Single-Step Hydroprocessing of Biological Feed Using NiW Dewaxing Catalyst

Solution Overview

Problem

Current processes for producing fuel components from biological sources require multiple steps, leading to reduced yield, increased investment costs, and complexity due to sulfur poisoning of catalysts, especially in isomerization stages.

Innovation Solution

A single-step hydroprocessing method using a dewaxing catalyst capable of hydrodeoxygenating, isomerizing, and cracking, which tolerates sulfur, allowing for the direct conversion of biological feeds into fuel components without the need for sulfur removal pretreatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a two-stage process with HDO/HDS followed by isomerisation is used, then fuel components can be produced from biological materials, but the process complexity increases and yield decreases due to multiple steps and purification requirements

Engineering Contradiction:

Improveyield of fuel componentsVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines HDO, HDS, isomerisation, and cracking functions into a single hydroprocessing stage using a bifunctional catalyst system (NiW/Al2O3), eliminating the need for separate purification stages and intermediate handling, thereby maintaining high yield while reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dewaxing catalyst performs multiple functions simultaneously: hydrodeoxygenation, hydrodesulphurisation, isomerisation of n-paraffins to isoparaffins, and cracking, making the process more efficient and reducing the number of required process steps

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional HDO/HDS catalysts are used in the first stage, then heteroatoms are removed, but the isomerisation catalyst is poisoned by sulphur compounds requiring intermediate purification

Engineering Contradiction:

Improvecatalyst performanceVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The dewaxing catalyst performs multiple functions simultaneously: hydrodeoxygenation, hydrodesulphurisation, isomerisation of n-paraffins to isoparaffins, and cracking, making the process more efficient and reducing the number of required process steps

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The catalyst system tolerates and utilizes sulphur compounds present in biological feeds, converting them to hydrogen sulphide that can be removed with gas stream, while the sulphur-tolerant catalyst maintains its isomerisation activity without poisoning

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If multiple process steps are arranged in series, then fuel components can be produced, but the final yield rate decreases due to cumulative yield loss in each step

Engineering Contradiction:

Improvefinal yield rateVSAvoidprocessing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent combines HDO, HDS, isomerisation, and cracking functions into a single hydroprocessing stage using a bifunctional catalyst system (NiW/Al2O3), eliminating the need for separate purification stages and intermediate handling, thereby maintaining high yield while reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single-stage continuous hydroprocessing operation maintains high yield by performing all necessary conversions in one continuous process without interruption for purification or catalyst replacement, maximizing productivity

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 simplifies the process, maintains high yield, reduces costs, and improves cold flow properties of fuels by eliminating the need for intermediate purification steps and using sulfur-tolerant dewaxing catalysts like NiW on Al2O3 supports.

Implementation Method 1

The dewaxing catalyst is used for hydrogenating the double bonds of the feed originating from biological material and for removing by hydrogenation heteroatoms of the feed molecules, especially oxygen

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Implementation Method 2

a catalyst system comprising dewaxing catalyst capable of hydrodeoxygenating, isomerising and cracking

Methodology Applied

Scientific EffectHydrodeoxygenation:

Implementation Method 3

At the same time sulphur compounds are reduced to hydrogen sulphide

Methodology Applied

Scientific EffectHydrodesulphurisation:

Implementation Method 4

The dewaxing catalyst is also capable of isomerizing straight carbon backbones of n-paraffins (linear alkanes) to branched backbones of isoparaffins (branched alkanes) and cracking

Methodology Applied

Scientific EffectIsomerisation:

Implementation Method 5

a catalyst system comprising dewaxing catalyst capable of hydrodeoxygenating, isomerising and cracking

Methodology Applied

Scientific EffectCracking:

Data Source

PatentUS9790439B2Process and apparatus for producing fuel from a biological origin through a single hydroprocessing step in the presence of a NiW catalyst

Publication Date: 2017.10.17 UPM KYMMENE OYJ

AI summary

The present invention relates to a process for producing mixture of fuel components, which process comprises providing a feed of biological origin; subjecting said feed of biological origin and a hydrogen gas feed to a single step of hydroprocessing in the presence of a catalyst system comprising dewaxing catalyst to form a mixture of fuel components. The present invention relates also to an apparatus for producing a mixture of fuel components from a feed of biological origin. The invention relates also to the use of the fuel components.