FCC Quench Riser Biomass Co-Processing

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Solution Overview

Problem

The integration of biomass-derived renewable fuels into existing hydrocarbon-based refinery systems is hindered by issues such as low hydrocarbon yields, reactor fouling, and catalyst deactivation due to the oxygen content in biomass, which complicates the production of transportation fuels.

Innovation Solution

Introducing a renewable fuel oil, derived from biomass through rapid thermal processing, into a fluid catalytic cracker (FCC) unit in a quench riser system downstream of petroleum fraction feedstock injection, increasing the mix-zone temperature to enhance co-processing with petroleum fractions and improve product yields.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If biomass-derived renewable fuel is introduced into FCC unit for co-processing with petroleum fractions, then gasoline yield and conversion efficiency are improved, but reactor fouling and catalyst deactivation occur due to oxygen content in biomass

Engineering Contradiction:

Improvegasoline yieldVSAvoidcatalyst activity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by introducing the renewable fuel oil into the quench riser system downstream of the petroleum fraction feedstock injection nozzle, allowing the petroleum fractions to be cracked first and creating a favorable environment before the renewable fuel oil is introduced, thereby reducing catalyst deactivation while maintaining gasoline yield

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses the quench riser system as an intermediary device to separate the introduction of petroleum fraction feedstock and renewable fuel oil, allowing controlled co-processing while minimizing direct interaction between oxygenated compounds and the catalyst that would cause deactivation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If renewable fuel oil is introduced downstream of petroleum fraction feedstock injection in quench riser system, then mix-zone temperature increases improving conversion efficiency, but energy input requirements increase

Engineering Contradiction:

Improveconversion efficiencyVSAvoidenergy input

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by increasing the mix-zone temperature through the specific introduction of renewable fuel oil downstream, which enhances conversion efficiency by altering the thermal conditions in the reaction zone to favor cracking reactions

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If rapid thermal processing is used to produce renewable fuel oil from biomass, then liquid yield approaches 80% with light pourable appearance, but processing time must be extremely short less than 5 seconds

Engineering Contradiction:

Improveliquid yieldVSAvoidprocessing time

Core Design Contradiction:

Quantity of substanceVSDuration of action of moving object

Solution Approach 1:

The patent applies the skipping principle by implementing rapid thermal processing that completes the pyrolysis conversion in less than 5 seconds, rushing through the transformation process to achieve high liquid yields before secondary reactions can degrade the product quality

Inventive Principle:

Principle #21Skipping (Rushing through)

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 results in increased gasoline yields and improved conversion efficiency, reducing undesirable byproducts like dry gas and coke, while maintaining catalyst activity and extending its lifespan.

Implementation Method 1

An example of thermal conversion is pyrolysis where the biomass is converted to a liquid and char, along with a gaseous co-product by the action of heat in essentially the absence of oxygen

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

fluid catalytic cracker (FCC) unit in a quench riser system downstream of petroleum fraction feedstock injection, increasing the mix-zone temperature to enhance co-processing with petroleum fractions

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Data Source

PatentEP3913037B9Methods for renewable fuel

Publication Date: 2023.09.27 ENSYN RENEWABLES INC

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AI summary

The present application generally relates to the introduction of a renewable fuel oil as a feedstock into refinery systems or field upgrading equipment. For example, the present application is directed to methods of introducing a liquid thermally produced from biomass into a petroleum conversion unit; for example, a refinery fluid catalytic cracker (FCC), a coker, a field upgrader system, a hydrocracker, and/or hydrotreating unit; for co-processing with petroleum fractions, petroleum fraction reactants, and/or petroleum fraction feedstocks and the products, e.g., fuels, and uses and value of the products resulting therefrom.