Oxidic Supported Metal Catalyst Biomass Hydropyrolysis
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Solution Overview
Problem
Conventional biomass conversion processes using sulfided catalysts face challenges with catalyst handling, contamination of hydrocarbon products with sulfur, and limited adaptability to various biomass feedstocks due to the need for ex-situ sulfiding and sensitivity to air and moisture.
Innovation Solution
A process utilizing supported metal catalysts in their oxidic state, with metals like cobalt, molybdenum, nickel, and tungsten on metal oxide supports, eliminating the need for sulfiding and allowing broader catalyst adaptability to different biomass feedstocks, reducing sulfur contamination and improving handling logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sulfided catalysts are used for biomass conversion, then catalytic activity is improved, but sulfur contamination of hydrocarbon products occurs and catalyst handling becomes complex
Solution Approach 1:
The invention extracts and removes the sulfur component from the catalyst system. Instead of using sulfided catalysts that require ex-situ sulfiding and produce sulfur contamination, the patent employs unsulfided catalysts where sulfur is completely eliminated from the catalyst formulation, thereby preventing sulfur contamination of hydrocarbon products while maintaining catalytic functionality through alternative promoter systems.
Solution Approach 2:
The invention replaces expensive, complex sulfided catalysts requiring careful handling and ex-situ sulfiding with simpler, unsulfided catalysts that can be directly used in the reactor. The unsulfided catalysts are more stable during storage and transport, eliminating the need for complex sulfiding infrastructure and reducing operational complexity.
2Productivity
If ex-situ sulfiding is applied to catalysts, then catalytic performance is enhanced, but logistics and handling complexity increase due to air and moisture sensitivity
Solution Approach 1:
The invention extracts the sulfiding step from the catalyst preparation process. By using unsulfided catalysts that are stable in air and moisture, the patent eliminates the entire ex-situ sulfiding operation, including associated infrastructure for controlled atmosphere handling, sulfurization reactors, and specialized storage facilities, thereby dramatically simplifying logistics.
Solution Approach 2:
The invention changes the chemical state of the catalyst from sulfided to unsulfided form. This parameter change transforms the catalyst from being air and moisture sensitive to being stable under ambient conditions, eliminating the need for complex logistics and handling procedures while maintaining catalytic effectiveness through alternative promoter systems.
3Productivity
If sulfided catalysts are used, then hydroconversion efficiency is improved, but adaptability to different biomass feedstocks is reduced
Solution Approach 1:
The invention creates a universal catalyst system based on unsulfided catalysts with alternative promoters that can effectively process multiple types of biomass feedstocks including wood, agricultural residues, and municipal solid waste. The catalyst formulation is designed to be feedstock-agnostic, providing consistent performance across diverse biomass compositions without requiring feedstock-specific catalyst modifications.
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 enables efficient and high-yielding conversion of solid biomass to liquid hydrocarbons with reduced sulfur content and improved catalyst handling, producing hydrocarbon products that are substantially free from oxygen, sulfur, and nitrogen, suitable for use as biofuels.
Implementation Method 1
a supported metal catalyst in which metals are present in their oxidic state when they are first contacted with the biomass feedstock and molecular hydrogen
Data Source
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AI summary
The present invention provides a process for producing liquid hydrocarbon products from a solid biomass feedstock, said process comprising the steps of: a) providing in a first hydropyrolysis reactor vessel a first hydropyrolysis catalyst composition, said composition comprising one or more active metals selected from cobalt, molybdenum, nickel, tungsten, ruthenium, platinum, palladium, iridium and iron on an oxide support, wherein the one or more active metals are present in an oxidic state; b) contacting the solid biomass feedstock with said first hydropyrolysis catalyst composition and molecular hydrogen in said first hydropyrolysis reactor vessel at a temperature in the range of from 350 to 600°C and a pressure in the range of from 0.50 to 7.50MPa, to produce a product stream comprising partially deoxygenated hydropyrolysis product, H2O, H2, CO2, CO, C1 - C3 gases, char and catalyst fines; c) removing said char and catalyst fines from said product stream; d) hydroconverting said partially deoxygenated hydropyrolysis product in a hydroconversion reactor vessel in the presence of one or more hydroconversion catalyst and of the H2O, CO2, CO, H2, and C1 - C3 gas generated in step a), to produce a vapour phase product 25 comprising substantially fully deoxygenated hydrocarbon product, H2O, CO, CO2, and C1 – C3 gases.