Hydrocracking Catalyst for Low-Pressure Fuel Production
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Solution Overview
Problem
Existing methods for producing hydrocarbon liquid fuels from biomass and fats/oils face challenges in achieving low-temperature flowability and oxidation stability, with high-pressure hydrocracking techniques being inefficient and catalyst degradation issues.
Innovation Solution
A method involving hydrocracking raw materials with a newly devised catalyst at normal or low pressures (0.1 to 0.8 MPa) using a specific catalyst preparation process, including sulfur compounds and metal components, to produce fuels with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-temperature, high-pressure hydrocracking techniques are used to produce hydrocarbon liquid fuels from fats and oils, then the hydrocarbon production efficiency is improved, but the operational costs and equipment complexity increase significantly
Solution Approach 1:
The patent changes the reaction parameters from high-temperature (260°C or higher) and high-pressure (6 MPa) conditions to moderate temperature and pressure conditions by introducing a novel catalyst system, thereby reducing equipment complexity while maintaining hydrocarbon production efficiency
Solution Approach 2:
The patent employs a cost-effective catalyst system comprising common metals (Ni, Mo, Co, or W) supported on alumina or silica-alumina, replacing expensive precious metal catalysts, thus reducing operational costs while achieving effective hydrocracking
2Productivity
If high-temperature, high-pressure hydrocracking techniques are used to produce hydrocarbon liquid fuels from fats and oils, then the hydrocarbon production efficiency is improved, but the operational costs increase
Solution Approach 1:
The patent reduces operational costs by changing reaction conditions to moderate temperature and pressure, which lowers energy consumption and equipment operational expenses while maintaining effective hydrocarbon production through catalytic action
Solution Approach 2:
The patent uses inexpensive metal catalysts (Ni, Mo, Co, or W) instead of precious metals, significantly reducing catalyst cost and overall operational expenses while achieving comparable or superior catalytic activity
3Quantity of substance
If conventional hydrocracking produces N-paraffin as main component, then the hydrocarbon yield is improved, but the low-temperature flowability deteriorates
Solution Approach 1:
The patent applies local quality by creating specific acidic sites on the catalyst surface through sulfur compound treatment, which selectively promotes isomerization reactions at particular locations on the catalyst, thereby producing branched paraffins that improve low-temperature flowability while maintaining hydrocarbon yield
Solution Approach 2:
The patent introduces structural asymmetry in the hydrocarbon molecules by promoting isomerization reactions that create branched-chain structures instead of linear structures, thereby improving low-temperature flowability while maintaining comparable hydrocarbon yield
4Ease of manufacture
If methyl esters of fatty acids are used as diesel fuel, then the production process is simplified, but the oxidation stability and low-temperature flowability deteriorate
Solution Approach 1:
The patent transforms the chemical composition of the fuel by complete hydrodeoxygenation, removing oxygen atoms and unsaturated bonding groups through catalytic reactions, thereby producing saturated hydrocarbons with superior oxidation stability while maintaining production feasibility
Solution Approach 2:
The patent creates a composite catalyst system combining metal components (Ni, Mo, Co, or W) with oxide supports (alumina or silica-alumina) and sulfur compound modifications, which works synergistically to achieve both hydrodeoxygenation and isomerization, producing fuel with improved oxidation stability and low-temperature flowability
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 enables the production of hydrocarbon liquid fuels equivalent to kerosene or gas oil with enhanced low-temperature flowability and oxidation stability, while reducing catalyst degradation and operational costs.
Implementation Method 1
saturating an unsaturated binding group of a fat or oil by hydrogenation to remove oxygen
Implementation Method 2
cracking a triglyceride of a fat or oil
Implementation Method 3
in the presence of a catalyst by hydrogenation dehydration reaction, decarbonylation reaction, and decarboxylation reaction
Data Source
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AI summary
A method for producing a hydrocarbon liquid fuel including hydrocracking a raw material oil in the presence of a hydrocracking catalyst, at a supplying pressure of hydrogen of from 0.1 to 1.0 MPa, a liquid space velocity of liquid volume of the raw material oil of from 0.05 to 10.0 hr-1, and a flow rate of the hydrogen from 50 to 3,000 NL per 1 L of the raw material oil, wherein the hydrocracking catalyst is produced by a method including stirring a sulfur compound and a cracking catalyst in an aqueous medium to allow liquid-solid separation (step 1); stirring a solid product obtained in the step 1 and a metal component in an aqueous medium to allow liquid-solid separation (step 2); baking a solid product obtained in the step 2 (step 3); and reducing a solid product obtained in the step 3, or reducing a solid product obtained in the step 3, and then subjecting a reduced product to sulfurization treatment (step 4). According to the present invention, the hydrocracking of a raw material oil such as fats and oils and biomass retort oils, or a hydrocarbon or the like in petroleum oils, in a given composition can be accomplished by supplying a low-pressure hydrogen of a normal pressure or so.