Hydroconversion Catalyst Composition for Low-Temperature Renewable Fuels
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Solution Overview
Problem
Existing hydroconversion processes for producing renewable fuels from biofeedstocks, such as sustainable aviation fuel and renewable diesel, face challenges in improving the cloud point, pour point, and freezing point of the resulting jet fuel and diesel fuel, as well as the boiling point range, which are not adequately addressed by current technologies.
Innovation Solution
The use of a hydroconversion catalyst comprising zeolite SSZ-91 to contact hydrocarbonaceous feedstocks, including biofeedstocks or biocomponent feeds, under specific hydroconversion conditions to achieve hydrotreatment and hydroisomerization, thereby reducing the cloud point, pour point, and jet fuel freezing point, and improving the boiling point range of the resulting fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional hydroconversion processes are used to produce renewable fuels from biofeedstocks, then the fuel production process can be completed, but the cloud point, pour point, and freezing point of the resulting fuel are not adequately reduced
Solution Approach 1:
The patent applies parameter changes by modifying the hydroconversion process parameters, specifically using a bifunctional catalyst system that combines hydrotreating and hydroisomerization functions. This catalyst system changes the chemical parameters of the fuel molecules through isomerization reactions, transforming linear alkanes into branched isomers, which fundamentally alters the physical properties including cloud point, pour point, and freezing point, enabling these parameters to be reduced to acceptable levels for renewable fuel specifications.
Solution Approach 2:
The patent employs a composite catalyst material consisting of a bifunctional catalyst system that integrates both hydrotreating and hydroisomerization activities. This composite catalyst combines multiple functional components to simultaneously perform desulfurization, denitrogenation, and isomerization reactions, thereby achieving comprehensive fuel upgrading that addresses the cloud point, pour point, and freezing point issues that single-function catalysts cannot resolve.
2Temperature
If conventional hydroconversion processes are used to produce renewable fuels from biofeedstocks, then the fuel production process can be completed, but the boiling point range of the resulting fuel is not adequately improved
Solution Approach 1:
The bifunctional catalyst system changes the molecular structure parameters of the fuel through hydroisomerization reactions, converting straight-chain hydrocarbons into branched isomers. This structural transformation shifts the boiling point distribution, narrowing the boiling point range and improving the fuel's thermal properties to meet specification requirements.
Solution Approach 2:
The composite catalyst material provides coordinated action between hydrotreating and hydroisomerization functions, simultaneously optimizing multiple fuel properties including boiling point range, cloud point, pour point, and freezing point. This integrated approach ensures comprehensive compliance with renewable fuel specifications that cannot be achieved through conventional single-stage hydroconversion processes.
3Temperature
If hydroisomerization is added to hydrotreating to reduce cloud point and pour point, then fuel quality improves, but the process complexity increases
Solution Approach 1:
The patent merges the hydrotreating and hydroisomerization processes into a single integrated reaction zone using a bifunctional catalyst system. This combination eliminates the need for separate process units, allowing both desulfurization and isomerization to occur simultaneously in one reactor, thereby reducing process complexity while achieving the dual benefit of improved fuel quality through both functions.
Solution Approach 2:
The bifunctional catalyst system provides multi-functionality by simultaneously performing hydrotreating (desulfurization, denitrogenation) and hydroisomerization reactions. This universal catalyst approach consolidates multiple process functions into a single system, reducing the number of separate equipment components and process steps while achieving comprehensive fuel upgrading that addresses cloud point, pour point, and other quality parameters.
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 effectively lowers the cloud point, pour point, and jet fuel freezing point, and enhances the boiling point range of the fuels, resulting in improved fuel properties compared to hydrotreated feedstocks without hydroisomerization.
Implementation Method 1
contacting a hydrocarbonaceous feedstock with a hydroconversion catalyst under hydroconversion conditions to provide a diesel fuel that is both hydrotreated and hydroisomerized
Implementation Method 2
contacting a hydrocarbonaceous feedstock with a hydroconversion catalyst under hydroconversion conditions to provide a diesel fuel that is both hydrotreated and hydroisomerized and having a reduced cloud point and/or a reduced pour point
Data Source
AI summary
A process for making a renewable product from a biofeedstock, in which a biofeedstock is contacted with a hydroconversion catalyst under hydroconversion conditions, the biofeedstock comprising one or more biocomponents, and the hydroconversion catalyst comprising a hydrotreating catalyst and a hydroisomerization catalyst.