Hydrotreatment Catalyst Composition for Renewable Fuel Processing
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Solution Overview
Problem
Current hydrotreatment processes for producing diesel and kerosene fuels from renewable and petroleum sources face challenges such as catalyst deactivation, corrosion, and high operating costs due to the presence of carbon monoxide and carbon dioxide byproducts, which require additional investments and complex gas management.
Innovation Solution
A two-step hydrotreatment process using a specific catalyst in the first step that favors hydrodeoxygenation, followed by a conventional hydrodesulfurization step, to minimize the production of carbon monoxide and carbon dioxide, thereby avoiding catalyst inhibition and corrosion, and improving fuel quality and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrotreatment catalysts are used to treat renewable feedstocks, then deoxygenation reactions occur, but carbon monoxide and carbon dioxide are produced which cause catalyst deactivation and corrosion
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating zinc oxide (0.1-5 wt%) alongside molybdenum oxide (10-30 wt%) and nickel oxide (0.1-5 wt%). This parameter modification alters the catalyst's selectivity to favor hydrodeoxygenation reactions that produce water instead of carbon oxides, thereby eliminating catalyst deactivation and corrosion issues while maintaining effective deoxygenation
Solution Approach 2:
The invention converts the harmful decarboxylation and decarbonylation reactions (which produce CO and CO2) into beneficial hydrodeoxygenation reactions (which produce H2O). By using the specific catalyst composition, the process transforms what would be harmful byproducts into harmless water, eliminating the need for complex gas management systems and corrosion-resistant materials
2Quantity of substance
If decarboxylation and decarbonylation pathways are used for deoxygenation, then oxygen removal is achieved, but carbon monoxide and carbon dioxide byproducts require additional gas management equipment
Solution Approach 1:
The patent modifies the reaction pathway selectivity by changing the catalyst composition to include zinc oxide with molybdenum oxide and nickel oxide. This parameter change shifts the dominant reaction mechanism from decarboxylation/decarbonylation (producing CO and CO2) to hydrodeoxygenation (producing H2O), thereby simplifying the overall process and eliminating the need for complex gas management equipment
3Productivity
If high nickel content catalysts are used to promote hydrodeoxygenation, then oxygen removal is enhanced, but catalyst cost increases
Solution Approach 1:
The patent optimizes the catalyst composition parameters by limiting nickel oxide content to 0.1-5 wt% and introducing zinc oxide at 0.1-5 wt%. This parameter optimization achieves effective hydrodeoxygenation through the synergistic effect of zinc oxide promoting the reaction and nickel oxide providing catalytic activity, while controlling material costs by avoiding excessive nickel usage
Solution Approach 2:
The invention creates a composite catalyst material combining zinc oxide, molybdenum oxide, and nickel oxide in specific proportions. This composite structure leverages the complementary properties of each component: zinc oxide promotes hydrodeoxygenation selectivity, molybdenum oxide provides robust catalytic framework, and nickel oxide enhances reaction activity, achieving cost-effective high productivity
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 significantly reduces catalyst deactivation, corrosion, and operating costs, while achieving diesel and kerosene fuels with low sulfur content and improved cetane index, meeting environmental specifications without the need for expensive corrosion-resistant materials or complex gas management systems.
Implementation Method 1
hydrogenation of unsaturations, deoxygenation according to two reaction pathways: hydrodeoxygenation (HDO): elimination of oxygen by consumption of hydrogen and leading to the formation of water
Implementation Method 2
hydrogenation of unsaturations
Implementation Method 3
the second unit operates at higher severity to promote hydrodesulfurization
Data Source
Figure 1
AI summary
The invention relates to a method for the coprocessing-based hydroprocessing of petroleum feedstocks mixed with at least one charge from renewable sources, in order to produce fuel bases (kerosene and/or gas oil) having a sulphur content below 10 ppm. The method comprises: (a) a first hydroprocessing step in which the charge moves into at least a first fixed-bed catalytic area including at least one supported or solid catalyst comprising an active phase formed by at least one element from group VIB and at least one element group VIII, whereby said elements take the form of sulphide and the atomic ratio of the metal (or metals) from group VIII in relation to the metal (or metals) from group VIB is strictly greater than 0 and less than 0.095; and (b) a second hydroprocessing step in which the effluent resulting from the first hydroprocessing step is transferred directly and in which said effluent moves into at least a second fixed-bed catalytic area including at least one hydroprocessing catalyst.