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Catalytic Hydrotreating of Waste Cooking Oil For Renewable Diesel Production
Catalytic Hydrotreating of Waste Cooking Oil For Renewable Diesel Production
Catalytic Hydrotreating of Waste Cooking Oil For Renewable Diesel Production
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Stella Bezergianni
Centre for Research and Technology Hellas (CERTH), Thessaloniki, Greece
sbezerg@cperi.certh.gr
Athanasios Dimitriadis
Centre for Research and Technology Hellas (CERTH), Thessaloniki, Greece
Summary
A new technology based on catalytic hydrotreating of Waste Cooking Oil (WCO) for biodiesel
production has been developed in the Centre for Research and Technology Hellas (CERTH). The main
premise of this process is the conversion of the WCO fatty acids into normal- and iso-paraffins. The
technology was evaluated in hydroprocessing pilot plants of CERTH where feedstock origin as well as
optimal catalysts and operating parameters where identified. The fractionated diesel product, called
“white” diesel exhibits excellent fuel properties including higher heating value (over 49MJ/kg),
negligible acidity, higher oxidation stability and higher cetane number (~77) than conventional
biodiesel. The overall product yield is ~92% v/v. This new suggested technology is extremely
appealing as it employs existing refinery infrastructure and expertise, offers feedstock flexibility,
leaves no by-product and above all is economically attractive.
Gas
Product
to vent
PC
N2 recycle
Gas
(for blanket) Product
LC
HPLT
P-2 LPLT
Oil
P-1 LC
RX-1 RX-2
Liquid
Product
Figure 1: Simplified diagram of the large-scale hydroprocessing pilot plant HDS1 of CPERI/CERTH
The total liquid product is collected daily and heavy molecules. The capacity of the HYDIS
several analyses take place in the analytical unit is 40L. The overall process of converting
laboratory of CPERI. The product is separated WCO to white diesel is shown in the
among the gas and total liquid product. The simplified process diagram in fig. 3.
gas product contains the excess H2, the Product characterization was performed by
decarbonylation and decarboxylation by collecting and analyzing total liquid product
products CO and CO2, as well as light samples in terms of simulated distillation
hydrocrarbons (C1-C6). It should be noted that (Agilent 6890N), density (DMA4500), sulfur
in an industrial-scale application, the gas (ASTM D5453-93), nitrogen ASTM D 4629),
product, after cleaning is compressed and then bromine index (ASTM 2719), carbon and
recycled as a main source of H2. The total hydrogen content (ASTM D 5291), organic
liquid product contains the useful diesel phase water (ASTM D 1744), viscosity
molecules, which are mainly paraffins and (ASTM D445), heating value (ASTM D 4809),
isoparaffins [11], as well as the resulting water pour point (ASTM D 97), flash point (ASTM
from the decarbonylation and deoxygenation D 93), oxidation stability (ASTM D 2274),
reactions. The water is then separated as a cetane number (ASTM D 976). Finally the
different phase in a precipitation vessel. The reaction gases were analyzed with a Gas
water-free product finally undergoes Chromatograph equipped with a flame
fractionation in a batch distillation unit ionization detector (FID) and a thermal
(HYDIS) shown in fig. 2, in order to isolate the conductivity detector (TCD).
useful diesel molecules from the unconverted
N2
production was of interest, while lower
reaction temperatures have been more suitable
Condenser Vent
CWT
when diesel production was more important
[13].
Fractionation
Trap Furthermore, in the authors’ previous work the
column
PC
effect of pressure, hydrogen-to-oil ratio
(H2/oil) and liquid hourly space velocity
(LHSV) have been also examined. Reaction
Liquid product pressure is a very important parameter as it
Oil heater
affects the hydrogenation and cracking
Figure 2: Simplified diagram of the HYDIS reactions. Three hydrotreating pressures within
unit a typical range 1200-1400psig have been
examined. The results have shown that, lower
pressures favour biodiesel production while
3 Results and Discussion
higher pressures promote cracking reactions
The selection of a hydroprocessing catalyst is a which reduce the biodiesel selectivity.
