Matthew Flake

Conversion of biomass-derived small oxygenates over HZSM-5 and its deactivation mechanism

HZSM-5 catalyst deactivation was studied using aqueous feed mixtures containing ethanol, ethanol + acetic acid, ethanol + ethyl acetate, or ethanol + acetaldehyde in a fixed bed reactor at 360 °C and 300 psig. Compared to an ethanol alone experiment, addition of other oxygenates reduced catalyst life in the order of: ethyl acetate < acetic acid < acetaldehyde. Based on the liquid product and spent catalyst analyses from the individual ethanol, acetaldehyde, acetic acid, and ethyl acetate feeds, the presence of acetaldehyde appears to produce high molecular weight aromatic compounds which deactivate the catalyst through a pore-blocking mechanism. Acetic acid deactivates the catalyst through an active site poisoning mechanism or strong adsorption of acetate intermediates on the active sites (hydroxyl groups). Ethanol deactivates the catalyst primarily through its pore-blocking mechanism, but the rate of ethanol deactivation is orders of magnitude slower than that of acetaldehyde. Ethyl acetate hydrolyzes to form acetic acid and ethanol which deactivate the catalyst through their respective mechanisms. In addition, each functional group of oxygenates requires different active sites/catalysts and different operating conditions due to competitive adsorptions on active sites for their conversion to the desired products. Therefore, it is necessary to pre-treat the mixture of oxygenates to produce a feed stream containing the same or similar functional group compounds before converting the feed stream to hydrocarbon compounds over the HZSM-5 catalyst.

Integrated process for the catalytic conversion of biomass-derived syngas into transportation fuels

Efficient synthesis of renewable fuels that will enable cost competitiveness with petroleum-derived fuels remains a grand challenge. In this paper, we report on an integrated catalytic approach for producing transportation fuels from biomass-derived syngas. This novel process represents an alternative to conventional fuel synthesis routes (e.g., Fischer–Tropsch, Methanol-to-Gasoline) that have drawbacks, particularly at the scale of biomass. Composition of the resulting hydrocarbon fuel can be modulated to produce predominantly middle distillates, which is constantly increasing in demand compared to gasoline fraction. In this process biomass-derived syngas is first converted over an Rh-based catalyst into a complex aqueous mixture of condensable C2+ oxygenated compounds (predominantly ethanol, acetic acid, acetaldehyde, ethyl acetate). This multi-component aqueous mixture then is fed to a second reactor loaded with a ZnxZryOz mixed oxide catalyst, which has tailored acid–base sites, to produce an olefin mixture rich in isobutene. The olefins then are oligomerized using a solid acid catalyst (e.g., Amberlyst-36) to form condensable olefins with molecular weights that can be targeted for gasoline, jet, and/or diesel fuel applications. The product rich in long-chain olefins (C7+) is finally sent to a fourth reactor required for hydrogenation of the olefins into paraffin fuels. Simulated distillation of the hydrotreated oligomerized liquid product indicates that ∼75% of the hydrocarbons (iso-paraffins and cyclic compounds) are in the jet-fuel range. Process optimization for the oligomerization step could further improve yield to the jet-fuel range. All of these catalytic steps have been demonstrated in sequence, thus providing proof-of-concept for a new integrated process for the production of drop-in biofuels. Overall, we demonstrate approximately 41% carbon efficiency for converting syngas into jet-range hydrocarbons. This unique and flexible process does not require external hydrogen and also could be applied to non-syngas derived feedstock, such as fermentation products (e.g., ethanol, acetic acid, etc.), other oxygenates, and mixtures thereof containing alcohols, acids, aldehydes and/or esters.

