Pyrolysis Oil Upgrading to Fuels by Catalytic Cracking: A Refinery Perspective

  • Desavath Viswanatha Naik
  • Vimal Kumar
  • Basheshwar Prasad
Chapter
First Online:
Part of the Energy, Environment, and Sustainability book series (ENENSU)

Abstract

Pyrolysis oil produced using lignocellulosic material is an alternate source of energy. Pyrolysis is an attractive option for the conversion of lignocellulosic biomass into liquid, pyrolysis oil, and gaseous hydrocarbons and is considered as an emerging and challenging research area in the current scenario of renewable energy. To ensure the production of “drop-in” liquid hydrocarbons from biomass, there is urgency of integration of pyrolysis process with conventional petroleum refinery’s trillion dollars worldwide infrastructure. This will happen into reality only after going through the necessary actions and precautions at various process development stages, such as biomass pyrolysis, pyrolysis oil upgrading, and effective integration of biomass pyrolysis with refinery. Herein, the opportunities lie in upgrading of pyrolysis oil in petroleum refinery units such as catalytic cracking and steam reforming, is described. The challenges arise ahead of pyrolysis oil upgrading in fluid catalytic cracking (FCC) approach have been reviewed. The extent of pyrolysis oil coprocessing with vacuum gas oil (VGO) in a refinery FCC unit is discussed. The advances in biomass pyrolysis process integration schemes with petroleum refinery have been revealed.

Keywords

Alternative fuel Biomass Fluid catalytic cracking Pyrolysis Pyrolysis oil Upgrading 
This is a preview of subscription content, log in to check access.