critical step defining the hydrotreating Moreover, the H2/oil ratio also affects the
products’ yields and their corresponding hydrogenation reactions. Three typical ratios
quality as well as the expected run-length of (3000, 4000 and 5000scfb) have been
the process. In an authors’ previous work [12] examined [14]. The results have shown that
the process of selecting a suitable WCO conversion decreases with H2/oil ratio
hydroprocessing catalyst for the conversion of and cracking reactions are triggered, lowering
waste cooking oil into biofuels was presented. biodiesel production. Finally, the
In particular three commercial hydroprocessing hydrotreatment extent can also be observed via
catalysts have been evaluated: a hydrotreating the feed flow (ml/hr) to catalyst volume (m3)
catalyst, a mild-hydrocracking catalyst and a or else LHSV. The LHSV is a key parameter
severe hydrocracking catalyst. The catalyst for regulating both catalyst effectiveness and
effectiveness has been assessed over a life expectancy. Three typical LHSV (0.5, 1.0
temperature range suggested by the catalyst and 1.5 hr-1) have been tested in the same
manufacturers, covering a temperature range of authors’ previous study (Bezergianni 2011),
330°-390°C, under constant LHSV (1hr-1) and indicating that higher LHSV values were
a range pressure 1200-2000psig. The results preferable as they promoted diesel production.
have shown that the hydrotreating catalyst From all the aforementioned studies the
exhibited the highest conversion (~83%) as authors concluded that the optimal operating
well as the highest diesel selectivity. In all parameters were reactor temperature of 350ºC,
cases the diesel yields have been over 94%. pressure 1200psig, H2/oil ratio 4000scfb and
The hydrotreating catalyst has showed a drastic LHSV 1.0hr-1.
activity on heteroatoms removal as well as The optimal catalyst and operating parameters
saturation, while all catalyst have achieved were employed for an extended white diesel
over 99% saturation of the WCO double production in a larger-scale hydroprocessing
bonds. Therefore the hydrotreating catalyst is pilot plant (HDS1) which also incorporated a
the best catalyst for WCO hydroprocessing for fractionation unit that enables the diesel
biodiesel production. separation, as shown in Figure 3. The HDS1
Hydrotreating of WCO was studied as a daily capacity allowed 14.4L/d of WCO to be
process for biofuels production. The processed
hydrotreatment temperature is the most According to the unit HDS1 daily capacity,
dominant operating parameter which defines 14.4L of WCO are processed daily utilizing.
catalyst performance as well as catalyst life. A ~7200 nL H2/day to satisfy the desired H2/oil
hydrotreating temperature range of 330°- ratio of 500 nL/L, necessary for the
398°C has been explored via a series of five hydroprocessing reactions (saturation,
experiments (330, 350, 370 385 and 398°C) cracking, deoxygenation, decarbonylation,
presented in an authors’ previous work [13]. decarboxylation and heteroatom removal). The
For all experiments the same commercial reactor product was flashed in a High Pressure
hydrotreating catalyst identified as optimal in Low Temperature (HPLT) separator into a
the aforementioned study has been utilized, gaseous and a total liquid product. The gas
while the remaining operating parameters product yield was around 4,416 L/d and
remained constant (pressure 1200psig, LHSV consisted of the excess H2, CO and CO2 (from
1hr-1 and H2/oil ratio 4000scfb). The results decarbonylation and decarboxylation
have indicated that higher reactor temperatures reactions) and some light hydrocarbons. The
have been more attractive when gasoline total liquid product yield was around 15.3 L/d
which included the desired hydrocarbons and order to separate the desired white diesel from
an aqueous phase. The total liquid product was the remaining hydrocarbons. The white diesel
separated into the two separate phases, i.e. the is by far the most significant product in terms
organic phase (paraffins, iso-paraffins, of volume production, while a heavier fraction
unconverted fatty acids) and the aqueous phase of hydrocarbons was also produced, consisting
(resulting from the decarbonylation and of the residual unconverted heavy molecules.
deoxygenation reactions). The overall white diesel yield of the process
Finally, the organic phase, which renders (Figure 3) was 91.7% v/v while of the residue
93.4%v/v of the total liquid product, was 7.7%v/v.
fractionated in the HYDIS unit (Figure 2) in
Hydrogen (Η2)
7200 lit/day Gas product
4416 lit/day
High Pressure
Separator
WCO
White Diesel
14.4 lit/day
13.2 lit/day
Reactor 14.3 lit/day
Liquid product
15.3 lit/day Precipitator Fractionation
Water
1 lit/day Residue
(6.6%) 1.1 lit/day
Figure 3: Overall pilot plant process for WCO conversion to white desel
500
Distillation of 90% °C 302.6
400
Net heating value MJ/kg 49
300
Cold Filter Plugging
200 °C 20
Point (CFPP)
100
Pour point °C 23
0
IBP 5 10 20 30 40 50 60 70 80 90 95 FBP
percent (%) Moreover, hydrotreating reactions also include
Figure 4: Distillation curve of WCO, HDT- heteroatom removal (mainly sulphur, nitrogen
WCO, white diesel and Residue (WCO •••, and oxygen) which is an important measure of
the overall hydrotreatment effectiveness, as
HDT-WCO •, white diesel (solid) and
heteroatoms are not desired in the final
Residue ()
product. Sulfur is removed via
hydrodesulfurization reactions as H2S, nitrogen hydrotreatment leads to a significant density
is removed via denitrogenation reactions as decrease and heteroatom removal.
