Renewable Base Oil Fractionation for Aviation Fuel Yield Balance
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Solution Overview
Problem
There is a limited availability and high cost of bio-originating alternatives for aviation fuels and base oils, and existing processes struggle to efficiently produce lighter fuels meeting aviation fuel requirements while also producing high-quality renewable base oils with improved properties such as low viscosity and high flash point.
Innovation Solution
A method involving hydrotreatment and isomerization of biological feedstock followed by fractionation to produce a lighter fraction suitable for aviation fuel and a heavier fraction suitable for base oil, with specific properties meeting ASTM and API specifications, including high saturates, low sulfur, and controlled kinematic viscosities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If existing processes are used to produce bio-originating aviation fuels and base oils, then production cost is reduced, but product availability and quality improve
Solution Approach 1:
The process separates the production into distinct stages: hydrotreatment to remove oxygen, isomerization to create branched hydrocarbons, and fractionation to divide the product into aviation fuel fraction (C8-C16) and base oil fraction (C17-C40). This segmentation allows simultaneous production of both products from a single feedstock, improving availability while maintaining cost-effectiveness through process integration
Solution Approach 2:
The hydrotreatment-isomerization-fractionation process serves multiple functions: it produces both aviation fuel and base oil from the same biological feedstock, removes oxygen and sulfur, creates appropriate molecular structures for each product, and enables flexible yield adjustment. This multi-functionality resolves the contradiction by making the process adaptable to market demands for either or both products
2Productivity
If processes are optimized for lighter aviation fuel fractions, then aviation fuel yield is improved, but base oil production and quality deteriorate
Solution Approach 1:
The fractionation process is designed to be dynamic and adjustable, allowing the cut points between aviation fuel and base oil fractions to be shifted based on market demands. The isomerization conditions (temperature, catalyst, residence time) can be optimized to produce the desired carbon distribution, enabling flexible yield adjustment without compromising base oil quality when base oil production is prioritized
Solution Approach 2:
By changing process parameters such as isomerization temperature, catalyst type, and fractionation cut points, the product distribution can be adjusted. When aviation fuel yield is prioritized, the process produces more C8-C16 hydrocarbons; when base oil quality is prioritized, the process optimizes for C17-C40 hydrocarbons with appropriate viscosity and saturation levels
3Manufacturing precision
If processes are optimized for heavier base oil fractions, then base oil quality is improved, but aviation fuel yield deteriorates
Solution Approach 1:
The process parameters can be adjusted to shift the product distribution toward heavier fractions when base oil quality is prioritized. This includes optimizing isomerization conditions to produce more C17-C40 hydrocarbons and adjusting fractionation cut points to maximize base oil yield while maintaining sufficient aviation fuel production
Solution Approach 2:
The flexible fractionation system allows dynamic adjustment of product splits between aviation fuel and base oil. When base oil quality is the priority, the process can be configured to produce higher quality base oil with appropriate viscosity indices and saturation levels, while still maintaining viable aviation fuel yields through optimized cut points
4Adaptability or versatility
If biological feedstock is used instead of mineral oil, then sustainability is improved, but production cost and process complexity increase
Solution Approach 1:
The use of biological feedstock is enabled by segmenting the processing into specialized stages: hydrotreatment to handle the oxygenated nature of bio-feedstock, isomerization to create appropriate hydrocarbon structures, and fractionation to produce final products. This segmentation manages the complexity by addressing the unique requirements of biological feedstock at each stage
Solution Approach 2:
The integrated hydrotreatment-isomerization-fractionation process serves as a universal platform that can handle various biological feedstocks (vegetable oils, animal fats, waste oils) and produce both aviation fuel and base oil. This multi-functionality justifies the increased complexity by providing a sustainable, versatile solution that replaces mineral oil processing
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 method achieves high yields of both aviation fuel and base oil components with improved properties, enhancing production flexibility and efficiency, and providing sustainable, cost-effective solutions for both sectors.
Implementation Method 1
hydrotreatment and isomerization of biological feedstock
Implementation Method 2
hydrotreatment and isomerization of biological feedstock
Implementation Method 3
fractionation to produce a lighter fraction suitable for aviation fuel and a heavier fraction suitable for base oil
Data Source
AI summary
The present disclosure provides a base oil produced from feedstock of biological origin and a method for producing the same. The present disclosure provides base oil blends including the base oil of biological origin and at least one additional base oil.