References

  1. Abdel-A HK, Mohamed A, Fahim MA (2003) Petroleum and gas field processing handbook. Marcel Dekker Inc., New York, Basel, pp 317–329CrossRefGoogle Scholar
  2. Adjaye JD, Bakhshi NN (1995a) Production of hydrocarbons by catalytic upgrading of a fast pyrolysis bio-oil, Part II: comparative catalyst performance and reaction pathways. Fuel Process Technol 45:185–202CrossRefGoogle Scholar
  3. Adjaye JD, Bakhshi NN (1995b) Production of hydrocarbons by catalytic upgrading of a fast pyrolysis bio-oil. Fuel Process Technol 45:161–183CrossRefGoogle Scholar
  4. Adjaye JD, Katikaneni SPR, Bakhshi NN (1996) Catalytic conversion of a biofuel to hydrocarbons: effect of mixtures of HZSM-5 and silica-alumina catalysts on product distribution. Fuel Process Technol 48:115–143CrossRefGoogle Scholar
  5. Agblevor FA, Besler S (1996) Inorganic compounds in biomass feedstocks, 1, effect on the quality of fast pyrolysis oils. Energy Fuels 10:293–298CrossRefGoogle Scholar
  6. Aguado R, Olazar M, San Jose MJ, Aguirre G, Bilbao J (2000) Pyrolysis of sawdust in a conical spouted bed reactor: yields and product composition. Ind Eng Chem Res 39:1925–1933CrossRefGoogle Scholar
  7. Alhajri I, Alper E, Is G, Fung J, Lo J, Yanez K, Elkamel A (2014) Optimization model for the integration of biomass into a conventional oil refinery. In: Proceedings of international conference on industrial engineering and operations management, Indonesia, JanuaryGoogle Scholar
  8. Anh (2014) Simultaneous cracking of phenolic compounds and hydrocarbons over zeolites. PhD Thesis, Norman, OklahomaGoogle Scholar
  9. Ardiyanti AR, Ermakov D, Heeres HJ, Khromova S, Parmon V, Venderbosch RH (2012) Process for the hydrotreatment of vegetal materials. Patent: WO 2012030215 A1Google Scholar
  10. Bardalai M, Mahanta DK (2015) A review of physical properties of biomass pyrolysis oil. Int J Renew Energy Res 5:277–286Google Scholar
  11. Branca C, Giudicianni P, Blasi CD (2003) GC/MS characterization of liquids generated from low-temperature pyrolysis of wood. Ind Eng Chem Res 42:3190–3202CrossRefGoogle Scholar
  12. Brown JN (2009) Development of a lab-scale auger reactor for biomass fast pyrolysis and process optimization using response surface methodology. Graduate Thesis and Dissertations. Paper 10996Google Scholar
  13. Cantu TS, Daugaard DE, Gong K, Platon A, (2012) Integrated FCC biomass pyrolysis/upgrading. Patent No. WO2012091815 A1Google Scholar
  14. Chen NY, Degnan JTF, Koenig LR (1986) Liquid fuel from carbohydrates. Chem Technol 16:506–511Google Scholar
  15. Corma A, Huber GW, Sauvanaud L, Connor PO (2007) Processing biomass-derived oxygenates in the oil refinery: Catalytic cracking (FCC) reaction pathways and role of catalyst. J Catal 247:307–327Google Scholar
  16. Czernik S, French R, Feik C, Chornet E (2001) Production of hydrogen from biomass derived liquids. In: Proceedings of the 2001 DOE Hydrogen Program Review. NREL/CP-570-30535Google Scholar
  17. Czernik S, French R, Feik C, Chornet E (2002) Hydrogen by catalytic steam reforming of liquid byproducts from biomass thermoconversion processes. Ind Eng Chem Res 41:4209–4215Google Scholar
  18. Demirbas A (2010) Biorefineries: for biomass upgrading facilities. Green Energy Technol :75–92Google Scholar
  19. Diebold JP (2005) A review of the chemical and physical mechanisms of the storage stability of fast pyrolysis bio-oils. In: Fast pyrolysis of biomass: a handbook. CPL Press, Newbury, UKGoogle Scholar
  20. Dinjus E, Henrich E, Weirich F (2004) A two stage process for synfuel from biomass. In: IEA bioenergy agreement task 33: thermal gasification of biomass, task meeting, Vienna, May 3–5Google Scholar
  21. Dudley B (2014) BP Energy Outlook 2035. http://www.bp.com/content/dam/bp/pdf/Energy-economics/Energy-Outlook/EnergyOutlook2035_booklet.pdf. Accessed 23 May 2014, January
  22. Elliott DC, Baker EG (1984) Upgrading biomass liquefaction products through hydrodeoxygenation. Biotechnol Bioenergy Symp 14:159–174Google Scholar
  23. Elliott DC, Schiefelbein GF (1989) Liquidhydrocarbon fuels from biomass. Abstr Papers Am Chem Soc 34:1160–1166Google Scholar
  24. Elliott DC, Hart TR, Neuenschwander GG, Rotness LJ, Zacher AH (2009) Catalytic hydroprocessing of biomass fast pyrolysis bio-oil to produce hydrocarbon products. Environ Progress Sustain Energy 28:441–449CrossRefGoogle Scholar
  25. Fogassy G, Thegarid N, Toussaint G, van Veen AC, Schuurman Y, Mirodatos C (2010) Biomass derived feedstock coprocessing with vacuum gas oil for second-generation fuel production in FCC units. Appl Catal B 96:476–485CrossRefGoogle Scholar
