Biomass Pyrolysis Oil Catalyst via Co-Mulling
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Solution Overview
Problem
Existing catalysts for converting biomass-derived pyrolysis oil are either too expensive or pose safety risks due to the use of volatile, flammable, and toxic solvents, and they are not effective in handling high water contents and high temperatures, leading to catalyst inactivation and coke formation.
Innovation Solution
A process using a co-mulling technique to prepare a catalyst with a high loading of Group VIII metals, such as nickel, and a refractory oxide, with a small amount of liquid, followed by shaping, drying, and calcination, which is more economical and stable, and does not require a sulfidation step for activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalysts are used for converting biomass-derived pyrolysis oil, then catalytic activity can be achieved, but the catalysts become deactivated and form coke due to high water content and high temperature conditions
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific metal compounds (nickel, copper, zinc, manganese, cobalt, or iron) in optimized weight ratios (metal compound:refractory oxide = 1:9 to 4:6). This compositional parameter change enables the catalyst to maintain stability and resist deactivation under high water content and high temperature conditions, preventing coke formation while maintaining catalytic activity.
2Productivity
If expensive catalyst formulations are used to improve catalytic activity, then conversion efficiency increases, but manufacturing cost increases significantly
Solution Approach 1:
The patent employs inexpensive metal compounds (nickel, copper, zinc, manganese, cobalt, or iron) that can be readily obtained and processed. The catalyst is prepared using simple co-mulling with readily available refractory oxides like alumina, silica, or titania. This approach achieves effective pyrolysis oil conversion without requiring expensive precious metals or complex catalyst formulations, significantly reducing manufacturing costs while maintaining productivity.
Solution Approach 2:
The patent creates a composite catalyst material by combining metal compounds with refractory oxide carriers in specific ratios. This composite structure integrates the catalytic activity of metal compounds with the thermal stability and mechanical strength of refractory oxides, achieving both high conversion efficiency and cost-effectiveness through synergistic material combination rather than using expensive single-component catalysts.
3Ease of manufacture
If volatile, flammable, and toxic solvents are used in catalyst preparation, then catalyst formation can be achieved, but safety risks increase due to volatility, flammability, and toxicity
Solution Approach 1:
The patent extracts and eliminates volatile, flammable, and toxic solvents from the catalyst preparation process. Instead of using conventional impregnation methods requiring such solvents, the invention employs a co-mulling technique where metal compounds and refractory oxides are mixed directly with a small amount of water or no liquid binder, forming a moldable paste that can be shaped and calcined. This extraction of hazardous substances maintains ease of manufacture while eliminating safety risks.
4Productivity
If high metal loading is used to increase catalytic activity, then conversion efficiency improves, but catalyst mechanical strength decreases
Solution Approach 1:
The patent constructs a composite catalyst where metal compounds are dispersed on refractory oxide carriers (alumina, silica, titania, or zirconia) in optimized ratios (metal compound:refractory oxide = 1:9 to 4:6). The refractory oxide provides robust mechanical strength and thermal stability, while the metal compounds provide catalytic activity. This composite architecture enables high metal loading (1-4 parts metal compound per 9-6 parts refractory oxide) without compromising mechanical integrity, achieving both high productivity and structural strength.
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 resulting catalyst is safe, cost-effective, and maintains high catalytic activity, effectively stabilizing biomass-derived pyrolysis oil by reducing oxygen content and preventing catalyst deactivation, making it suitable for commercial-scale use.
Implementation Method 1
hydro-deoxygenation of this pyrolysis oil at a temperature in the range from 200 to 400° C. with a catalyst that may for example comprise metals of Group VIII and/or Group VIB of the Periodic Table of Elements
Implementation Method 2
The resulting catalyst is safe, cost-effective, and maintains high catalytic activity, effectively stabilizing biomass-derived pyrolysis oil by reducing oxygen content and preventing catalyst deactivation
Implementation Method 3
preparing a catalyst containing at least one or more Group VIII metal(s)... by a method comprising (a) comulling (1) a refractory oxide, (2) a small amount of liquid, chosen such that the Loss On Ignition (LOI) at 485° C. of the mixture is from equal to or more than 20 wt % to equal to or less than 70 wt % based on the total weight of the catalyst composition, and (3) at least one or more metal component(s)
Implementation Method 4
calcination of the composition thus obtained to provide a calcined catalyst
Data Source
AI summary
A process for converting a biomass-derived pyrolysis oil in which the pyrolysis oil is contacted with hydrogen in the presence of a certain catalyst containing one or more Group VIII metals is provided. The catalyst is prepared by (a) comulling (1) a refractory oxide, (2) a small amount of liquid, chosen such that the Loss On Ignition (LOI) at 485° C. of the mixture is from equal to or more than 20 wt % to equal to or less than 70 wt % based on the total weight of the catalyst composition, and (3) at least one or more metal component(s), which is/are at least partially insoluble in the amount of liquid used, to form a mixture, and the metal component(s) is/are one or more Group VIII metal component,(b) optionally shaping, and drying of the mixture thus obtained; and(c) calcining the composition thus obtained to provide a calcined catalyst.