Bio-feedstock Hydroprocessing for Low Aromatic Fuel
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Solution Overview
Problem
Current processes for converting feedstock from renewable materials into hydrocarbons often result in hydrocarbon products with aromatics content exceeding the 5% weight limit required by regulations, such as the Swedish MK1 standard for diesel fuel, due to the feedstock's inherent aromatic and cyclic structures.
Innovation Solution
A process involving evaporation followed by hydroprocessing using a combination of hydrodeoxygenation (HDO), hydrodewaxing (HDW), and hydrodearomatization (HDA) catalysts, where hydrodearomatization is performed subsequent to hydrodeoxygenation and hydrodewaxing, to reduce the aromatics content in hydrocarbons to less than 5% by weight and improve cetane rating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If feedstock from renewable materials is subjected to hydroprocessing, then hydrocarbons are produced, but the aromatics content in the hydrocarbon product exceeds the 5% weight limit
Solution Approach 1:
The hydroprocessing is divided into multiple sequential stages with different catalysts: first HDO catalyst for hydrodeoxygenation, then HDW catalyst for hydrodewaxing, and finally HDA catalyst for hydrodearomatization. This segmentation allows each stage to target specific functional groups and progressively reduce aromatics content below 5% while maintaining hydrocarbon production.
Solution Approach 2:
The process utilizes parameter changes by adjusting catalyst type and reaction conditions at each stage. The sequential use of different catalysts (HDO, HDW, HDA) with varying activities and selectivities enables control over the degree of aromatic reduction, transforming the feedstock composition to meet the 5% aromatics limit while preserving fuel quality.
2Adaptability or versatility
If feedstock with high aromatic and cyclic content is used, then renewable material utilization is maximized, but the final hydrocarbon product fails to meet fuel quality standards
Solution Approach 1:
The process performs preliminary actions by sequentially removing oxygen (HDO stage) and wax structures (HDW stage) before addressing aromatic content. This preliminary treatment prepares the feedstock for the final HDA stage, enabling effective aromatic reduction while maintaining versatility in handling various renewable feedstocks with different initial compositions.
Solution Approach 2:
The invention employs a composite catalytic system combining three different catalyst types (HDO, HDW, HDA) in sequence. Each catalyst contributes specific functionality, and their combination enables simultaneous achievement of feedstock versatility and precise control over final fuel quality parameters, including aromatic content below 5%.
3Object-generated harmful factors
If multiple hydroprocessing stages are implemented, then aromatics content is reduced below 5%, but process complexity increases
Solution Approach 1:
The process merges three distinct hydroprocessing functions (HDO, HDW, HDA) into a single integrated flow scheme with sequential catalyst beds. This merging approach achieves comprehensive aromatic reduction below 5% while avoiding the need for separate independent processing units, thereby managing complexity through functional integration.
Solution Approach 2:
The hydroprocessing operates continuously through sequential catalyst stages without intermediate separation or batch processing. The continuous flow through HDO, then HDW, then HDA catalysts maintains constant aromatic reduction activity, achieving the 5% limit while minimizing downtime and operational complexity associated with discontinuous processing.
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 effectively and economically converts feedstock from biological origin into hydrocarbons with low aromatic content and improved cetane rating, meeting stringent fuel quality standards while minimizing residue and by-products.
Implementation Method 1
hydrodeoxygenation (HDO) catalyst
Implementation Method 2
at least one hydrodeoxygenation (HDO) catalyst
Implementation Method 3
hydrodewaxing (HDW) catalyst
Implementation Method 4
at least one hydrodewaxing (HDW) catalyst
Implementation Method 5
hydrodearomatization (HDA) catalyst
Implementation Method 6
at least one hydrodearomatization (HDA) catalyst
Implementation Method 7
said feedstock is subjected to evaporation
Data Source
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AI summary
The present invention relates to a process for converting feedstock comprising materials of biological origin into hydrocarbons, said process comprising the steps where a) feedstock comprising at least one material of biological origin is subjected to purification treatment to obtain purified feedstock, and b) the purified feedstock is subjected to hydroprocessing in the presence of at least one hydrodeoxygenation catalyst, at least one hydrodewaxing catalyst and at least one hydrodearomatization catalyst to obtain a hydroprocessing product.