Biofuels Refining Engineering

Abstract

The goal of this project is the development of novel catalysts and knowledge of reaction pathways and mechanisms for conversion of biomass-based compounds to fuels that are compatible with oil-based fuels and with acceptable or superior fuel properties. The research scope included both catalysts to convert lignocellulosic biomass-based molecules (from pyrolysis) and vegetable oil-based molecules (i.e., triglycerides and fatty acid methyl esters). This project comprised five technical tasks. Each task is briefly introduced below, and major technical accomplishments summarized. Technical accomplishments were described in greater detail in the quarterly progress reports, and in even more detail in the >50 publications acknowledging this DoE project funding (list of publications and presentations included at the end of this report). The results of this research added greatly to the knowledge base necessary for upgrading of pyrolysis oil to hydrocarbon fuels and chemicals, and for conversion of vegetable oils to fungible diesel fuel. Numerous new catalysts and catalytic reaction systems were developed for upgrading particular compounds or compound families found in the biomass-based pyrolysis oils and vegetable oils. Methods to mitigate catalyst deactivation were investigated, including novel reaction/separation systems. Performance and emission characteristics of biofuels in flames and engines were measured. Importantly, the knowledge developed from this project became the basis for a subsequent collaborative proposal led by our research group, involving researchers from the University of Wisconsin, the University of Pittsburg, and the Idaho National Lab, for the DoE Carbon, Hydrogen and Separations Efficiency (CHASE) program, which was subsequently funded (one of only four projects awarded in the CHASE program). The CHASE project examined novel catalytic processes for lignocellulosic biomass conversion as well as technoeconomic analyses for process options for maximum carbon capture and hydrogen efficiency. Our research approach combined catalyst synthesis, measurements of catalyst activity and selectivity in different reactor systems and conditions, and detailed catalyst characterization to develop fundamental understanding of reaction pathways and the capability to predict product distributions. Nearly all of the candidate catalysts were prepared in-house via standard techniques such as impregnation, co-impregnation, or chemical vapor deposition. Supports were usually purchased, but in some cases coprecipitation was used to simultaneously create the support and active component, which can be advantageous for strong active component-support interactions and for achieving high active component dispersion. In-house synthesis also allowed for studies of the effects on catalyst activity and selectivity of such factors as support porosity, calcination temperature, and reduction/activation conditions. Depending on the physical characteristics of the molecule, catalyst activity measurements were carried out in tubular flow reactors (for vapor phase reactions) or stirred tank reactors (for liquid phase reactions) over a wide range of pressures and temperatures. Reactant and product concentrations were measured using gas chromatography (both on-line and off-line, with TCD, FID, and/or mass spectrometric detection). For promising catalysts, detailed physicochemical characterization was carried out using FTIR, Raman, XPS, and XRD spectroscopies (all available in our laboratories) and TEM spectroscopy (available at OU). Additional methods included temperature programmed techniques (TPD, TPO) and surface area measurements by nitrogen adsorption techniques.