Jet Fuel Production with Steamcracking Recycle of Oligomerized Olefins
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Solution Overview
Problem
Current processes for producing jet fuel from oxygenates suffer from low efficiency, high complexity, and high costs, with a significant portion of the carbon from the oxygenate starting material not being converted into jet-range hydrocarbons.
Innovation Solution
A process that involves processing an oxygenate stream to produce an olefin stream, followed by oligomerization and hydrogenation, with a fraction of the oligomerized olefin stream being recycled to a steamcracking unit to produce a steamcracking product stream that is included in the oligomerization feed, optimizing the oligomerization process to enhance jet-range hydrocarbon yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional oxygenate to fuel processes are used, then jet fuel can be produced, but the efficiency is low and a high proportion of carbon from oxygenates does not end up as jet fuel
Solution Approach 1:
The patent implements a feedback loop where hydrocarbon streams boiling outside the jet fuel range are cracked and the resulting olefins are recycled back to the oligomerization unit. This allows unconverted carbon to be reprocessed and converted into jet fuel range hydrocarbons, thereby reducing carbon loss and improving overall yield.
Solution Approach 2:
Instead of discarding hydrocarbon streams that fall outside the jet fuel boiling range, the patent recovers these streams by cracking them into olefins and feeding them back into the oligomerization process. This transforms what would be waste streams into valuable feedstock for additional jet fuel production.
2Productivity
If conventional oxygenate to fuel processes are used, then jet fuel production is achieved, but the process complexity and costs are high
Solution Approach 1:
The patent combines multiple functions into integrated process units. The oligomerization unit processes both fresh oxygenate-derived olefins and recycled cracked olefins in a single continuous operation. The hydrocarbon stream fractionation and cracking units are integrated to directly feed recycled material back into the oligomerization process, reducing the need for separate waste handling and reprocessing systems.
Solution Approach 2:
The oligomerization unit serves multiple functions: it converts fresh oxygenate-derived olefins to jet fuel range hydrocarbons and simultaneously processes recycled olefins from the cracking unit. This multi-functionality reduces the need for dedicated separate processing lines for different feed streams.
3Productivity
If conventional oxygenate to fuel processes are used, then jet fuel is produced, but capital and operating costs are high
Solution Approach 1:
The patent establishes a continuous cycle where hydrocarbon streams outside the jet fuel range are continuously cracked and the resulting olefins are continuously fed back to the oligomerization unit. This eliminates idle time and ensures that all carbon from the original oxygenates is continuously being converted into jet fuel, maximizing energy utilization 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 significantly increases the efficiency and yield of jet-range hydrocarbons, reducing capital and operating costs by optimizing the oligomerization process and utilizing steamcracking to recycle non-jet-range fractions, thereby maximizing the conversion of oxygenate carbon into high-value jet fuel.
Implementation Method 1
a fraction of the oligomerized olefin stream is withdrawn as a recycle stream and passed to a steamcracking unit to produce a steamcracking product stream
Implementation Method 2
Processing an oligomerization feed comprising at least a portion of the olefin stream in an oligomerization unit to produce an oligomerized olefin stream
Implementation Method 3
Hydrogenating at least a portion of the oligomerized olefin stream
Data Source
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AI summary
The present invention relates to a process for producing a jet fuel composition (12), the process comprising: a) Processing an oxygenate stream (1) in an Oxygenate-to-Olefin (OtO) unit (2) to produce an olefin stream (3); b) Processing an oligomerization feed (8) comprising at least a portion of the olefin stream (3) in an oligomerization unit (9) to produce an oligomerized olefin stream (10); c) Hydrogenating at least a portion of the oligomerized olefin stream (10); wherein a fraction of the oligomerized olefin stream (10) is withdrawn as a recycle stream (40a, 40b) and passed to a steamcracking unit (41) to produce a steamcracking product stream (42), wherein at least a portion of the steamcracking product stream (42) is included in the oligomerization feed (8).