Conversion of syngas-derived C2+ mixed oxygenates to C3–C5 olefins over ZnxZryOz mixed oxide catalysts

In this study we report on a ZnxZryOz mixed oxide type catalyst capable of converting a syngas-derived C2+ mixed oxygenate feedstock to isobutene-rich olefins. Aqueous model feed comprising of ethanol, acetaldehyde, acetic acid, ethyl acetate, methanol, and propanol was used as representative liquid product derived from a Rh-based mixed oxygenate synthesis catalyst. Greater than 50% carbon yield to C3–C5 mixed olefins was demonstrated when operating at 400–450 °C and 1 atm. In order to rationalize formation of the products observed feed components were individually evaluated. Major constituents of the feed mixture (ethanol, acetaldehyde, acetic acid, and ethyl acetate) were found to produce isobutene-rich olefins. C–C coupling was also demonstrated for propanol feedstock – a minor constituent of the mixed oxygenate feed – producing branched C6 olefins, revealing scalability to alcohols higher than ethanol following an analogous reaction pathway. Using ethanol and propanol feed mixtures, cross-coupling reactions produced mixtures of C4, C5, and C6 branched olefins. The presence of H2 in the feed was found to facilitate hydrogenation of the ketone intermediates, thus producing straight chain olefins as byproducts. While activity loss from coking is observed complete catalyst regeneration is achieved by employing mild oxidation. For conversion of the mixed oxygenate feed a Zr/Zn ratio of 2.5 and a reaction temperature of 450 °C provides the best balance of stability, activity, and selectivity. X-ray diffraction and scanning transmission electron microscopy analysis reveals the presence of primarily cubic phase ZrO2 and a minor amount of the monoclinic phase, with ZnO being highly dispersed in the lattice. The presence of ZnO appears to stabilize the cubic phase resulting in less monoclinic phase as the ZnO concentration increases. Infrared spectroscopy shows the mixed oxide acid sites are characterized as primarily Lewis type acidity. The direct relationship between isobutene production and the ratio of basic/acidic sites was demonstrated. An optimized balance of active sites for isobutene production from acetone was obtained with a basic/acidic site ratio of ∼2. This technology for the conversion of aqueous mixtures of C2+ mixed oxygenates provides significant advantages over other presently studied catalysts in that its unique properties permit the utilization of a variety of feeds in a consistently selective manner.

Nuclear Energy Research Initiative Project No. 02 103 Innovative Low Cost Approaches to Automating QA/QC of Fuel Particle Production Using On Line Nondestructive Methods for Higher Reliability Final Project Report

This Nuclear Energy Research Initiative (NERI) project was tasked with exploring, adapting, developing and demonstrating innovative nondestructive test methods to automate nuclear coated particle fuel inspection so as to provide the United States (US) with necessary improved and economical Quality Assurance and Control (QA/QC) that is needed for the fuels for several reactor concepts being proposed for both near term deployment [DOE NE & NERAC, 2001] and Generation IV nuclear systems. Replacing present day QA/QC methods, done manually and in many cases destructively, with higher speed automated nondestructive methods will make fuel production for advanced reactors economically feasible. For successful deployment of next generation reactors that employ particle fuels, or fuels in the form of pebbles based on particles, extremely large numbers of fuel particles will require inspection at throughput rates that do not significantly impact the proposed manufacturing processes. The focus of the project is nondestructive examination (NDE) technologies that can be automated for production speeds and make either: (I) On Process Measurements or (II) In Line Measurements. The inspection technologies selected will enable particle “quality” qualification as a particle or group of particles passes a sensor. A multiple attribute dependent signature will be measured and used for qualification or process control decisions. A primary task for achieving this objective is to establish standard signatures for both good/acceptable particles and the most problematic types of defects using several nondestructive methods.

Standing ultrasonic wave separator

This paper presents the design and preliminary results for a flow-through particle separation unit using standing ultrasonic waves. The results indicate that good separation is obtained at residence times as low as 14 seconds and liquid velocities of 2 mm/sec. The effects of thermally and acoustically induced streaming are discussed. The unit is being used to assess the effective ranges and limits for key parameters in the design of larger scale units.