Hydrogen-Rich Co-Feed for FCC Biomass Oil Processing
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Solution Overview
Problem
The challenge in fluid catalytic cracking (FCC) processes is the reduction of carbon oxide and coke formation when processing biomass oil, which leads to yield loss and decreased product value, as oxygenates in biomass oil convert to carbon oxides and coke under FCC conditions.
Innovation Solution
Incorporating a high hydrogen content co-feed, such as a vacuum gas oil boiling range fraction with a hydrogen content of 13.2 wt % or more, into the FCC process to act as hydrogen donors, reducing carbon oxide and coke formation by providing alternative reaction pathways that favor the formation of olefins and water instead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If biomass oil is processed in an FCC unit, then biomass oil can be converted to fuel products, but carbon oxides (CO, CO2) are produced representing loss of potential yield
Solution Approach 1:
The patent applies this principle by converting the harmful carbon oxides (CO, CO2) that would normally be produced from biomass oil oxygenates into beneficial liquid fuel products. This is achieved by introducing a hydrogen-rich co-feed that provides hydrogen for hydrocarbonization reactions, transforming the carbon oxides from waste products into valuable fuel components through chemical reactions with the biomass-derived oxygenates.
Solution Approach 2:
The patent changes the chemical parameters of the FCC process by introducing a hydrogen-rich co-feed with specific hydrogen content (greater than 13.8 wt%) and specific composition (naphthenes, aromatics, paraffins). This parameter change alters the reaction pathways in the FCC unit, enabling hydrocarbonization of biomass oxygenates and conversion of carbon oxides into liquid fuels rather than their traditional conversion to gaseous carbon oxides.
2Ease of manufacture
If conventional FCC processing is used on biomass oil, then processing can be performed without additional hydrogen, but yield and product value are reduced due to carbon oxide and coke formation
Solution Approach 1:
The patent introduces a hydrogen-rich co-feed as an intermediary substance that mediates between the biomass oil and the FCC catalyst. This co-feed acts as a hydrogen donor that facilitates the conversion of biomass oxygenates and carbon oxides into liquid fuels, thereby improving yield and product value while maintaining the continuous operation of the existing FCC unit without requiring separate hydrogenation equipment.
3Loss of substance
If hydrogen rich co-feed is added to reduce carbon oxide formation, then yield of desirable products is improved, but process complexity increases
Solution Approach 1:
The hydrogen-rich co-feed serves multiple functions simultaneously: it provides hydrogen for hydrocarbonization reactions, acts as a hydrogen donor to reduce carbon oxide formation, and enables the conversion of biomass oxygenates into liquid fuels. By introducing a single multi-functional co-feed stream, the patent achieves multiple benefits without requiring multiple separate process modifications or additional equipment.
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 enhances the yield of desirable products by minimizing the formation of carbon oxides and coke, thereby improving the overall product value and efficiency of the FCC process.
Implementation Method 1
Incorporating a high hydrogen content co-feed, such as a vacuum gas oil boiling range fraction with a hydrogen content of 13.2 wt % or more, into the FCC process to act as hydrogen donors, reducing carbon oxide and coke formation by providing alternative reaction pathways that favor the formation of olefins and water instead
Data Source
AI summary
Systems and methods are provided for increasing the yield of products generated during co-processing of biomass oil in a fluid catalytic cracking (FCC) system. The systems and methods can allow for increased yield by reducing or minimizing formation of carbon oxides, gas phase products, and/or coke yields during the co-processing. This can be achieved by adding a hydrogen-rich co-feed to the co-processing environment. Examples of hydrogen-rich co-feeds include high hydrogen content vacuum gas oil co-feed, high hydrogen content distillate co-feed, and/or high hydrogen content naphtha co-feed. Additionally or alternately, various types of fractions that contain a sufficient amount of hydrogen donor compounds can be used to reduce or minimize carbon oxide formation.