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Catalytic Cracking of BioDiesel:
Institute of Chemical Engineering
Working Group Fluidized Bed Systems and Refinery Technology
Prof. Alexander Reichhold
Catalytic Cracking of BioDiesel:
Using the FCC Process to Convert FAME into
Oxygen-free Gasoline
Alexander Weinert
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyContents
• Aims of the work
• The Feedstock: Fatty Acid Methyl Ester (FAME)• The Feedstock: Fatty Acid Methyl Ester (FAME)
• The FCC-pilot plant
• Results of the cracking experiments
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyAims
• Testing an alternative feedstock for FCC-process
• Analyzing the gaseous phase of the product (olefins)• Analyzing the gaseous phase of the product (olefins)
• Comparison of the product with conventional FCC-
feedstock (vacuum gas oil, VGO)
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyFatty Acid Methyl Ester (FAME)
• Commonly used as BioDiesel
• Made from renewable resources, non-fossil• Made from renewable resources, non-fossil
• Carboxylic group causes hygroscopicity
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyFatty Acid Methyl Ester (FAME)
• Objective:
produce gasoline & olefins from renewable resources
• Refining of vegetable oils
• Degumming (remove lecithins and phospholipids)
• Neutralization (remove free fatty acids)
• Transesterification of vegetable oils
• Glycerin accrues (valuable, produce H2)
• Excess FAME can be sold as BioDiesel
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyThe FCC-Pilot Plant
Heating System
Regenerator
Return Flow Tube
Particle
Separator
Riser Flue Gas
Product Gas
Height of pilot plant
Riser length
Riser diameter
Regenerator diameter
Catalyst
Catalyst mass
Cat-Particle size spectrum
2.5 m
2.022 m
0.0205 m
0.18 m
Grace Space®
9 – 11 kg
20 – 200 μm
Nitrogen
Air
Regenerator
Zone
Siphon
Feed Inlet Zone
FAME
Preheating
Oven
Schematic of the FCC-pilot plant
Nitrogen
Cat-Particle size spectrum 20 – 200 μm
Riser temperature
Regenerator temperature
Feed flow
Catalyst to oil ratio
Riser residence time
Pressure
550°C
635°C
3 L/h
28 – 33
0.9 s
atmospheric
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyThe FCC-Pilot Plant
• Compact design
• Simplified architecture• Simplified architecture
• Heat coupling regenerator – riser
• Possible to measure catalyst circulation rate directly
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyThe FCC-Pilot Plant
27
29
31
33
35
Re
ge
ne
rato
r [m
ba
r]
Δp
15
17
19
21
23
25
0 20 40 60 80 100 120 140 160 180 200
Pre
ssu
reR
eg
en
era
tor
Time [s]
Δp
Δt
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyGeneral Results - Lumps
30%
40%
50%
60%
70%
80%
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
0%
10%
20%
30%
0% 20% 40% 60% 80% 100%Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
FAME-Content [% m.]
Total Fuel Yield Gasoline Crack Gas LCO & Residue Water Coke
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyLumps compared to VGO as Feed
56%
45%
30%
40%
50%
60%
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
VGO
FAME
23%
0%
17%
4%0% 0%
18%
2%
17%
4%
12%
1%0%
10%
20%
30%
Gasoline Gas CO LCO &
Residue
Coke Water CO2
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyLumps corrected by Oxygen
56%53%
30%
40%
50%
60%
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
VGO
FAME
23%
0%
17%
4%0% 0%
21%
0%
21%
5%
0% 0%0%
10%
20%
30%
Gasoline Gas CO LCO &
Residue
Coke Water CO2
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyOlefin-content of Crack-Gas
4%
6%
8%
10%
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
0%
2%
4%
0% 20% 40% 60% 80% 100%Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
FAME-Content [% m.]
Ethene Propene 1-Butene 2-Butene
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyTemperature-dependency of cracking
46%48%
30%
40%
50%
60%
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
550°C
580°C
18%
2%
17%
5%
12%
0%
22%
3%
13%
3%
11%
1%0%
10%
20%
30%
Gasoline Gas CO LCO &
Residue
Coke Water CO2
Pe
rce
nta
ge
fe
ed
ba
sed
[%
m.]
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyConclusions & Acknowledgement
• Pure FAME were processed successfully
• Unlike BioDiesel, the produced gasoline is oxygen-free• Unlike BioDiesel, the produced gasoline is oxygen-free
• The gasoline & olefins are chemically equivalent to
conventionally produced products (from VGO)
This work was supported by OMV Corporation.
Thank you for your Attention!
Institute of Chemical Engineering Institute of Chemical Engineering
Working Group Working Group Fluidized Bed Systems and
Refinery Technology
Prof. Alexander Reichhold
Getreidemarkt 9/166-3
1060 Vienna/ Austria
www.vt.tuwien.ac.at
DI Alexander Weinert
eMail: [email protected]
Tel.: +43 1 588 01 – 166328
Institute of Chemical Engineering
Working Group Fluidized Bed Systems
and Refinery TechnologyResults – Gasoline & Crack-Gas
• Gasoline
• High octane numbers
• Oxygen-free• Oxygen-free
• Contains no lead & almost no sulphur
• Crack-Gas
• High amounts of propylene (34% wt.)
• Possible source to produce bio-plastics
Property Jatropha
Gasoline
Conventional
FCC-Gasoline
RON [-]
MON [-]
Density [kg/m³]
Pb-Content [mg/L]
S-Content [mg/kg]
O-Content [%m.]
95
81
801.1
< 0.1
2.0
< 0.3
91 – 96
78 – 84
100 – 2000
