Hydroisomerisation-Hydrocracking Switching for Aviation Fuel Yield
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Solution Overview
Problem
Existing processes for producing aviation fuel components from renewable sources have low yield and quality, and there is a need to reduce C1-C4 hydrocarbon formation and prolong catalyst lifetime.
Innovation Solution
A process involving hydroisomerization and hydrocracking of a paraffinic hydrocarbon feed, with catalyst deactivation monitoring and switching between modes to optimize yield and quality, using a hydroisomerization catalyst and hydrocracking catalysts to produce aviation fuel components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroisomerisation process is used to produce aviation fuel components from renewable sources, then the process is simple and catalyst lifetime is extended, but the yield of aviation fuel components is low and quality is poor
Solution Approach 1:
The process is divided into two distinct modes: a first mode using only hydroisomerisation for normal operation, and a second mode using hydrocracking when catalyst deactivation is detected. This segmentation allows optimization of yield through hydrocracking while maintaining simplicity through hydroisomerisation during normal operation.
Solution Approach 2:
The process dynamically switches between two operational modes based on monitored catalyst deactivation parameters. When deactivation reaches predetermined thresholds, the system transitions from the first mode (hydroisomerisation only) to the second mode (hydrocracking), enabling adaptive optimization of aviation fuel component yield and quality.
2Productivity
If hydrocracking is continuously applied to increase aviation fuel component yield, then yield and quality improve, but C1-C4 hydrocarbon formation increases and energy consumption rises
Solution Approach 1:
Hydrocracking is applied periodically rather than continuously - specifically, only when catalyst deactivation parameters reach predetermined thresholds. This periodic application increases aviation fuel component yield and quality while minimizing unnecessary C1-C4 hydrocarbon formation and energy consumption during normal catalyst operation.
3Ease of operation
If hydroisomerisation catalyst is used to maintain simple process operation, then ease of operation is maintained, but catalyst lifetime decreases due to deactivation
Solution Approach 1:
The system continuously monitors parameters indicative of hydroisomerisation catalyst deactivation and compares them against predetermined thresholds. This feedback mechanism enables detection of catalyst state, triggering a mode switch to hydrocracking when deactivation occurs, thereby extending effective catalyst utilization while maintaining operational simplicity through automated control.
4Adaptability or versatility
If renewable feedstocks with higher impurity content are used to increase feed flexibility, then adaptability improves, but catalyst deactivation accelerates and process reliability decreases
Solution Approach 1:
The system performs preliminary monitoring of catalyst deactivation parameters before significant performance degradation occurs. By detecting early signs of deactivation from impurity-containing feeds and switching to hydrocracking mode in advance, the process maintains reliability even when using adaptable renewable feedstocks with higher impurity content.
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
Enhances the yield and quality of aviation fuel components, extends catalyst lifetime, and allows the use of heavier and impure feeds, while maintaining flexibility in product selectivity and quality adjustment.
Implementation Method 1
subjecting the paraffinic hydrocarbon feed in a first reactor to hydroisomerisation in the presence of a hydroisomerisation catalyst to obtain a hydroisomerisation effluent
Implementation Method 2
subjecting a second reactor feed comprising the recycle stream to hydrocracking in a second reactor in the presence of a hydrocracking catalyst to obtain a recycle effluent
Implementation Method 3
subjecting the hydroisomerisation effluent to fractionation to separate from the fractionation at least a recycle stream
Data Source
AI summary
Here is provided a process for producing at least one liquid transportation fuel component, wherein in the first mode of running the process a paraffinic hydrocarbon feed is converted to a hydroisomerisation effluent, fractionated, and a fraction thereof is recycled via hydrocracking reactor back to the fractionation from which a liquid transportation fuel component, including an aviation fuel component, is recovered. In the process, parameters indicative of deactivation of a hydroisomerisation catalyst are monitored and when these reach predetermined values, the process is switched to a second mode of running wherein the hydroisomerisation effluent is subjected to hydrocracking and the obtained hydrocracking effluent fractionated to yield a liquid transportation fuel component, such as an aviation fuel component.