Renewable Naphtha Aromatization for High-Octane Gasoline
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Solution Overview
Problem
Current processes fail to effectively convert renewable feedstocks into high-quality gasoline with an octane number of at least 85, as they lack a dedicated aromatization stage to increase aromatics content and produce a valuable light hydrocarbon gas like LPG for hydrogen production.
Innovation Solution
A process involving hydroprocessing stages including hydrodeoxygenation, optionally hydrodewaxing, and hydrocracking, followed by an aromatization stage using a catalyst supported on aluminosilicate zeolite to upgrade renewable naphtha, producing high-quality gasoline with at least 20 wt% aromatics and a separate LPG stream for hydrogen production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If renewable naphtha is produced from hydroprocessing of renewable feedstocks, then the volume of naphtha is increased, but the octane number remains too low for use as a blending component in gasoline
Solution Approach 1:
The patent applies parameter changes by conducting aromatization at specific temperature ranges (300-500°C) and pressure conditions to transform the chemical composition of renewable naphtha. This changes the molecular structure from paraffinic to aromatic, thereby increasing the octane number from insufficient levels to at least 85, making it suitable for gasoline blending while maintaining the increased volume produced through hydroprocessing
2Manufacturing precision
If a dedicated aromatization stage is added to increase aromatics content, then the octane number is improved, but the process complexity is increased
Solution Approach 1:
The patent merges the aromatization stage with the existing hydroprocessing train by integrating it as a sequential unit that receives renewable naphtha from the hydroprocessing section. This combination approach increases aromatics content to at least 20 wt% and achieves octane numbers of at least 85 without requiring completely separate or complex additional equipment, as the aromatization reactor is incorporated into the overall process flow
Solution Approach 2:
The aromatization process is designed to be self-sufficient by producing its own hydrogen requirements through the hydrocarbon feed conversion and by generating valuable co-products (LPG, hydrogen) that can be utilized within the same process, thereby reducing the need for external hydrogen supply and simplifying the overall process complexity
3Quantity of substance
If LPG is produced from aromatization, then a valuable light hydrocarbon gas is obtained, but the process requires additional hydrogen production infrastructure
Solution Approach 1:
The patent applies universality by designing the hydrogen producing unit to serve multiple functions: it processes LPG from aromatization, produces hydrogen for the hydroprocessing and aromatization stages, and generates steam for process heating. This multi-functional unit reduces the need for separate dedicated infrastructure for each function, thereby achieving LPG production without proportionally increasing overall process complexity
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 process significantly increases the octane number of renewable naphtha to 85 or higher, produces a valuable LPG for hydrogen generation, and achieves a balance between gasoline yield and aromatics content, while reducing greenhouse gas emissions and operational costs.
Implementation Method 1
upgrading the renewable naphtha stream by passing it through an aromatization stage comprising contacting the renewable naphtha stream with a catalyst, preferably a catalyst supported on an aluminosilicate zeolite, thereby producing said hydrocarbon product boiling in the gasoline boiling range
Implementation Method 2
converting a feedstock originating from a renewable source by one or more hydroprocessing stages into a hydrocarbon product boiling at above 30° C., including a renewable naphtha stream; wherein the one or more hydroprocessing stages comprises: hydrodeoxygenation (HDO), optionally hydrodewaxing (HDW) and optionally hydrocracking (HCR)
Data Source
AI summary
The present invention relates to a process and plant for producing hydrocarbon product boiling in the gasoline boiling range from a feedstock originating from a renewable source, the process and plant comprising a hydroprocessing stage which includes hydrodoxygenation for producing renewable diesel and renewable naphtha, and subsequent aromatization of the renewable naphtha thereby also producing a lighthydrocarbon gas stream, such as liquid petroleum gas (LPG), from which a hydrogen stream is produced.