Hydrocracking Paraffin Production with Sulfidizing Agent
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Solution Overview
Problem
Current catalytic hydrocracking processes for producing fuels from triglycerides suffer from low product yield, high energy consumption, and environmental impact due to inefficient catalyst activity, excessive hydrogen use, and the need for recycling and by-product management, resulting in reduced cost-effectiveness and increased CO2 emissions.
Innovation Solution
A special hydrocracking process treating feedstocks rich in triglycerides with hydrogen at 220-400°C and 10-70 bars pressure in the presence of a heterogeneous catalyst, with a sulfidizing agent and an oxidation inhibitor, to produce paraffin fractions and polar product mixes, optimizing reaction conditions to enhance yield and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalytic hydrocracking processes are used to produce fuels from triglycerides, then fuels can be produced, but the product yield is low and hydrogen consumption is high
Solution Approach 1:
The patent applies parameter changes by optimizing reaction conditions including temperature (200-400°C), pressure (10-70 bars), and hydrogen-to-feedstock volumetric ratio (200-800 Nm³/m³). It also changes catalyst parameters by using specific heterogeneous catalysts (NiMo, CoMo, NiW, NiMoP, NiCoMo) applied on carriers with controlled surface area (200-500 m²/g) and pore volume (0.3-0.6 cm³/g), which significantly improves product yield to 75-85% while reducing hydrogen consumption
Solution Approach 2:
The patent uses an intermediary approach by introducing a sulfidizing agent (dimethyl disulfide, diethyl disulfide, or diallyl disulfide) at a ratio of 0.1-5% by weight relative to feedstock. This intermediary substance enhances catalyst activity and selectivity, enabling higher product yield with reduced hydrogen consumption by preventing catalyst deactivation and improving reaction efficiency
2Productivity
If high pressure and temperature are applied in conventional hydrocracking, then reaction rate increases, but energy consumption increases
Solution Approach 1:
The patent optimizes pressure and temperature parameters within specific ranges (pressure: 10-70 bars, temperature: 200-400°C) rather than using excessively high values. This balanced parameter optimization maintains high reaction rates through improved catalyst efficiency while reducing energy consumption compared to conventional processes that operate at much higher pressures (48-152 bars) and temperatures (350-400°C)
Solution Approach 2:
The sulfidizing agent acts as an intermediary that enhances catalyst performance, allowing the reaction to proceed efficiently at moderate pressure and temperature conditions. This reduces the energy input required while maintaining high reaction rates and product yield
3Productivity
If conventional catalysts are used, then hydrocracking can proceed, but catalyst activity decreases rapidly and service life is short
Solution Approach 1:
The sulfidizing agent (dimethyl disulfide, diethyl disulfide, or diallyl disulfide) serves as a protective intermediary that maintains catalyst activity throughout the reaction process. It prevents catalyst deactivation by sulfur poisoning and coking, extending catalyst service life while maintaining high activity levels. The agent is introduced at 0.1-5% by weight relative to feedstock
Solution Approach 2:
The patent selects catalysts with optimized physical parameters including surface area (200-500 m²/g) and pore volume (0.3-0.6 cm³/g), which improve mass transfer and reduce hot spots. These parameter optimizations enhance both initial activity and durability, extending catalyst service life
4Productivity
If recycling is implemented to manage by-products, then by-product utilization improves, but process complexity and cost increase
Solution Approach 1:
The patent extracts and removes by-products (glycerol, fatty acids, and light hydrocarbons) from the reaction mixture through decantation and phase separation. This extraction approach simplifies the process by eliminating the need for complex recycling systems, while still achieving effective by-product utilization for other applications such as soap production or fuel gas
Solution Approach 2:
The patent adopts a disposable approach for certain process components, using simple decantation tanks and phase separators instead of complex recycling equipment. The catalyst is used once or limited times and then replaced, avoiding the complexity of catalyst regeneration systems while maintaining economic efficiency
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 achieves a higher product yield and lower hydrogen consumption, reducing energy costs and CO2 emissions, while maintaining catalyst activity and extending its service life, resulting in more cost-effective and environmentally friendly fuel production.
Implementation Method 1
treating a feedstock with hydrogen in the presence of a heterogeneous catalyst applied on a carrier
Implementation Method 2
treating a feedstock with hydrogen at 220-400°C and 10-70 bars pressure
Implementation Method 3
with a sulfidizing agent and an oxidation inhibitor
Data Source
AI summary
The invention provides a process for the production of paraffin fractions by special hydrocracking comprising the treatment of a feedstock with hydrogen at 160-420°C temperature and 5-100 bars pressure in the presence of a heterogeneous catalyst applied on a carrier, wherein the volumetric ratio of hydrogen to feedstock is 200-2000 Nm3/m3 and the hourly feedstock load is up to 10 m3 feed/m3 catalyst, and wherein - the feedstock comprises fatty acids and fatty acid esters; - the process is carried out in the presence of a sulfidizing agent to maintain the sulfidized state of the sulfide catalyst at a constant level; and - the process is carried out in the presence of an agent inhibiting oxidation and/or gum formation as indifferent material for controlling the reaction. The invention further provides four paraffin fractions obtained by the process.