Co-processing Biomass Liquids in FCC Units
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Solution Overview
Problem
The integration of biomass-derived fuels into existing hydrocarbon-based refinery systems is hindered by the oxygen content in biomass, leading to inefficient conversion, reactor fouling, and low hydrocarbon yields, with existing methods requiring complex and costly upgrading processes.
Innovation Solution
Co-processing thermally-produced biomass-derived liquids with petroleum fractions in refinery units, such as fluid catalytic crackers, without prior hydrotreatment, to reduce oxygen content and improve hydrocarbon production, using a method that includes adjusting feed addition rates and catalyst ratios to optimize fuel product profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If biomass-derived liquids are introduced into refinery systems, then renewable fuel production is achieved, but oxygen content causes inefficient conversion and reactor fouling
Solution Approach 1:
The patent uses a co-processing approach where biomass-derived liquids are mixed with petroleum fractions before entering the refinery system. This intermediary mixture acts as a mediator that allows the oxygen-containing biomass to be processed alongside hydrocarbon-rich petroleum, reducing the direct negative impact of oxygen on conversion efficiency while maintaining renewable fuel production
Solution Approach 2:
The patent modifies operational parameters including feed addition rates and catalyst ratios to optimize the co-processing of biomass-derived liquids. By adjusting these parameters, the system maintains efficient conversion despite the presence of oxygen-containing compounds, resolving the contradiction between renewable fuel production and conversion efficiency
2Productivity
If biomass-derived liquids are introduced into refinery systems, then renewable fuel production is achieved, but reactor fouling and operational complexities increase
Solution Approach 1:
The patent enables existing refinery units to perform multiple functions: processing both traditional petroleum fractions and biomass-derived liquids simultaneously. This multi-functionality allows the same equipment to handle diverse feedstocks without requiring separate dedicated biomass processing facilities, thus avoiding increased operational complexity while maintaining renewable fuel production
Solution Approach 2:
The patent employs co-processing where biomass-derived liquids are introduced at controlled ratios (typically 1-20% by weight) rather than as pure feedstock. This partial action approach allows the refinery to benefit from renewable fuel production while limiting the amount of oxygen-containing compounds that could cause fouling and operational issues
3Reliability
If complex upgrading processes are used to remove oxygen from biomass, then conversion efficiency improves, but process complexity and cost increase
Solution Approach 1:
Instead of using complex upgrading processes to extract and remove oxygen from biomass-derived liquids before refining, the patent takes a different approach by introducing the biomass liquids directly into the refinery system where they are co-processed with petroleum fractions. The oxygen is effectively managed through the refining process itself rather than requiring separate extraction steps, thereby maintaining conversion efficiency while avoiding additional process complexity
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 achieves equivalent or greater fuel yields and product compatibility with petroleum-derived fuels, reducing reactor fouling and operational complexities while maintaining environmental compliance with renewable fuel standards.
Implementation Method 1
co-processing with petroleum fractions, petroleum fraction reactants, and/or petroleum fraction feedstocks and the products, e.g., fuels
Implementation Method 2
An example of thermal conversion is pyrolysis where the biomass is converted to a liquid and char, along with a gaseous co-product by the action of heat in essentially the absence of oxygen
Data Source
AI summary
The present application generally relates to the introduction of a renewable fuel oil as a feedstock into refinery systems or field upgrading equipment. For example, the present application is directed to methods of introducing a liquid thermally produced from biomass into a petroleum conversion unit; for example, a refinery fluid catalytic cracker (FCC), a coker, a field upgrader system, a hydrocracker, and/or hydrotreating unit; for co-processing with petroleum fractions, petroleum fraction reactants, and/or petroleum fraction feedstocks and the products, e.g., fuels, and uses and value of the products resulting therefrom.