Bulk Metal Catalyst Deoxygenation for Biofeed Processing
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Solution Overview
Problem
Conventional hydroprocessing methods face challenges when dealing with biocomponent feeds derived from renewable sources, such as high oxygen content leading to catalyst poisoning, contaminant build-up, and hydrogen consumption, which complicates temperature control and catalyst activity in refinery processing.
Innovation Solution
The use of bulk metal catalysts comprising at least 80 wt% active metals, specifically Group VI and Group VIII metals, in a deoxygenation zone to selectively remove oxygen from biocomponent feeds, followed by hydrotreatment, helps manage temperature and reduce hydrogen consumption, and can be used in standalone or multi-stage processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing methods are used to remove oxygen from biocomponent feeds, then oxygen content is reduced, but catalyst poisoning and contaminant build-up occur
Solution Approach 1:
The hydroprocessing system is divided into separate functional zones: a deoxygenation zone with bulk metal catalysts specifically for oxygen removal, and a hydrotreatment zone for sulfur and nitrogen removal. This segmentation allows each zone to be optimized for its specific function, preventing catalyst poisoning in the deoxygenation zone while maintaining overall system reliability.
Solution Approach 2:
A bulk metal catalyst system acts as an intermediary between the biocomponent feed and the conventional hydrotreatment catalyst. This intermediary deoxygenates the feed first, removing oxygen that would otherwise poison the subsequent hydrotreatment catalyst, thereby protecting the main catalytic system from degradation.
2Quantity of substance
If conventional hydroprocessing methods are used to remove oxygen from biocomponent feeds, then oxygen content is reduced, but hydrogen consumption increases
Solution Approach 1:
The deoxygenation zone operates under specific parameter conditions (temperature, pressure, hydrogen partial pressure) that are optimized for oxygen removal with minimal hydrogen consumption. By controlling these parameters, the system achieves effective deoxygenation while reducing the overall hydrogen demand compared to conventional methods.
3Quantity of substance
If conventional hydroprocessing methods are used to remove oxygen from biocomponent feeds, then oxygen content is reduced, but temperature control becomes difficult
Solution Approach 1:
The reaction system is segmented into a deoxygenation zone and a hydrotreatment zone, each operating at optimized temperature conditions. The deoxygenation zone can operate at lower temperatures with bulk metal catalysts, while the hydrotreatment zone operates at higher temperatures for sulfur and nitrogen removal, making overall temperature control more manageable.
4Reliability
If bulk metal catalysts are used in a deoxygenation zone, then oxygen content is reduced and catalyst activity is stabilized, but device complexity increases
Solution Approach 1:
The bulk metal catalyst deoxygenation system is integrated with the conventional hydrotreatment system in a unified refinery processing train. The deoxygenation zone is positioned upstream of the hydrotreatment zone, and both systems share common utilities and control infrastructure, thereby reducing the actual complexity increase despite the added functional zone.
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 effectively reduces oxygen content, stabilizes catalyst activity, and minimizes hydrogen usage, enhancing the efficiency and manageability of the deoxygenation process, particularly at lower temperatures, thus addressing the challenges posed by biocomponent feeds.
Implementation Method 1
methods for hydroprocessing feeds derived in part or whole from renewable biological sources utilizing bulk metal catalysts to deoxygenate the biocomponent feeds
Implementation Method 2
The use of bulk metal catalysts comprising at least 80 wt% active metals, specifically Group VI and Group VIII metals, in a deoxygenation zone to selectively remove oxygen from biocomponent feeds
Data Source
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AI summary
This invention relates to methods for deoxygenation utilizing bulk metal catalysts feedstocks derived in part or whole from biological sources and alternatively, further hydrotreatment processing of such deoxygenated feedstocks. Feedstocks containing bio-derived feed components, and preferably additionally mineral oil feed components, are deoxygenated in a first stage or zone using a bulk metal catalyst. In additional embodiments, the deoxygenated feedstock effluent from the deoxygenation stage is further subjected to a hydrodesulfurization stage or zone.