Triglyceride Hydrogenation with Diluting Agent Injection
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Solution Overview
Problem
Existing processes for the hydrogenation of triglycerides in fixed bed reactor systems face challenges such as high hydraulic load due to excessive recycle, catalyst deactivation, and loss of valuable paraffin products due to decarb-reactions, which require significant revamp of units and result in corrosion issues.
Innovation Solution
A process where triglyceride-containing raw materials and hydrogen gas are passed through multiple catalyst beds in series, with a diluting agent composed of recycled hydrogenation products, maintaining a controlled temperature and hydrogen excess to minimize recycle and prevent decarb-reactions, allowing for efficient hydrogenation with reduced corrosion and product loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high recycle ratio is used to provide sufficient diluting agent, then temperature control is improved, but hydraulic downstream load increases and reactor volume must be enlarged
Solution Approach 1:
The patent changes the parameter of recycle ratio from high (conventional) to low (optimized), achieving temperature control with minimal recycle by using a diluting agent injection system instead of relying on high recycle flows
Solution Approach 2:
The patent introduces a diluting agent (external to the recycle stream) that acts as an intermediary to control temperature and reaction conditions, allowing the system to function with low recycle ratios while maintaining thermal management
2Quantity of substance
If deoxygenation through decarb-reactions is promoted to reduce hydrogen consumption, then hydrogen consumption is reduced, but valuable paraffin product is lost and catalyst deactivation occurs
Solution Approach 1:
The patent converts the harmful effect of oxygen-containing compounds into a beneficial process by using them as diluting agents that control reaction temperature and prevent unwanted side reactions, rather than removing them through decarb-reactions
Solution Approach 2:
The patent changes the approach from chemical modification (decarb-reactions) to physical utilization (using oxygenates as diluents), fundamentally altering how oxygen is handled in the process to avoid product loss and catalyst deactivation
3Quantity of substance
If deoxygenation through decarb-reactions is performed, then hydrogen consumption is reduced, but corrosion due to CO2 presence increases
Solution Approach 1:
The patent converts the harmful CO2 byproduct into a beneficial diluting agent that controls reaction temperature and prevents further unwanted reactions, thereby eliminating the corrosion problem while maintaining low hydrogen consumption
4Adaptability or versatility
If free fatty acids are present in raw materials, then catalytic hydrotreating can be performed, but undesirable side reactions are promoted
Solution Approach 1:
The patent uses free fatty acids and oxygen-containing compounds as intermediary diluting agents that mediate the reaction by controlling temperature and preventing direct harmful interactions, allowing processing of raw materials with high free fatty acid content without side reactions
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 achieves stable operation with minimal recycle, reducing hydraulic load and corrosion, maximizing valuable product yield while maintaining catalyst effectiveness and avoiding side reactions, thus optimizing existing units and product quality.
Implementation Method 1
a fixed bed reactor system having several catalyst beds comprising hydrogenation catalyst
Implementation Method 2
continuous hydrogenation of triglyceride containing raw materials
Implementation Method 3
Due to the highly exothermic nature of these reactions, temperature control is very important to avoid undesirable side reactions
Data Source
AI summary
Process for the continuous hydrogenation of triglyceride containing raw materials in a fixed bed reactor system having several catalyst beds arranged in series and comprising hydrogenation catalyst. The raw material feed, hydrogen containing gas and diluting agent are passed together through the catalyst beds at hydrogenation conditions. The raw material feed stream as well as the stream of hydrogen containing gas are divided into an equal number of different partial streams. These are each passed to one catalyst bed in such a manner that the weight ratio of diluting agent to raw material feed is essentially the same at the entrance of all catalyst beds and does not exceed 4:1. The claimed process is preferably conducted at low temperatures and allows the utilization of existing units due to the low recycle ratio. Further, a sufficient excess of hydrogen is used so that no valuable product is lost through decarb-reactions.