Steam Cracking and Catalytic Conversion for Alcohol Fuel Production
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Solution Overview
Problem
Current processes for producing isopropanol for fuel components face challenges such as high costs and hazards associated with sulfuric acid in indirect hydrolysis, and limited yields in direct hydrolysis, while existing methods do not effectively convert renewable hydrocarbons to higher value oxygenate components like propene and butanols for gasoline blends.
Innovation Solution
A process involving steam cracking of hydrocarbon feeds, followed by catalytic conversion of propene and butenes in the presence of water to produce a composition of 2-propanol and butanols, which can be used as a gasoline component, offering improved properties like reduced vapor pressure and increased octane numbers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If indirect hydrolysis with sulfuric acid is used to produce isopropanol, then the process is robust for propene impurities, but the post treatment cost is expensive and sulfuric acid is hazardous and corrosive
Solution Approach 1:
The patent extracts and removes the hazardous sulfuric acid from the process by using a solid acid catalyst instead, eliminating the need for liquid acid handling, post-treatment, and waste disposal while maintaining catalytic functionality
Solution Approach 2:
The patent employs a solid acid catalyst that can be easily replaced or regenerated, avoiding the long-term hazards and costs associated with sulfuric acid management while maintaining process robustness
2Object-affected harmful factors
If direct hydrolysis with solid acidic catalyst is used to produce isopropanol, then there are no hazardous wastes from catalyst, but the yields are limited due to equilibrium constraints
Solution Approach 1:
The patent changes the physical and chemical parameters of the reaction system by using a specific solid acid catalyst with optimized acidity and porosity, allowing the reaction to proceed at lower temperatures and pressures while achieving higher yields by shifting the equilibrium
Solution Approach 2:
The patent uses composite solid acid catalysts that combine multiple functional properties (acidity, porosity, thermal stability) to simultaneously improve conversion efficiency and yield while avoiding hazardous waste
3Ease of manufacture
If existing methods are used to convert hydrocarbons to alcohols, then the process is simple, but they do not effectively convert renewable hydrocarbons to higher value oxygenate components like propene and butanols
Solution Approach 1:
The patent develops a multi-functional catalytic system that can convert various renewable hydrocarbon feeds (fats, oils, waxes) into multiple valuable oxygenate products (propene, butanols, alcohols) through a single integrated process, enhancing both versatility and efficiency
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 process yields a gasoline composition with 68-75 wt% 2-propanol and 99-100 wt% total 2-propanol and butanols, providing decreased vapor pressure, high octane numbers, and lowered particulate matter emissions, making it suitable for use in gasoline blends.
Implementation Method 1
steam cracking of hydrocarbon feeds
Implementation Method 2
catalytic conversion of propene and butenes in the presence of water to produce a composition of 2-propanol and butanols
Data Source
AI summary
A process for converting steam cracking products into an alcohol composition consisting essentially of 2-propanol and butanols is disclosed. The process includes steam cracking and recovery of a stream including propene and butenes, which are next converted catalytically in the presence of water to 2-propanol and butanols respectively.