C3-C12 Oxygenate Conversion via Segmented Sulphided Catalysis
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Solution Overview
Problem
Existing processes for converting C3-C12 oxygenates to middle distillate boiling products face catalyst deactivation issues due to coke formation and poisoning, limiting their operational duration and efficiency.
Innovation Solution
A process involving a sulphided hydrogenation catalyst, followed by a sulphided carbon-carbon coupling catalyst under high hydrogen pressure, and optionally sulphided hydrotreating and hydroisomerization catalysts, to produce a middle distillate boiling product with extended catalyst stability and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing processes for converting C3-C12 oxygenates are used, then conversion to middle distillate boiling products is achieved, but catalyst deactivation occurs due to coke formation and poisoning, limiting operational duration
Solution Approach 1:
The conversion process is divided into multiple sequential reaction steps, each performed in a separate reactor with a specific catalyst type optimized for that step. This segmentation allows each catalyst to operate under optimal conditions for its specific function, reducing overall deactivation and extending operational duration while maintaining high conversion efficiency.
Solution Approach 2:
The invention employs a multi-reactor system where reaction parameters (temperature, pressure, catalyst type) are changed between steps. By optimizing parameters for each specific reaction step rather than using a single set of conditions, the process achieves high conversion efficiency while reducing catalyst deactivation through parameter optimization at each stage.
2Shape
If high temperature oligomerization is used to convert alcohols to hydrocarbons, then longer chain hydrocarbons are produced, but excessive coking and catalyst deactivation occur
Solution Approach 1:
The oligomerization process is segmented into multiple reaction steps across different reactors, with each step producing hydrocarbons of controlled chain length. This prevents the formation of excessively long chains that would lead to severe coking, while still achieving the desired longer chain products through cumulative growth across steps.
Solution Approach 2:
Hydrogen is introduced as an intermediary substance that reacts with coke precursors during the oligomerization process. This hydrogen mediation reduces coke formation by converting carbonaceous deposits into hydrocarbons that can be managed, thereby extending catalyst life while maintaining product quality.
3Duration of action of stationary object
If multiple catalysts are used in sequence, then catalyst stability is extended, but process complexity increases
Solution Approach 1:
The process uses multiple reactors with different catalysts, each optimized for a specific conversion step. This segmentation extends catalyst stability by matching catalyst type to reaction step, while the modular reactor design keeps process complexity manageable through standardized units.
Solution Approach 2:
Each reactor unit is designed with multi-functionality, serving as a complete reaction stage that can be independently operated and maintained. This universal design approach allows the same reactor configuration to handle different catalyst types and reaction conditions, reducing overall process complexity while maintaining catalyst stability.
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 process allows for prolonged catalyst stability and efficient conversion of C3-C12 oxygenates to middle distillate boiling products with a smooth distillation curve, suitable for biofuel production, while reducing coke formation and catalyst deactivation.
Implementation Method 1
contacting a feed comprising one or more C3-C12 oxygenates with a source of hydrogen in the presence of a sulphided hydrogenation catalyst to produce a partially hydrogenated effluent
Implementation Method 2
contacting at least part of the partially hydrogenated effluent with a source of hydrogen at a hydrogen partial pressure of at least 0.1 MegaPascal in the presence of a sulphided carbon-carbon coupling catalyst to produce a conversion product
Data Source
AI summary
A process for converting one or more C3-C12 oxygenates comprising:1) contacting a feed comprising C3-C12 oxygenates with hydrogen in the presence of a sulphided hydrogenation catalyst to produce a partially hydrogenated effluent;2) contacting the partially hydrogenated effluent with hydrogen at a hydrogen partial pressure of at least 0.1 MegaPascal in the presence of a sulphided carbon-carbon coupling catalyst to produce a conversion product;3) optionally contacting at least part of the conversion product with hydrogen in the presence of a sulphided hydrotreating catalyst and/or a sulphided hydroisomerization catalyst to produce a conversion product; and4) optionally purifying the conversion product, optionally hydrotreated and/or hydroisomerized, conversion product to obtain a final product,wherein the carbon-carbon coupling catalyst comprises at least 60 wt % of a zeolite and in the range from 0.1 wt % to 10 wt % of a hydrogenation metal, based on the total weight of the carbon-carbon coupling catalyst.