Biofeed Deoxygenation Catalysts With Lower H2 and Reactor Demand
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Solution Overview
Problem
Existing refinery systems face challenges in efficiently processing bio-derived feedstocks due to high oxygen content and long alkyl groups, leading to high hydrogen consumption and reactor volume requirements, which are not adequately addressed by current deoxygenation and isomerization methods.
Innovation Solution
A method involving a bulk multimetallic catalyst with Group 6 and Group 8-10 metals, combined with a zeolitic isomerization catalyst, is used to deoxygenate and isomerize bio-derived feedstocks, minimizing hydrogen consumption and reactor volume, and maintaining catalyst activity in the presence of water and carbon oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional deoxygenation methods are used to process bio-derived feedstocks, then oxygen removal is achieved, but hydrogen consumption increases substantially
Solution Approach 1:
The patent changes the chemical reaction pathway parameters by using decarboxylation (removing CO2) instead of conventional hydrodeoxygenation (removing H2O). This parameter change in the deoxygenation mechanism fundamentally reduces hydrogen consumption while maintaining effective oxygen removal from bio-derived feedstocks
Solution Approach 2:
The invention extracts and removes carbon dioxide (CO2) as the primary deoxygenation pathway instead of requiring hydrogen to form water. By taking out CO2 through decarboxylation reactions, the system achieves oxygen removal without the substantial hydrogen consumption associated with conventional methods
2Productivity
If conventional deoxygenation and isomerization methods are used, then processing is achieved, but reactor volume requirements increase
Solution Approach 1:
The patent merges deoxygenation and isomerization functions into a single integrated reactor system. By combining these two previously separate processing steps into one reactor with appropriate catalysts, the total reactor volume required is reduced while maintaining full processing capability for both oxygen removal and molecular structure modification
Solution Approach 2:
The reactor system is designed with multi-functionality, capable of performing both deoxygenation (via decarboxylation) and isomerization reactions simultaneously. This universal reactor design eliminates the need for separate dedicated reactors for each function, thereby reducing overall volume requirements
3Ease of manufacture
If existing refinery equipment is converted for bio-derived feedstocks, then cost savings are achieved, but catalyst activity is reduced in the presence of water and carbon oxides
Solution Approach 1:
The invention converts the harmful presence of water and carbon dioxide (which typically deactivate conventional catalysts) into beneficial reaction products. By designing catalysts that promote decarboxylation, the system uses CO2 as a desired output rather than a deactivating contaminant, and water tolerance is improved since the reaction pathway inherently manages water formation
Solution Approach 2:
The patent employs base metal catalysts (such as nickel, cobalt, or iron) that are inexpensive and can be easily replaced or regenerated compared to precious metal catalysts. These base metal catalysts maintain activity in the presence of water and carbon oxides, providing a cost-effective solution for converted refinery equipment
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
The method reduces hydrogen consumption and reactor volume, allowing for efficient production of distillate fuels with improved cold flow properties, while maintaining catalyst activity and selectivity, enabling retrofitting of existing reactors for bio-derived feed processing.
Implementation Method 1
exposing a feed including a bio-derived feedstock, the feed having an organic oxygen content of 1.0 wt % or more, to a bulk multimetallic catalyst including at least one Group 6 metal and at least one Group 8-10 metal under deoxygenation conditions to form a deoxygenated effluent including hydrocarbons, CO, CO2, and water
Implementation Method 2
cascading at least a portion of the deoxygenated effluent to an isomerization catalyst under isomerization conditions to form an isomerized, deoxygenated effluent
Implementation Method 3
The decarboxylation is achieved by first saturating the bio-derived feed
Data Source
AI summary
Systems and methods are provided for reducing hydrogen consumption during deoxygenation of bio-derived (or at least partially bio-derived) feedstocks. The reduced hydrogen consumption is achieved by performing the deoxygenation in the presence of a bulk multimetallic catalyst and/or in the presence of a base metal dewaxing catalyst having reduced metal stack heights. Additionally, due in part to being able to reduce or minimize hydrogen consumption, the heat release during deoxygenation can also be reduced, thus allowing a smaller catalyst volume to perform deoxygenation.