Biorenewable Naphtha via Hydrotreating and Hydrocracking
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Solution Overview
Problem
Current methods for producing biorenewable naphtha from biomass face challenges such as high capital costs, low reliability of gasifiers, and inefficiencies in the Fischer-Tropsch process, as well as existing production facilities being designed for petroleum-based hydrocarbons, making it difficult to transition to a green chemical industry.
Innovation Solution
A method involving hydrotreating and hydrocracking of triglycerides and fatty acids from biomass to produce a biorenewable naphtha composition that can be used as a feedstock for existing refining processes, resulting in a naphtha boiling range hydrocarbon product free of oxygenates and benzene, suitable for use in chemical production, fuel, and solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Fischer-Tropsch process is used to convert biomass to naphtha, then biorenewable naphtha can be produced, but capital costs are very high and reliability is low
Solution Approach 1:
The patent changes the fundamental processing parameters by replacing gasification (high temperature, complex solids handling) with direct hydroprocessing (moderate temperature, liquid phase). This parameter change eliminates the need for gasifiers and F-T synthesis while achieving the same end goal of producing biorenewable naphtha from triglyceride feedstocks.
Solution Approach 2:
The patent extracts and eliminates the problematic intermediate steps (gasification, syngas purification, F-T conversion) from the process chain. By directly hydroprocessing triglycerides to naphtha, it removes the gasifier component entirely, thereby improving reliability and reducing capital costs associated with solids handling and heat removal provisions.
2Adaptability or versatility
If existing production facilities are used, then current infrastructure can be utilized, but they are designed for petroleum-based hydrocarbons and cannot process biomass
Solution Approach 1:
The patent makes existing hydroprocessing facilities universal by demonstrating that they can process both traditional petroleum feedstocks and biorenewable triglyceride feedstocks using the same technology platform. This multi-functionality allows refineries to adapt to biorenewable feedstocks without building entirely new infrastructure, thereby improving adaptability while avoiding increased device complexity.
Solution Approach 2:
The patent uses hydroprocessing as an intermediary technology that bridges petroleum-based and biorenewable chemistry. The hydroprocessing unit acts as a mediator that can handle both feedstock types, enabling a transition pathway that doesn't require complete infrastructure replacement and maintains compatibility with existing facilities.
3Object-affected harmful factors
If multiple purification steps are used to remove benzene from naphtha, then food-contact quality hexane can be obtained, but the process becomes costly and complex
Solution Approach 1:
The patent converts the potential harm of benzene formation into a benefit by designing a process that inherently prevents benzene formation. By using hydroprocessing of triglycerides rather than steam cracking of petroleum naphtha, the process produces a benzene-free product from the outset, eliminating the need for costly purification steps while still achieving food-contact quality standards.
Solution Approach 2:
The patent performs preliminary action by preventing benzene formation at the source through the choice of feedstock and processing method. Instead of removing benzene after formation through multiple purification steps, the process design ensures benzene is never formed in the first place, thereby eliminating subsequent purification costs and 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
The method effectively converts high oxygen content biomass into a biorenewable naphtha with a high paraffinic content, suitable for use in steam crackers, gasoline blends, and as a solvent, while avoiding the need for new infrastructure and reducing capital costs by utilizing standard refining processes.
Implementation Method 1
The D2500 steam cracker is designed to process biorenewable naphtha feedstock and produce olefin products
Implementation Method 2
The R1000 catalytic reformer is configured to process biorenewable naphtha and maximize production of BTX aromatics
Data Source
AI summary
The present invention generally relates to a method for producing a naphtha product from a renewable feedstock. The method includes hydrotreating the renewable feedstock to produce a hydrotreating unit heavy fraction that includes n-paraffins, and hydrocracking the hydrotreating unit heavy fraction to produce a hydrocracking unit product that includes the naphtha product. The method also includes separating the naphtha fraction and optionally recycling the hydrocracking unit heavy fraction through the hydrocracking unit. The present invention also relates to a biorenewable naphtha product suitable for use as feed stock for steam crackers and catalytic reforming units, and for use as fuel, or fuel blend stock.