NH3 and oxygen is removed via deoxygenation The fuel properties of white diesel are finally
reactions as CO, CO2 and water. However, given in table 2. This new biodiesel shows
sulphur is artificially added to the feedstock as remarkable properties. It is a light diesel with
DMDS (Dimethyl Disulfide) in significant no impurities (S, N, O, H2O). It has an
amount to regulate catalyst activity and impressive cetane index which exceeds 77
catalyst life, the absolute value of sulfur is (compared to fossil diesel with values ~50) and
20000wppm. a net heating value of 49 MJ/kg (compared to
The basic properties (density, heteroatom conventional fossil diesel with 42-43 MJ/kg).
content and distillation curve) of white diesel Furthermore, even though white diesel is a bio-
are compared with the ones of WCO and based fuel, it shows high oxidation stability
organic phase of total liquid product in table 1. (>22hr while the EN standard is 6hr) and also
Heteroatom removal is expressed as the negligible acidity TAN (mg KOH/gr). As
percentage of the sulphur, nitrogen and oxygen white diesel is highly paraffinic it exhibits
contained in the feed, which has been removed problems with its cold flow properties which
during hydrotreatment reactions. The produced are going to be addressed downstream via
white diesel contains only traces of sulphur. additives.
From this comparison it is clear that catalytic
Hydrotreated White
WCO Residue
WCO (organic) Diesel
3
Density (at 60ºC) gr/cm 0.896 0.7562 0.7532 0.8088
C Wt% 76.74 84.59 86.67 85.48
H Wt% 11.61 15.02 14.74 14.29
S wppm 38 11.80 1.54 14.60
N wppm 47.42 0.77 1.37 2.02
O wt% 14.57 0.38 0 0.2283
Distillation (vol%)
0% °C 431.6 195.6 234.1 301.6
5% °C 525.6 271.6 291.7 318.6
10% °C 556.4 287.4 294.1 321.4
20% °C 593 302.8 295.7 369.0
30% °C 599 304.0 296.8 399.4
40% °C 601.4 305.0 297.6 422.4
50% °C 603.2 314.4 298.3 447.2
60% °C 606.8 318.0 299.1 463.0
70% °C 609 319.0 300 469.8
80% °C 610.4 319.8 301.1 475.4
90% °C 612.4 320.4 298.3 483.4
95% °C 623.6 401.6 304.2 522.2
100% °C 727.2 475.4 306.2 590.6
Finally the residue product that comes from the (WCO) for biodiesel production has been
fractionation of hydrotreating waste cooking developed in the Centre for Research and
oil is a heavy diesel fraction with boiling point Technology Hellas (CERTH). The main
above 310°C and for that reason it is not premise of this process is the conversion of the
appropriate as a fuel in car engines, but it could WCO fatty acids into normal- and iso-
probably be used as heating oil. The residue paraffins. Firstly, a small scale
characteristics are shown in table 1 and are hydroprocessing unit for the initial
compared with the one of white diesel. experiments as far as the evaluation of the
optimum catalyst and optimum operating
4 Conclusions parameters are concerned was utilized.
Secondly, the new technology was applied in
In this paper a new technology based on large-scale pilot plant hydroprocessing and
catalytic hydrotreating of Waste Cooking Oil distillation units in order to produce 2 tons of
this new biodiesel to be called white diesel. Premium quality renewable diesel fuel by
The overall process exhibits an impressive hydroprocessing of sunflower oil. Fuel,
91.7%v/v yield from WCO to white diesel. Issue 90 (2011), p 2473–2479.
Furthermore, the new white diesel has superior
qualities over conventional fossil diesel as well [8] Šimácek,P., Kubicka, D., Šebor, G.,
as conventional biodiesel (FAME). In Pospíšil, M.: Fuel properties of
particular, white diesel has high cetane number hydroprocessed rapeseed oil. Fuel, Issue
and heating value, increased oxidation stability 89(2010), p 611–615.
as well as no water and no acidity. The only
drawback of white diesel is associated with its [9] Furimsky E. Carbons and carbon supported
cold flow properties, which is addressed catalysts in hydroprocessing. RSC
downstream via additives. Publishing, Cambridge UK. (2008).
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