  26. Fu CM, Schaffer AM (1985) Effect of nitrogen compounds on cracking catalysts. Ind Eng Chem Prod Res Dev 1:68–75CrossRefGoogle Scholar
  27. Garcia-Perez M, Chen S, Zhou S, Wang Z, Lian J, Johnson RL, Liaw S, Das O (2009) New bio-refinery concept to convert soft bark wood to transport fuels. Washington State University, Ecology Publication. 09-07-061Google Scholar
  28. Gayubo AG, Aguayo AT, Atutxa A, Valle B, Bilbao J, Gayubo AG, Aguayo AT, Atutxa A, Valle B, Bilbao J (2005) Undesired components in the transformation of biomass pyrolysis-oil into hydrocarbons on a HZSM-5 zeolite. J Chem Technol Biotechnol 80:1244–1251CrossRefGoogle Scholar
  29. Ghosh S (2002) Fluid catalytic cracking: an overview and future scenario. Indian Chem Eng (Special Issue) 1:27Google Scholar
  30. Graça I, Ribeiro FR, Cerqueira HS, Lam YL, de Almeida MBB (2009) Catalytic cracking of mixtures of model bio-oil compounds and gasoil. Appl Catal B 90:556–563CrossRefGoogle Scholar
  31. Graça I, Lopes JM, Ribeiro MF, Ribeiro FR, Cerqueira HS, de Almeida MBB (2011) Catalytic cracking in the presence of guaiacol. Appl Catal B 101:613–621CrossRefGoogle Scholar
  32. Ibsen K (2006) Equipment design and cost estimation for small modular biomass systems, synthesis, gas cleanup, and oxygen separation equipment. Contract report NREL/SR-510-39943, NREL Technical Monitor, MayGoogle Scholar
  33. Iojoiu EE, Domine ME, Davidian T, Guilhaume N, Mirodatos C (2007) Hydrogen production by sequential cracking of biomass-derived pyrolysis oil over noble metal catalysts supported on ceria-zirconia. Appl Catal A 323:147–161CrossRefGoogle Scholar
  34. Jones SB, Holladay JE, Valkenburg C, Stevens DJ, Walton CW, Kinchin C, Elliott DC, Czernik S (2009) Production of gasoline and diesel from biomass via fast pyrolysis, hydrotreating and hydrocracking: a design case. PNNL Report No-18284, US Department of Energy, FebruaryGoogle Scholar
  35. Kechagiopoulos PN, Voutetakis SS, Lemonidou AA, Vasalos IA (2006) Hydrogen production via steam reforming of the aqueous phase of bio-oil in a fixed bed reactor. Energy Fuels 20:2155–2163CrossRefGoogle Scholar
  36. Lan P, Xu Q, Zhou M, Lan L, Zhang S, Yan Y (2010) Catalytic steam reforming of fast pyrolysis bio-oil in fixed bed and fluidized bed reactors. Chem Eng Technol 33:2021–2028CrossRefGoogle Scholar
  37. Lappas AA, Bezergianni S, Vasalos IA (2009) Production of biofuels via coprocessing in conventional refining processes. Catal Today 145:55–62CrossRefGoogle Scholar
  38. Lea-Langton A, Md Zin R, Dupont V, Twigg MV (2012) Biomass pyrolysis oils for hydrogen production using chemical looping reforming. Int J Hydrogen Energy 37:2037–2043CrossRefGoogle Scholar
  39. Lehto J, Oasmaa A, Solantausta Y, Power M, Chiaramonti D (2013) Fuel oil quality and combustion of fast pyrolysis bio-oils. VTT Technol 87, EspooGoogle Scholar
  40. Magrini-Bair K, Czernik S, French R, Parent Y, Ritland M, Chornet E (2002) Fluidizable catalysts for producing hydrogen by steam reforming biomass pyrolysis liquids. In: Proceedings of the 2002 U.S. DOE hydrogen program review NREL/CP-610-32405Google Scholar
  41. Melero JA, Iglesias J, Garcia A (2012) Biomass as renewable feedstock in standard refinery units. Feasibility, opportunities and challenges. Energy Environ Sci 5:7393CrossRefGoogle Scholar
  42. Mercader FM (2010) Pyrolysis oil upgrading for coprocessing in standard refinery units. Ph.D. Thesis, University of Twente, NetherlandsGoogle Scholar
  43. Milne TA, Elam CC, Evans RJ (2002) Hydrogen from biomass: state of the art and research challenges. NREL-IEA/H2/TR-02/001Google Scholar
  44. Mortensen PM, Grunwaldt JD, Jensen PA, Knudsen KG, Jensen AD (2011) A review of catalytic upgrading of bio-oil to engine fuels. Appl Catal A 407:1–19CrossRefGoogle Scholar
  45. Naik DV, Kumar V, Prasad B, Behera B, Atheya N, Singh KK, Adhikari DK, Garg MO (2014a) Catalytic cracking of pyrolysis oil oxygenates (aliphatic and aromatic) with vacuum gas oil and their characterization. Chem Eng Res Des 92:1579–1590CrossRefGoogle Scholar
  46. Naik DV, Kumar V, Prasad B, Behera B, Atheya N, Adhikari DK, Nigam KDP, Garg MO (2014b) Catalytic cracking of C2-C3 carbonyls with vacuum gas oil. Ind Eng Chem Res 53:18816–18823CrossRefGoogle Scholar
  47. Naik DV, Kumar V, Prasad B, Behera B, Poddar MK, Bal R, Khatri OP, Adhikari DK, Garg MO (2015) Catalytic cracking of jatropha-derived fast pyrolysis oil with VGO and their NMR characterization. RSC Adv 5:398–409CrossRefGoogle Scholar
  48. Ng SH, Nakajima N, Fairbridge C, Kuehler C (2006) Production of light olefins through gas oil cracking. http://www.nt.ntnu.no/users/skoge/prost/proceedings/aiche-2006/data/papers/P61373.pdf
