Catalytic Process for Aromatic Aviation Fuel via Stream Segmentation
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Solution Overview
Problem
Current processes for converting renewable feedstocks into aviation fuel and hydrocarbons are energy intensive and highly exothermic, leading to high hydrogen consumption, catalyst deactivation, and unwanted side reactions, making them costly and inefficient.
Innovation Solution
A low-energy catalytic process that combines hot and cold streams of renewable feedstocks with metal sulfide catalysts under controlled conditions to reduce exothermicity and hydrogen consumption, utilizing in-situ generated energy to drive reactions and prevent side products, thereby enhancing catalyst life and product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing processes are used to convert renewable feedstocks into aviation fuel, then complete conversion of triglycerides can be achieved, but high exothermicity leads to high hydrogen consumption and catalyst deactivation
Solution Approach 1:
The hydroprocessing reaction is divided into two sequential stages: first stage converts triglycerides to FAMEs and mono/diglycerides with controlled exothermicity, second stage completes conversion to hydrocarbons. This segmentation prevents runaway exothermic reactions and reduces hydrogen consumption by avoiding simultaneous occurrence of all reactions.
Solution Approach 2:
The first stage performs preliminary conversion of triglycerides to FAMEs before the second stage completes the conversion to hydrocarbons. This preliminary action controls the exothermic heat release in manageable steps, preventing catalyst deactivation and reducing overall hydrogen consumption.
2Productivity
If high temperature and pressure are applied to achieve complete conversion, then product yield increases, but catalyst deactivation occurs due to unwanted side reactions
Solution Approach 1:
The catalytic process is segmented into two stages with different catalysts optimized for each stage. Stage 1 uses a catalyst optimized for triglyceride conversion to FAMEs, while stage 2 uses a catalyst optimized for FAME conversion to hydrocarbons. This segmentation allows each catalyst to operate under optimal conditions without suffering from side reactions that would cause deactivation.
Solution Approach 2:
Different catalysts with specific properties are used in each reaction stage. The first catalyst has properties optimized for triglyceride hydrolysis/transesterification, while the second catalyst has properties optimized for FAME hydrodeoxygenation. This local quality optimization ensures high product yield while maintaining catalyst stability in each specific reaction environment.
3Temperature
If additional quench gas is used to control reactor temperature, then temperature control is improved, but capital cost increases
Solution Approach 1:
The process uses the exothermic heat generated in the first stage reaction to preheat the feedstock for the second stage reaction. This self-service approach to temperature control eliminates or reduces the need for additional quench gas and external heating systems, thereby reducing capital costs while maintaining proper temperature control.
Solution Approach 2:
The exothermic heat that would normally require quenching to control is instead utilized as a beneficial heat source to preheat the feed for the second reaction stage. This converts the harmful excessive heat into a useful resource, eliminating the need for quench gas and associated capital investment.
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 hydrogen consumption, prevents catalyst deactivation, and increases the yield of desired hydrocarbons, including aromatics and kerosene, while maintaining stable reaction temperatures and reducing capital costs by eliminating the need for additional quench gas.
Implementation Method 1
A low-energy catalytic process that combines hot and cold streams of renewable feedstocks with metal sulfide catalysts under controlled conditions
Implementation Method 2
utilizing in-situ generated energy to drive reactions
Data Source
AI summary
A single step catalytic process for the preparation of aromatic rich aviation fuel from renewable resource in the presence of a hydrogen stream, and one or more hydroprocessing catalysts, under operating conditions for hydroconversion reactions, as defined herein, with mixed hot and cold streams of the renewable feed and getting desired product after separation of water, lighter hydrocarbon gases and carbon oxides, the said product comprising of hydrocarbons C6-C24, rich in aromatic content in the aviation fuel range, including kerosene range.