Biomass Lubricant Base Oil Production via Single Reactor Catalyst Mixture
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Solution Overview
Problem
Current methods for processing biomass to produce lubricant base oils face challenges such as the need for separate reactors for deoxygenation, which increases costs and complexity, and the difficulty in controlling the production of diesel and lubricant boiling range molecules simultaneously.
Innovation Solution
A method involving a single reactor configuration using a catalyst mixture with rare earth metal salts, alkali metal salts, or alkaline earth metal salts, along with a dewaxing catalyst, to convert glycerides into ketones and subsequently deoxygenate and isomerize them, allowing for the production of both diesel and lubricant boiling range molecules without intermediate separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate reactors are used for deoxygenation and isomerization steps, then each reaction can be optimized independently, but device complexity and processing costs increase
Solution Approach 1:
The patent combines deoxygenation and isomerization reactions into a single reactor by using a bifunctional catalyst system. The first catalyst (e.g., metal oxide or hydroxide) performs deoxygenation of fatty acids to form ketones, while the second catalyst (e.g., zeolite or alumina) simultaneously performs isomerization. This merging of functions into one reactor reduces device complexity and processing costs while maintaining reaction effectiveness.
Solution Approach 2:
The single reactor system is designed to perform multiple functions: deoxygenation, isomerization, and product separation in one vessel. The catalyst bed is configured to handle different reaction types at different zones, making the reactor a multi-functional unit that replaces what would traditionally require separate specialized reactors.
2Device complexity
If a single reactor is used for deoxygenation and isomerization, then device complexity is reduced, but controlling the ratio of diesel to lubricant boiling range molecules becomes more difficult
Solution Approach 1:
The single reactor is divided into distinct functional zones or beds. The first catalyst zone is optimized for deoxygenation reactions, while the second catalyst zone is optimized for isomerization. This segmentation allows each catalyst to perform its specific function optimally while maintaining overall control over the product distribution between diesel and lubricant boiling range molecules.
Solution Approach 2:
Different catalysts are placed in different locations within the reactor to create local optimization. The deoxygenation catalyst is positioned where fatty acid conversion is needed, while the isomerization catalyst is positioned to optimize the subsequent isomerization of ketones. This local quality approach allows precise control over reaction pathways and product ratios.
3Loss of time
If multiple processing steps are integrated in a single reactor, then processing time is reduced, but catalyst stability under reaction conditions becomes more critical
Solution Approach 1:
The catalyst system uses composite materials that combine multiple functional components. The first catalyst (metal oxide/hydroxide) and second catalyst (zeolite/alumina) are used in combination, either as separate beds or mixed, to achieve both deoxygenation and isomerization. This composite catalyst approach allows each component to contribute its specific functionality while maintaining stability under the integrated reaction conditions.
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 reduces costs by integrating deoxygenation and isomerization steps in a single reactor, effectively controlling the ratio of diesel to lubricant boiling range molecules and improving the efficiency of biomass processing.
Implementation Method 1
converting the triglyceride containing feed to fatty ketones via a condensation reaction
Implementation Method 2
The ketones are then deoxygenated in a hydrogenation step to form paraffins
Implementation Method 3
which were then isomerized
Data Source
AI summary
Methods are provided for processing glycerides to form lubricant boiling range molecules in a single reactor and/or a single reaction zone. The glycerides are exposed to catalysts that are stable under the conditions present in the reaction zones during conversion of glycerides to fatty ketones via a coupling reaction in the presence of a first catalyst, and the subsequent deoxygenation and isomerization of the ketones in the presence of a second dewaxing catalyst. The glyceride-containing feedstock can further include free fatty acids or fatty acid derivatives that can also be used for formation of ketones and subsequent deoxygenation and isomerization. In some configuration, the processing can occur in a single reaction zone containing mixed beds of the first and second catalyst. Such configurations can be used to control the ratio of diesel boiling range molecules versus lubricant boiling range molecules generated by the methods.