Here we present a comprehensive study on the effect of reaction parameters on the upgrade of an acetone, butanol and ethanol mixture – key molecules and platform products of great interest within the chemical sector. Using a selected high performing catalyst, Fe/MgO-Al2O3, the variation of temperature, reaction time, catalytic loading and reactant molar ratio have been examined in this reaction. This work is aiming to not only optimise the reaction conditions previously used, but to step towards using less energy, time and material by testing those conditions and analysing the sufficiency of the results. Herein we demonstrate that this reaction is favoured at higher temperatures and longer reaction time. Also, we observe that increasing the catalyst loading had a positive effect on the product yields, while reactant ratios have shown to produce varied results due to the role of each reactant in the complex reaction network. In line with the aim of reducing energy and costs, this work showcases that the products from the upgrading route have significantly higher market value than the reactants; highlighting that this process represents an appealing route to be implemented in modern biorefineries.
With the aim of moving towards sustainability and renewable energy sources, we have studied the production of long chain hydrocarbons from a renewable source of biomass to reduce negative impacts of greenhouse gas emissions while providing a suitable alternative for fossil fuel-based processes. Herein we report a catalytic strategy for Acetone, Butanol and Ethanol (ABE) upgrading using economically viable catalysts with potential impact in modern bio-refineries. Our catalysts based on transition metals such as Ni, Fe and Cu supported on MgO–Al2O3 have been proven to perform exceptionally with outstanding conversions towards the production of a broad range of added value chemicals from C2 to C15. Although all catalysts displayed meritorious performance, the Fe catalyst has shown the best results in terms conversion (89%). Interestingly, the Cu catalyst displays the highest selectivity towards long chain hydrocarbons (14%). Very importantly, our approach suppresses the utilization of solvents and additives resulting directly in upgraded hydrocarbons that are of use in the chemical and/or the transportation industry. Overall, this seminal work opens the possibility to consider ABE upgrading as a viable route in bio-refineries to produce renewably sourced added value products in an economically favorable way. In addition, the described process can be envisaged as a cross-link stream among bio and traditional refineries aiming to reduce fossil fuel sources involved and incorporate “greener” solutions.
One of the main issues that many industrial sectors such as oil refineries have been facing nowadays is their sole dependency on fossil fuel. Not only have price fluctuations affected the products, but their environmental impact is an ever present problem that should be addressed. This has led to the search for alternatives such as biomass based processes in order to reduce the dependency on fossil fuel.
Bio-refinery processes, fed by biomass, produce high value chemicals and materials with the advantage of reduced environmental drawbacks, such as CO2 emissions, when compared to the conventional refinery. For the benefit of both systems, an integration approach has been considered connecting bio-refining and conventional refining processes together.
In this work we focus on the production of long chain hydrocarbons while maintaining production of chemicals that already originate from biomass such as Acetone, Butanol and Ethanol (ABE). The ABE used for this process is obtained as a product of sugar fermentation using the bacteria genus Clostridium. Through the upgrading and conversion of ABE, the products obtained will then be incorporated in the proposed integration system, connecting the conventional oil refinery to this process. A reaction involving a complex reaction network towards upgrading ABE with the aim of producing valuable products using economically viable catalysts has been carried out. The vast majority of research in this area either involves the separation of ABE after fermentation to be used in the chemical/or transportation industry that incurs large costs, or noble metal catalysts are used to upgrade this feed, which would also not be economically viable. However, our research has surpassed the necessity of noble metals, leading to a significant cost decrease that also produces outstanding results. The catalysts required for this process were synthesised successfully through the wetness incipient method and characterised by XRD, Raman, BET, TPR and N2 Isotherm. The reaction consists of the self-condensation and cross condensation of the alcohols and acetone, respectively, using a variety of active metals on basic supports as catalysts, at high temperatures and pressure in a batch reactor.
The results have shown exceptional performance for the catalysts in terms of conversion and selectivity, having conversions as high as 90%. The catalysts have proven to yield a range of C3-C15 hydrocarbons identified to be of need in the chemical industry. In conclusion, our route has produced valuable chemicals proven to have a considerably higher market value than the simple alcohol reactants, useful for both the petrochemical and the transportation industries, through the use of novel and economically favourable catalysts.
Towards Sustainable Industries: Industrial Symbiosis of an Oil Refinery and a Petrochemical Plant
(2019)
A common factor that can be seen in the history of all manufacturing and production sectors is that they all go through significant changes to keep them operating efficiently, thus a constant cycle of system development, obsolescence and advancement is formed. These sectors must be able to maintain the balance between the energy consumption and efficiency to keep the system optimised and preserve the opportunity to create value. Oil refineries are a prime example of one of these sectors that play an important role in our day-to-day lives. Due to an oil refineries’ major dependency on crude oil, the price fluctuation of which, has a profound impact on this industry. Thusly, this drives up prices and forcing a rise in the search for alternative solutions to tackle these efficacy and economic problems. Therefore, in this work, an integration approach has been considered based on the Industrial Symbiosis concept to connect an oil refinery with a petrochemical plant.
One main feature of the larger chemical industry that should be considered, is that they require careful management of material and energy to obtain valuable products. Of course, the processes key to the generation of the valuable products also produce fewer desirable chemicals, which have no value as waste products. Some of these waste materials can be used as feed-stock for other processes; turning probable costly chemical disposal into an economic boon. This “greener†approach opens avenues of improvement compatible with the idea of industrial symbiosis; where the waste from one process can be a feed-stock, useful for another. Taking this into account, a case study is presented involving the connection of an oil refinery with an ethylene production plant through material exchange and stream combination to benefit both plants.
As a result, we were able to improve not only product quality but the overall profit of both plants by a significant margin, while also decreasing dependency on outside sources for material supply.
In this work, the optimal integration between an oil refinery and an ethylene production plant has been investigated. Both plants are connected using intermediate materials aiming to remove, at least partially, the reliance on external sourcing. This integration has been proven to be beneficial in terms of quality and profit increase for both production systems. Thus, three mathematical models have been formulated and implemented for each plant individually as well as for the integrated system as MINLP models aiming to optimise all three systems. Moreover, a case study using practical data is presented to verify the feasibility of the integration within an industrial environment. Promising results have been obtained demonstrating significant profit increase in both plants.
This contribution presents a kinetic study for the identification of the complex reaction mechanism occurring during the ABE upgrading, and the development of a kinetic model. Employing graph theory analysis, a directed bipartite graph is constructed to reduce the complexity of the reaction network, and the reaction rate constants and reaction orders are calculated using the initial rate method, followed by the calculation of the activation energy and frequency factor for an Arrhenius-type law. Subsequently, using general mass balancing a proposed mathematical model is produced to determine the apparent reaction rates, which are successfully in line with the experimental results.