Selective HDO Stream Vaporization to Cut AC Catalyst Coke
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Solution Overview
Problem
Coke formation leads to the deactivation of acid condensation catalysts, necessitating time-consuming and costly regeneration processes, which disrupts the continuous operation of petrochemical and energy transformation processes.
Innovation Solution
A method involving hydrodeoxygenation (HDO) and acid condensation (AC) processes, where an aqueous feed stream is reacted with hydrogen, vaporized to produce a gaseous stream, and then reacted with an AC catalyst, with recycled AC product stream and superheated steam to reduce coke yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acid condensation catalyst is used to convert oxygenates into hydrocarbons, then hydrocarbon production is improved, but coke accumulates on the catalyst causing deactivation
Solution Approach 1:
The patent extracts and removes coke precursors (high molecular weight materials and condensed ring aromatic molecules) from the feed stream before they reach the catalyst. This is achieved through a vaporizer that selectively vaporizes lighter components, allowing heavier coke-prone components to be separated and removed, thereby preventing coke accumulation on the catalyst while maintaining hydrocarbon production efficiency
Solution Approach 2:
The patent applies preliminary action by pre-treating the feed stream through vaporization and separation before the acid condensation reaction. The vaporizer is positioned upstream of the catalyst, and the system operates in a mode where the vaporizer is activated before and during the reaction period, proactively removing coke precursors before they can deposit on the catalyst surface
2Reliability
If catalyst is periodically regenerated to maintain activity, then catalyst performance is restored, but process operation is interrupted and time is lost
Solution Approach 1:
The system performs preliminary removal of coke precursors through continuous vaporization and separation operations before the catalyst becomes significantly deactivated. This proactive approach allows the catalyst to operate longer before regeneration is needed, reducing the frequency and impact of regeneration interruptions
Solution Approach 2:
The patent implements continuous vaporization and separation operations that run alongside the acid condensation reaction. The vaporizer operates continuously or in cycles during the reaction period, maintaining a steady-state removal of coke precursors without interrupting the hydrocarbon production process, thereby ensuring continuous useful action
3Productivity
If high molecular weight materials are present in the feed stream, then oxygenate conversion is improved, but coke formation increases
Solution Approach 1:
The patent applies local quality by creating different physical states and phases for different components of the feed stream. The vaporizer selectively vaporizes lighter, less coke-prone components while leaving heavier, coke-prone components in the liquid phase. This phase separation creates local quality differences that allow the system to process oxygenates effectively while minimizing coke formation from high molecular weight materials
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 method effectively prolongs the activity of AC catalysts by reducing coke formation, thereby enhancing process efficiency and reducing the frequency of catalyst regeneration.
Implementation Method 1
vaporizing the HDO product stream in a vaporizer to produce a gaseous HDO product stream comprising C1+O1-3 hydrocarbons
Implementation Method 2
reacting the gaseous HDO product stream in the presence of an acid condensation (AC) catalyst at a condensation temperature and condensation pressure to produce an AC product stream comprising the C4+ compound
Data Source
AI summary
The present disclosure provides methods and systems for producing a C4+ compound, including the steps of: (i) reacting an aqueous feed stream comprising an oxygenated hydrocarbon with hydrogen in the presence of a hydrodeoxygenation (HDO) catalyst to produce an HDO product stream; (ii) vaporizing the HDO product stream in a vaporizer to produce a gaseous HDO product stream comprising C1+O1-3 hydrocarbons; and (iii) reacting the gaseous HDO product stream in the presence of an acid condensation (AC) catalyst at a condensation temperature and condensation pressure to produce an AC product stream comprising the C4+ compound.