Tall Oil Hydroprocessing with Polar Co-feed
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Solution Overview
Problem
Current processes for hydroprocessing tall oil materials to produce hydrocarbons face challenges such as decreased yields and catalyst inactivation due to reactive compounds, leading to frequent process shut-downs and increased costs, while also resulting in hydrocarbons with poor cold flow properties and high aromatic content.
Innovation Solution
A process involving the catalytic hydroprocessing of a combination of tall oil material and a polar co-feed comprising at least 75 wt% C12-C22 fatty acids, diluted with a non-polar diluent, using a catalyst system comprising HDO and HDW catalysts at specific temperature and pressure conditions to improve hydrocarbon yields and quality, reducing aromatic content and enhancing cold flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tall oil material is used as starting material in hydroprocessing, then renewable hydrocarbon production is achieved, but catalyst inactivation and process shut-downs occur due to reactive compounds
Solution Approach 1:
The patent applies preliminary action by adding a polar co-feed containing C12-C22 fatty acids to the tall oil material before hydroprocessing. This pre-treatment step modifies the feedstock composition to reduce the reactivity of compounds that would otherwise cause catalyst inactivation, thereby maintaining process continuity while preserving renewable hydrocarbon production
Solution Approach 2:
The polar co-feed acts as an intermediary substance that mediates between the tall oil material and the catalyst system. By introducing this intermediate component, the harmful reactive compounds in tall oil are neutralized or modified, protecting the catalyst from inactivation while allowing the hydroprocessing to proceed continuously
2Productivity
If tall oil material is hydroprocessed, then hydrocarbons are produced, but cold flow properties of the product deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the feedstock composition through the addition of polar co-feed containing specific chain length fatty acids (C12-C22). This compositional parameter change in the feedstock leads to improved cold flow properties in the hydrocarbon product while maintaining high hydrocarbon yields through optimized hydroprocessing
3Productivity
If tall oil material is hydroprocessed, then hydrocarbons are produced, but aromatic content in the product increases
Solution Approach 1:
The patent applies parameter changes by altering the feedstock composition through the addition of polar co-feed. This compositional modification shifts the reaction pathway during hydroprocessing to favor non-aromatic hydrocarbon formation, thereby reducing aromatic content in the product while maintaining high hydrocarbon production rates
4Reliability
If frequent shut-downs occur due to catalyst inactivation, then process reliability decreases, but operating costs increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-modifying the feedstock composition with polar co-feed before hydroprocessing. This prevents catalyst inactivation from occurring in the first place, eliminating the need for frequent shut-downs and associated restart costs, thereby improving both process reliability and reducing operating costs
Solution Approach 2:
The patent converts the potentially harmful reactive compounds in tall oil material into a beneficial situation by adding polar co-feed that reacts with or neutralizes these compounds. This transforms what would be a harmful effect (catalyst inactivation) into a beneficial outcome (protected catalyst, continuous operation) while maintaining process 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 achieves improved hydrocarbon yields, extended process duration without interruptions, and produces hydrocarbons with enhanced cold flow properties and reduced aromatic content, suitable for use as fuels and fuel additives.
Implementation Method 1
the feedstock is hydroprocessed by a catalyst system comprising a combination of a HDO catalyst and HDW catalyst
Implementation Method 2
catalytic hydroprocessing of tall oil material and polar co-feed to obtain hydrocarbons
Data Source
AI summary
The present invention relates to process for producing hydrocarbons, wherein starting material comprising tall oil material and polar co-feed, which polar co-feed comprises fatty acids, is diluted with a non-polar diluent to obtain feedstock, and said feedstock is catalytically hydroprocessed to obtain hydrocarbons, suitable as fuels, fuel blending components and fuel additives.