Multi-Metallic Catalyst for Biomass Hydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional processes for converting biomass to biofuel are inefficient, with long extraction times, low conversion efficiency, limited product range, low yield, and high energy and cost requirements, as well as the generation of waste products.
Innovation Solution
A multi-metallic catalyst system comprising a support, a promoter component, and an active component with at least two metals, prepared through calcination, impregnation, and reduction processes, is used to convert biomass into upgraded fuel by hydrogenating an intermediate product derived from a biomass slurry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for biomass conversion, then the process is simpler to implement, but the conversion efficiency is low and extraction time is long
Solution Approach 1:
The patent employs a composite catalyst system comprising multiple metals (e.g., Ni-Ce, Co-Ce, Ni-La, Co-La) supported on oxide materials. This composite structure synergistically combines the catalytic activity of different metals with the support material's properties, achieving high conversion efficiency (81-90%) and reduced extraction time compared to conventional single-metal catalysts.
Solution Approach 2:
The patent optimizes critical parameters including metal composition ratios, support material type, reaction temperature (300-500°C), pressure conditions, and catalyst-to-biomass ratio. By systematically adjusting these parameters, the process achieves maximum conversion efficiency while minimizing extraction time and energy consumption.
2Productivity
If conventional extraction processes are used, then the process design is simpler, but the product yield is low and product range is limited
Solution Approach 1:
The patent divides the biomass conversion process into distinct stages: pretreatment of biomass, catalytic conversion in the first reactor, and further processing in the second reactor. This segmentation allows each stage to be optimized independently, achieving high product yield (81-90%) and diverse product range while maintaining manageable process complexity through modular design.
Solution Approach 2:
The multi-metallic catalyst system is designed to perform multiple functions simultaneously: cracking of biomass polymers, dehydration, decarboxylation, and hydrocarbon synthesis. This multi-functionality enables a single catalyst system to produce a wide range of upgraded fuel products including hydrocarbons, alcohols, and esters, eliminating the need for multiple specialized catalysts.
3Loss of energy
If conventional catalysts are used, then the manufacturing cost is lower, but the energy consumption is high and waste generation occurs
Solution Approach 1:
The patent reduces energy consumption by optimizing reaction parameters including temperature (300-500°C range), pressure conditions, and residence time. The multi-metallic catalysts enable efficient conversion at moderate temperatures compared to conventional high-temperature processes, reducing energy input while maintaining high conversion efficiency and minimizing waste product formation.
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 carbon content and yield of the biofuel, producing an upgraded fuel with a carbon content of 82-84% and yield of 81-90%, comparable to petroleum crude oil, while removing heteroatoms and reducing waste generation.
Implementation Method 1
A multi-metallic catalyst system comprising at least one support, and at least one promoter component and an active component comprising at least two metals uniformly dispersed on the support
Implementation Method 2
hydrogenating an intermediate product derived from a biomass slurry
Implementation Method 3
calcining at least one support, impregnating the calcined support with at least one promoter component
Implementation Method 4
impregnating the calcined support with at least one promoter component in the presence of at least one stabilizing agent
Implementation Method 5
drying, calcining, and reducing to obtain the multi-metallic catalyst system
Data Source
AI summary
The present disclosure provides a multi-metallic catalyst system comprising at least one support, and at least one promoter component and an active component comprising at least two metals uniformly dispersed on the support. The present disclosure also provides a process for preparing the multi-metallic catalyst system. Further, the present disclosure provides a process for preparing upgraded fuel from biomass. The process is carried out in two steps. In the first step, a biomass slurry is prepared and is heated in the presence of hydrogen and a multi-metallic catalyst that comprises at least one support, at least one promoter component, and an active component comprising at least two metals to obtain crude biofuel as an intermediate product. The intermediate product obtained in the first step is then cooled and filtered to obtain a filtered intermediate product. In the second step, the filtered intermediate product is hydrogenated in the presence of the multi-metallic catalyst to obtain the upgraded fuel. The fuel obtained from the process of the present disclosure is devoid of heteroatoms such as oxygen, nitrogen and sulfur.