Renewable Fuel Blending via On-Site Hydroprocessing

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Solution Overview

Problem

Current renewable diesel facilities produce diesel products with low cetane numbers and dark color, making them unsuitable for blending with California Air Resources Board (CARB) diesel or ultra-low sulfur diesel (ULSD) without further processing, and existing technologies face high carbon intensity in transporting and processing these products.

Innovation Solution

Converting renewable feedstocks into intermediate hydrocarbon blend stocks on-site at co-located facilities, using hydrogenation, hydrodeoxygenation, and acid condensation processes, and blending these stocks to produce renewable transportation fuels like gasoline, aviation fuel, and marine fuel, thereby reducing the need for carbon-intensive transportation and leveraging existing infrastructure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If renewable diesel facilities produce diesel products using conventional processes, then renewable fuel is produced, but the diesel product has low cetane numbers and dark color making it unsuitable for blending with CARB diesel or ULSD

Engineering Contradiction:

Improvefuel qualityVSAvoidcetane number and color

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by modifying the chemical composition and physical properties of renewable diesel through controlled hydroprocessing conditions, temperature, pressure, and catalyst selection to achieve desired cetane numbers and color characteristics that meet blending specifications

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses intermediaries such as catalysts and hydroprocessing agents to mediate the transformation of renewable diesel from an unblendable state to a blendable state, enabling it to meet CARB diesel and ULSD specifications

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If renewable diesel products are transported to traditional refineries for blending and processing, then fuel standards can be met, but carbon intensity increases due to transportation and additional processing

Engineering Contradiction:

Improvefuel standard complianceVSAvoidcarbon intensity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges the production and blending operations into a single integrated facility, eliminating the need for separate transportation and external refining steps, thereby reducing carbon intensity while maintaining fuel standard compliance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent enables the renewable diesel facility to self-process and self-blend its products using on-site hydroprocessing units, making the system self-sufficient and eliminating dependence on external transportation and refining infrastructure

Inventive Principle:

Principle #25Self-service

3Ease of operation

If renewable diesel facilities are located separately from traditional refineries, then facility operations are independent, but transportation costs and carbon intensity increase

Engineering Contradiction:

Improvefacility independenceVSAvoidtransportation energy

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent segments the fuel production process into independent modular units that can be configured either separately or integrated, allowing facilities to maintain operational independence while choosing to co-locate for energy efficiency benefits

Inventive Principle:

Principle #1Segmentation

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 fully renewable transportation fuels with low carbon intensity, eliminating the need for costly and carbon-intensive transportation and processing, while ensuring compliance with stringent fuel standards by integrating co-located units for efficient production and blending.

Implementation Method 1

converting the sugar into an intermediate renewable hydrocarbon blend stock through hydrogenation of the sugar, hydrodeoxygenation of the hydrogenated sugar, and acid condensation of the hydrodeoxygenated, and hydrogenated sugar within the one or more reactors

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Implementation Method 2

Methodology Applied

Scientific EffectHydrodeoxygenation: Hydrogenation

Implementation Method 3

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS20240271050A1Systems and methods of converting renewable feedstocks into intermediate hydrocarbon blend stocks and transportation fuels

Publication Date: 2024.08.15 MARATHON PETROLEUM COMPANY LP

AI summary

Systems and methods to provide renewable transportation fuels for internal combustion engines by converting renewable feedstocks into two or more intermediate hydrocarbon blend stocks and blending at least two of the two or more intermediate hydrocarbon blend stocks to produce the renewable transportation fuel. Methods and/or processes may include selecting sugar from a sugar source and introducing the sugar into one or more reactors. The sugar may be converted into an intermediate renewable hydrocarbon blend stock and sent to a separation unit to separate out an intermediate renewable gasoline unit. The process may include selecting and converting a lipid from a lipid source into a renewable diesel product. The renewable diesel product may be sent to a second separation unit to separate out renewable diesel and a low-grade naphtha. The low-grade naphtha and intermediate renewable gasoline may be blended to define a finished renewable gasoline.