Integrated Hydroprocessing for Renewable Diesel and Jet Fuel
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Solution Overview
Problem
Existing processes struggle to produce renewable diesel that complies with the Renewable Fuels Standard II, as they often require co-processing of biomass and petroleum-derived feedstocks, leading to catalyst deactivation and interference from carbon monoxide, carbon dioxide, and water, which inhibits hydrorefining activity.
Innovation Solution
An integrated process using pre-existing hydroprocessing units, where petroleum and biomass-derived feedstocks are processed separately, with hydrogen sulfide recycled to maintain catalyst activity and prevent interference, allowing for the simultaneous production of renewable diesel and petroleum-based fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If biomass and petroleum-derived feedstocks are co-processed in the same hydroprocessing unit, then processing flexibility is improved, but catalyst deactivation and interference from carbon monoxide, carbon dioxide, and water increase
Solution Approach 1:
The patent divides the hydroprocessing system into separate units: a first hydroprocessing unit for petroleum-derived feedstocks and a second hydroprocessing unit for biomass-derived feedstocks. This segmentation prevents catalyst deactivation and chemical interference by isolating the processing of different feedstock types, while still allowing the refinery to process both types of feedstocks through the respective dedicated units.
2Reliability
If biomass feedstock is processed alone in stand alone hydrogenation units, then RFS II compliance is improved, but capital cost increases
Solution Approach 1:
The patent configures existing hydroprocessing units to perform multiple functions: the first unit processes petroleum-derived feedstocks and also provides hydrogen sulfide for the second unit, while the second unit is dedicated to biomass-derived feedstocks. This multi-functional arrangement allows the refinery to comply with RFS II by processing biomass separately while utilizing existing infrastructure to avoid additional capital costs.
3Reliability
If hydrogen sulfide is recycled to the biomass hydroprocessing zone, then catalyst activity is maintained, but process complexity increases
Solution Approach 1:
The patent implements a feedback loop where hydrogen sulfide from the first hydroprocessing unit is recycled to the second hydroprocessing unit. This feedback mechanism maintains catalyst activity in the biomass processing unit by providing the necessary sulfur compounds, while the system manages the added complexity through structured integration of the recycling stream into the existing process flow.
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 the production of renewable diesel at minimal capital cost, extends catalyst life, and allows for the treatment of 'difficult to process' petroleum feedstocks, while maintaining compliance with RFS II standards by isolating biomass-derived components and recycling hydrogen sulfide, thus improving refinery flexibility and reducing corrosion and fouling.
Implementation Method 1
contacting the feedstock of petroleum origin with hydrogen in the presence of a hydroprocessing catalyst at hydroprocessing conditions
Implementation Method 2
catalytic hydroprocessing of a feedstock of petroleum origin containing sulfur and the catalytic hydroprocessing of feedstock derived from biomass
Implementation Method 3
passing the first hydroprocessing zone effluent stream to a separation zone wherein the effluent stream is separated into a hydrogen and hydrogen sulfide -containing vapor stream and a liquid petroleum product stream
Data Source
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AI summary
A process is disclosed that permits the manufacture of renewable diesel while simultaneously manufacturing petroleum based jet fuel and/or diesel fuel. The process provides for the sulfiding of hydroprocessing catalyst used to hydroprocess sulfur deficient biomass derived feedstocks and permits the use of petroleum derived feedstock deactivated hydoprocessing catalyst in biomass derived feedstock service.