Non-Sulphided Catalysts for Renewable Oil Upgrading
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Solution Overview
Problem
Current processes for upgrading low sulphur, oxygen-containing renewable oils are inefficient and costly due to the instability of sulphided catalysts and the need for significant hydrogen gas cleaning, which limits their effectiveness and economic viability.
Innovation Solution
A process involving non-sulphided heterogeneous catalysts in multiple reaction zones, where the low sulphur renewable oil is pressurized, heated, and mixed with hydrogen, optimizing conditions to reduce oxygen content and improve catalyst stability, with a focus on reducing external hydrogen consumption and enhancing product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulphided catalysts are used for upgrading low sulphur renewable oils, then the catalyst shows initial activity, but the catalyst loses stability and activity over prolonged operation
Solution Approach 1:
The patent changes the chemical state parameter of the catalyst from sulphided form to non-sulphided form. This fundamental parameter change resolves the contradiction by providing a catalyst that maintains both stability and activity throughout prolonged operation, eliminating the deactivation issue inherent to sulphided catalysts when processing low sulphur feeds.
2Productivity
If sulphided catalysts are used for upgrading, then initial conversion is achieved, but significant H2S is produced requiring expensive gas cleaning
Solution Approach 1:
The patent eliminates the harmful H2S production by avoiding sulphided catalysts entirely. Instead of dealing with the harmful byproduct, the invention uses non-sulphided catalysts that process low sulphur feeds without generating significant H2S, thereby converting a harmful process into a cleaner alternative that minimizes gas cleaning requirements.
3Productivity
If external hydrogen is supplied in large amounts for upgrading, then the upgrading process can proceed, but the process becomes less economical
Solution Approach 1:
The patent enables the upgrading process to serve itself by utilizing hydrogen generated internally from the renewable oil feedstock. The non-sulphided catalysts facilitate reactions that produce hydrogen in situ, which then becomes available for the upgrading reactions, reducing or eliminating the need for external hydrogen supply and improving process economics.
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 results in a more stable, efficient, and economical process with higher yields of upgraded renewable oil, requiring less external hydrogen and minimizing downtime, while maintaining high product quality.
Implementation Method 1
Contacting said low sulphur oxygen containing renewable crude oil with at least one heterogeneous catalyst contained in a first reaction zone
Implementation Method 2
Pressurising the low sulphur oxygen containing renewable crude oil to an operational pressure in the range 20 to 200 bar
Implementation Method 3
Heating the oil to an operational temperature in the range 180-410° C. in one or more steps
Implementation Method 4
Adding and mixing hydrogen to the pressurized low sulphur oxygen containing renewable crude oil
Data Source
AI summary
The invention relates to a process for producing an upgraded renewable oil from renewable carbonaceous material(-s) comprising providing a low sulphur oxygen containing renewable crude oil having a sulphur content of less than 0.5 wt % and an oxygen content from about 2.0 wt to about 20 wt %, pressurising the low sulphur oxygen containing renewable crude oil to an operational pressure in the range 20 to 200 bar, adding and mixing hydrogen to the pressurized low sulphur oxygen containing crude oil, heating the oil to an operational temperature in the range 180-410° C. in one or more steps, contacting said oil with at least one heterogeneous catalyst contained in a first reaction zone, contacting the effluent from said first reaction zone with at least one heterogeneous catalyst contained in a second reaction zone, where in at least one of the heterogeneous catalysts in the first reaction zone and/or the second reaction zone is on a non-sulphided form.