Renewable Jet Fuel Fractionation With Sweet Hydrocracking
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Solution Overview
Problem
Conventional methods for producing renewable jet fuel involve multi-stage processes that increase complexity and cost, and single-stage processes often result in reduced selectivity and yield due to 'sour' conditions, leading to overcracking and loss of jet boiling range fractions.
Innovation Solution
A single-stage process is employed, utilizing a sweet hydrocracking stage followed by separation to produce a jet boiling range fraction, and either a dewaxing stage under sour conditions or a hydrocracking stage under sweet conditions, using noble metal catalysts to maintain selectivity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-stage process is used for renewable jet production, then device complexity is reduced, but manufacturing precision deteriorates due to overcracking and loss of jet boiling range fractions
Solution Approach 1:
The process is segmented into two distinct stages: a sweet hydrocracking stage followed by a sour dewaxing stage. This segmentation allows each stage to be optimized for its specific function, preventing overcracking while maintaining simplicity compared to conventional multi-stage processes.
Solution Approach 2:
The sweet hydrocracking stage is performed as a preliminary action before the sour dewaxing stage. This preliminary cracking reduces the carbon chain length appropriately, and subsequent dewaxing removes wax without causing further overcracking, thus preserving jet boiling range fractions.
2Device complexity
If a single-stage process is used for renewable jet production, then device complexity is reduced, but productivity deteriorates due to reduced yield of jet boiling range fractions
Solution Approach 1:
By segmenting the process into sweet hydrocracking followed by sour dewaxing, the yield is improved because each stage is optimized for its specific function. The hydrocracking stage controls cracking to produce appropriate carbon chain lengths, while the dewaxing stage removes wax without causing significant overcracking, thereby maximizing jet fraction yield.
Solution Approach 2:
The process utilizes parameter changes by transitioning from sweet to sour conditions between stages. This parameter change allows optimal control of reactions at each stage, preventing overcracking and maximizing the yield of jet boiling range fractions while maintaining process simplicity.
3Manufacturing precision
If conventional multi-stage processes are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The invention merges the hydrocracking and dewaxing functions into a simplified two-stage process where the first stage performs hydrocracking under sweet conditions and the second stage performs dewaxing under sour conditions. This merging maintains selectivity while reducing the complexity of conventional multi-stage processes with separate dedicated units for each function.
Solution Approach 2:
The first reactor unit serves multiple functions by performing both hydrocracking and partial dewaxing operations. This multi-functionality reduces the number of dedicated units required, simplifying the overall process while maintaining the manufacturing precision needed for selective production of jet boiling range fractions.
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 reduces complexity and cost while achieving a jet boiling range fraction with desirable cold flow properties, such as a freeze point of -40°C or lower, by minimizing exposure to hydrocracking and dewaxing conditions.
Implementation Method 1
triglycerides, FAME, FFA are hydrotreated with conventional hydrotreating catalysts under typical hydrotreating conditions to convert fatty acid chains to n-paraffins
Implementation Method 2
separating the deoxygenated liquid fraction to form at least i) a jet boiling range fraction and ii) a second fraction
Data Source
AI summary
Systems and methods are provided for production of renewable jet fuel and/or jet fuel blending component fractions using a single stage reaction system. Although only a single separation stage is used, the systems and methods can reduce or minimize the volume of feedstock that is exposed to hydrocracking conditions while still producing a jet boiling range fraction having beneficial cold flow properties.