Biofeedstock Hydrotreating Catalyst for Lower-Temperature Deoxygenation
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Solution Overview
Problem
Producing renewable fuels from biological feedstocks faces challenges such as high unsaturation, high oxygen content, and high hydrogen consumption, leading to difficult heat management and ammonia risks in catalyst manufacturing, with existing molybdenum-based catalysts requiring aqueous solutions.
Innovation Solution
A catalyst comprising low amounts of molybdenum, nickel, and phosphorus is used for hydrotreating, allowing lower reaction temperatures and reducing coke formation, pressure drop, and extending run lengths, while achieving good hydrodeoxygenation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional molybdenum-based catalysts are used for hydrotreating biological feedstocks, then hydrodeoxygenation activity is achieved, but high reaction temperatures are required which lead to increased coke formation and pressure drop
Solution Approach 1:
The patent applies composite materials by combining molybdenum sulfide with specific promoters (nickel and phosphorus) to create a catalyst that achieves high hydrodeoxygenation activity at lower temperatures. The composite structure allows the catalyst to maintain effectiveness while operating under milder conditions, thereby reducing coke formation and pressure drop issues associated with high-temperature operation
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by introducing specific promoters (nickel at 0.1-2 wt%, phosphorus at 0.01-1 wt%) to the molybdenum sulfide base. This parameter modification enables the catalyst to achieve optimal performance at lower temperatures, directly addressing the contradiction between maintaining activity and reducing operating temperature
2Ease of manufacture
If aqueous solutions are used in catalyst manufacturing to stabilize the catalyst, then catalyst production is enabled, but ammonia is released which poses risks to people, process, and environment
Solution Approach 1:
The patent extracts and eliminates the aqueous solution step from the catalyst manufacturing process. By using a non-aqueous impregnation method with controlled drying, the process avoids ammonia release while still achieving proper catalyst formation. This removes the harmful aspect while preserving the manufacturing functionality
Solution Approach 2:
The patent introduces a non-aqueous impregnation solution as an intermediary medium to replace water in the catalyst preparation process. This intermediary allows for stable catalyst formation without the harmful ammonia release associated with aqueous processing, thereby eliminating the harmful factor while maintaining ease of manufacture
3Reliability
If high hydrogen consumption is required for hydrodeoxygenation of high oxygen content feedstocks, then effective oxygen removal is achieved, but heat management becomes difficult at commercial scale
Solution Approach 1:
The patent changes the catalyst composition parameters by adding promoters that enhance oxygen removal efficiency. This allows the reaction to proceed more effectively at lower temperatures, reducing the heat release intensity while maintaining high hydrodeoxygenation efficiency, thereby making heat management feasible at commercial scale
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 catalyst achieves efficient hydrodeoxygenation at lower temperatures, mitigating coke formation and pressure drop issues, and extending reactor run lengths, with improved operational safety and efficiency.
Implementation Method 1
The process employs a specific molybdenum-based catalyst... a catalyst comprised of about 2 to 6 wt. % Mo, 0.2 to 0.9 wt. % Ni and 0.05 to 0.5 wt. % P
Implementation Method 2
The degree of unsaturation is often high with these feedstocks and hydrogenating the double bond is part of the reaction steps
Implementation Method 3
These renewable feedstocks often contain high levels of oxygen and require a hydrodeoxygenation reaction that consumes a large amount of hydrogen
Data Source
AI summary
The present process effectively produces hydrocarbon products upon hydrotreating a feedstock of biological origin. The process comprises first providing a bio feedstock, then passing the feedstock to a reactor comprising a catalyst comprised of about 2 to 6 wt. % Mo, 0.2 to 0.9 wt. % Ni, and 0.05 to 0.50 wt. % P. The bio feedstock is then reacted over the catalyst. The reaction provides good hydrodeoxygenation at a lower reactor temperature than typically required.