbon products with reduced oxygen content, typically between 0.005 wt.% to 6 wt.%, primarily removing oxygen as COx instead of water.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If hydroprocessing is used to remove oxygen from bio-oil, then oxygen content is reduced, but hydrogen consumption increases significantly and costs increase

Engineering Contradiction:

Improveoxygen contentVSAvoidhydrogen consumption

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The invention changes the fundamental reaction parameters by using catalytic cracking conditions (high temperature, catalyst presence) instead of hydroprocessing conditions (high pressure, hydrogen atmosphere). This transforms the deoxygenation mechanism from hydrogenation to cracking, eliminating the need for large amounts of hydrogen while achieving effective oxygen removal through CO2 and H2O formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention extracts and removes the oxygen component from bio-oil through catalytic cracking reactions that produce CO2 and H2O as separable byproducts. The oxygen is taken out in the form of gaseous products that can be easily separated from the liquid hydrocarbon products, avoiding the need for hydrogen addition

Inventive Principle:

Principle #2Taking out (Extraction)

2Quantity of substance

If hydroprocessing is used to remove oxygen from bio-oil, then oxygen content is reduced, but processing costs increase

Engineering Contradiction:

Improveoxygen contentVSAvoidprocessing cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The invention changes the process parameters from hydroprocessing (high pressure, hydrogen gas, specialized catalysts) to catalytic cracking (atmospheric pressure, air or inert gas, conventional cracking catalysts). This parameter change utilizes existing, well-established cracking technology and equipment, significantly reducing capital and operating costs while achieving the same deoxygenation objective

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention employs conventional catalytic cracking materials and conditions that are already widely available and economically proven in the petroleum industry. By using standard cracking catalysts and atmospheric pressure conditions rather than expensive hydroprocessing equipment and hydrogen gas, the process achieves cost-effective deoxygenation

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If biomass is converted through conventional processes, then fuel is produced, but the bio-oil has high oxygen content requiring further processing

Engineering Contradiction:

Improvefuel productionVSAvoidoxygen content in bio-oil

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The invention merges the biomass conversion process with a second catalytic cracking stage in one integrated flow. The bio-oil from biomass conversion is fed directly to the catalytic cracking unit without separate purification or stabilization steps, allowing simultaneous production of fuel and deoxygenation in a combined process sequence

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention maintains continuous useful action by directly feeding the bio-oil stream from biomass conversion into the catalytic cracking process. This eliminates intermediate storage, handling, and separate processing steps, creating a continuous flow that simultaneously achieves fuel production and oxygen removal in one operational sequence

Inventive Principle:

Principle #20Continuity of useful action

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 effectively reduces oxygen content in hydrocarbon products, achieving significant yields of liquid hydrocarbons with C3 or higher, while minimizing coke production and optimizing hydrogen usage, thus improving the efficiency and cost-effectiveness of the process.

Implementation Method 1

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

Deep deoxygenation of biocrudes utilizing fluidized catalytic cracking co-processing with hydrocarbon feedstocks

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS10647923B2Deep deoxygenation of biocrudes utilizing fluidized catalytic cracking co-processing with hydrocarbon feedstocks

Publication Date: 2020.05.12 ALBEMARLE CORP

AI summary

A system and method produce hydrocarbons from biomass by fluid catalytic cracking. In one embodiment, the system is a fluid catalytic cracking system. The system includes a riser. The riser contains a catalyst. The system also includes a biological feed comprising biomass-derived liquid for the riser. In addition, the system includes a hydrocarbon feed comprising hydrocarbons for the riser. The biological feed and the hydrocarbons react in the riser in the presence of the catalyst to convert at least a portion of the biological feed and the hydrocarbons to hydrocarbon products. The hydrocarbon products comprise a concentration of oxygen from about 0.005 wt. % to about 6 wt. %.