Mixed Decene Upgrading for Lower-Cost Sustainable Aviation Fuel
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Solution Overview
Problem
Current technologies for producing sustainable aviation fuels (SAF) are not economically viable, with SAF costing four to five times as much as conventional jet fuel and making up less than one percent of the market, despite offering environmental sustainability and drop-in fuel solutions.
Innovation Solution
A process is developed to upgrade the mixed decene by-product from ethylene oligomerization by further oligomerizing it with C4-C6 alpha-olefins to form a C16− olefin stream, which is then hydrogenated to produce C16− paraffins and cycloparaffins, usable as components in sustainable aviation fuels, leveraging the non-selectivity of the mixed decene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current SAF production technologies are used, then environmental sustainability is achieved, but production cost increases four to five times compared to conventional jet fuel
Solution Approach 1:
The patent converts the previously unwanted mixed decene by-product into a valuable SAF component through a two-step process: (1) oligomerization of mixed decenes with C4-C6 alpha-olefins to form C16- olefin stream, and (2) hydrogenation to produce C16- paraffins and cycloparaffins. This transforms a low-value by-product into high-value fuel components, reducing production costs while maintaining sustainability.
Solution Approach 2:
The patent changes the chemical parameters of the mixed decene by-product through controlled oligomerization and hydrogenation reactions. By adjusting reaction conditions and catalyst selection, the process transforms the molecular structure and composition of the by-product into desirable SAF components with appropriate carbon chain lengths and saturation levels.
2Ease of manufacture
If mixed decene by-product is sold as-is for low-cost fuel, then production cost is reduced, but fuel value and applicability are limited
Solution Approach 1:
The patent performs preliminary oligomerization of mixed decenes with C4-C6 alpha-olefins before final hydrogenation. This preliminary step creates the appropriate carbon chain length (C16-) and olefin structure needed for subsequent hydrogenation to produce high-value paraffin and cycloparaffin components, thereby enhancing fuel value while maintaining cost-effectiveness.
Solution Approach 2:
The patent creates a flexible processing pathway where the mixed decene by-product can be directed through different processing routes (oligomerization followed by hydrogenation, or direct hydrogenation) depending on specific operational conditions and market requirements, providing adaptability in fuel production.
3Manufacturing precision
If selective production of C4-C8 alpha-olefin is pursued, then main product quality is improved, but mixed decene by-product becomes more significant and less valuable
Solution Approach 1:
The patent accepts the non-selective production of mixed decenes as a given and converts this previously harmful by-product into a valuable resource. By implementing the oligomerization-hydrogenation sequence, the process transforms the loss of mixed decenes into a net gain, producing high-value C16- paraffins and cycloparaffins that are essential for SAF.
Solution Approach 2:
The patent merges the processing of mixed decenes with the main C4-C8 alpha-olefin production process by integrating the oligomerization and hydrogenation steps into the existing workflow. This consolidation allows simultaneous production of both main products and by-product utilization, eliminating waste and enhancing overall process 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
This process enhances the production economics of SAF by utilizing a low-value by-product to create desirable components for aviation fuels, reducing costs and improving the sustainability of jet fuel production.
Implementation Method 1
contacting the bio-ethylene feed with a first catalyst system comprising a first oligomerization catalyst to form an oligomerization product comprising at least one C4-C8 alpha-olefin and a mixture of decenes
Implementation Method 2
hydrogenating the C16− olefin stream in the presence of a first hydrogenation catalyst to provide C16− paraffins
Data Source
AI summary
Process for making sustainable aviation fuel (SAF) from specific bio-ethylene oligomerization reactions producing a C4-C8 alpha-olefin and a by-product mixture of C10 olefins. This mixed decene stream is upgraded by further oligomerizing with at least one C4-C6 alpha-olefin to provide a C16− olefin stream, which is hydrogenated to C16− paraffins which is used to form a SAF. Employing bio-ethylene to produce the mixed decene stream, which is relatively low-value due in part to its non-selectivity, leverages that non-selectivity into a desirable sustainable aviation fuel product where the low selectivity is preferable. These and other embodiments and aspects are described herein.