Hydrodeoxygenation Oxygenate Conversion via Phase Separation
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Solution Overview
Problem
Current hydrodeoxygenation processes face challenges in efficiently converting oxygenates due to low reactivity of certain oxygenates, leading to unreacted oxygenates partitioning into the aqueous phase, which complicates further processing and increases energy requirements and catalyst damage, necessitating a more efficient method without increasing process severity.
Innovation Solution
A process involving hydrodeoxygenation of oxygenates with a catalyst, followed by phase-separation and extraction of unreacted oxygenates using a water-immiscible solvent, allowing for recycling and reuse of unreacted oxygenates, along with hydrogen recovery and solvent recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the severity of the HDO process is increased (temperature, residence time, hydrogen partial pressure) to convert refractory oxygenates, then oxygenate conversion is improved, but undesired side reactions (cracking to lights and coking of catalyst) are promoted
Solution Approach 1:
The process segments the handling of different oxygenate fractions by separating unreacted oxygenates from the HDO product stream and subjecting them to a second HDO pass after water removal, rather than subjecting the entire stream to severe HDO conditions
Solution Approach 2:
Water is removed from the unreacted oxygenates before the second HDO pass, preparing the feedstock in advance to avoid the harmful effects of water during subsequent HDO processing
2Productivity
If the aqueous HDO product is subjected to additional HDO to recover unreacted oxygenates, then oxygenate conversion is improved, but the elevated water content increases heating and cooling requirements, damages the HDO catalyst, lowers hydrogen partial pressure, and increases reactor size and cost
Solution Approach 1:
Water is extracted and removed from the aqueous HDO product before the second HDO pass, eliminating the harmful effects of water on catalyst, energy consumption, and reactor design
Solution Approach 2:
The unreacted oxygenates are isolated as an intermediate stream between the first HDO and second HDO processes, allowing water removal to occur before the second pass
3Productivity
If the aqueous HDO product is subjected to additional HDO to recover unreacted oxygenates, then oxygenate conversion is improved, but the elevated water content increases heating and cooling requirements, damages the HDO catalyst, lowers hydrogen partial pressure, and increases reactor size and cost
Solution Approach 1:
Water is extracted and removed from the aqueous HDO product before the second HDO pass, eliminating the harmful effects of water on catalyst, energy consumption, and reactor design
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 enhances oxygenate conversion to hydrocarbon fuels while avoiding increased severity, reducing light hydrocarbon production and catalyst degradation, thereby improving overall yield and catalyst lifespan.
Implementation Method 1
contacting a feedstock comprising oxygenates with a hydrodeoxygenation catalyst in the presence of hydrogen gas at a temperature and pressure suitable for hydrodeoxygenation
Implementation Method 2
phase-separating the partially-deoxygenated product into an aqueous phase comprising unreacted oxygenates, a non-aqueous phase comprising hydrocarbons, and light gases comprising hydrogen
Implementation Method 3
mixing the aqueous phase with a solvent that is water-immiscible and extracting unreacted oxygenates from the aqueous phase into the water-immiscible solvent
Implementation Method 4
distilling the solvent comprising unreacted oxygenates to produce a separated solvent and separated unreacted oxygenates
Data Source
AI summary
The present disclosure relates generally to processes and systems for the hydrodeoxygenation of an oxygenate feedstock that increases the conversion of oxygenates to hydrocarbons while avoiding detrimental effects resulting from increasing the severity of the hydrodeoxygenation reaction.