  49. Oasmaa A (2005) Norms and standards for pyrolysis liquids: end-user requirements and specifications. Energy Fuels 19:2155–2163CrossRefGoogle Scholar
  50. Oasmaa A, Peacocke C (2010) Properties and fuel use of biomass-derived fast pyrolysis liquids: a guide. VTT Publications 731, EspooGoogle Scholar
  51. Oasmaa A, Leppamaki E, Levander PKJ, Tapola E (1997) Physical characterization of biomass-based pyrolysis liquids application of standard fuel oil analyses. VTT PUBLICATIONS 306Google Scholar
  52. Oasmaa A, Elliott DC, Korhonen J (2010) Acidity of biomass fast pyrolysis bio-oils. Energy Fuels 24:6548–6554CrossRefGoogle Scholar
  53. Osmont A, Catoire L, Gökalp I, Swihart MT (2007) Thermochemistry of C–C and C–H bond breaking in fatty acid methyl esters. Energy Fuels 21:2027–2032CrossRefGoogle Scholar
  54. Ringer M, Putsche V, Scahill J (2006) Large-scale pyrolysis oil production: a technology assessment and economic analysis. National Renewable Energy Laboratory Technical Report, NREL/TP-510–37779, NovemberGoogle Scholar
  55. Sadeghbeigi R (2000) Fluid catalytic cracking handbook: design, operation, and troubleshooting of FCC facilities, 2nd edn. Gulf Professional Publishing, HoustonGoogle Scholar
  56. Sadhukhan AK, Gupta P, Saha RK (2008) Modeling and experimental studies on pyrolysis of biomass particles. J Anal Appl Pyrol 81:183–192CrossRefGoogle Scholar
  57. Samolada MC, Baldauf W, Vasalos IA (1998) Production of a bio-gasoline by upgrading biomass flash pyrolysis liquids via hydrogen processing and catalytic cracking. Fuel 77:1667–1675CrossRefGoogle Scholar
  58. Scherzer J (1987) Process for the catalytic cracking of feedstock containing high levels of nitrogen. Patent US4810369, May 7Google Scholar
  59. Scherzer J (1990) Octane-enhancing zeolitic FCC catalysts: scientific and technical aspects. CRC PressGoogle Scholar
  60. Sedran UA (1994) Laboratory testing of FCC catalysts and hydrogen transfer properties evaluation. Catal Rev Sci Eng 36:405–431CrossRefGoogle Scholar
  61. Thegarid N, Fogassy G, Schuurman Y, Mirodatos C, Stefanidis S, Iliopoulou EF, Kalogiannis K, Lappas AA (2013) Second-generation biofuels by coprocessing catalytic pyrolysis oil in FCC units. Appl Catal B 145:161–166CrossRefGoogle Scholar
  62. Tiplady IR, Peacocke GVC, Bridgwater AV (1991) Physical properties of fast pyrolysis liquids from the Union Fenosa pilot plant. Bio-oil production & utilization. In: Bridgwater AV; Grassi G (eds) Elsevier Applied Science, London, pp 164–174Google Scholar
  63. Venderbosch RH, Prins W (2010) Review: fast pyrolysis technology development. Biofuels Bioprod Biorefin 4:178–208CrossRefGoogle Scholar
  64. Vispute TP, Huber GW (2009) Production of hydrogen, alkanes and polyols by aqueous phase processing of wood-derived pyrolysis oils. Green Chem 11:1433–1445CrossRefGoogle Scholar
  65. Wang D, Czernik S, Chornet E (1998) Production of hydrogen from biomass by catalytic steam reforming of fast pyrolysis oils. Energy Fuels 12:19–24CrossRefGoogle Scholar
  66. Wang C, Du Z, Pan J, Li J, Yang Z (2007) Direct conversion of biomass to bio-petroleum at low temperature. J Anal Appl Pyrol 78:438–444Google Scholar
  67. Way N, Meesala L, Moppi A, Fogassy G, Toussaint G, Schuurman Y, Geantet C, Mirodatos C (2011) Coprocessing of upgraded pyrolysis oils in lab scale standard refinery units. In: NWBC 2011 Conference Proceedings, NWBC 2011, Stockholm, March 22–24Google Scholar
  68. Whitmore FC (1934) Mechanism of the polymerization of olefins by acid catalysts. Ind Eng Chem 26:94–95CrossRefGoogle Scholar
  69. Ye T, Yuan L, Chen Y, Kan T, Tu J, Zhu X, Torimoto Y, Yamamoto M, Li Q (2009) High efficient production of hydrogen from bio-oil using low-temperature electrochemical catalytic reforming approach over NiCuZn–Al2O3 catalyst. Catal Lett 127:323–333CrossRefGoogle Scholar
  70. Zacher AH, Olarte MV, Santosa DM, Elliott DC, Jones SB (2014) A review and perspective of recent bio-oil hydrotreating research. Green Chem 16:491–515CrossRefGoogle Scholar
  71. Zapata PA, Faria J, Ruiz MP, Resasco DE (2012) Condensation/hydrogenation of biomass-derived oxygenates in water/oil emulsions stabilized by nanohybrid catalysts. Top Catal 55:38–52CrossRefGoogle Scholar
  72. Zhang H, Cheng Y, Vispute TP, Xiao R, Huber GW (2011) Catalytic conversion of biomass-derived feedstocks into olefins and aromatics with ZSM-5: the hydrogen to carbon effective ratio. Energy Environ Sci 4:2297–2307CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2018

Authors and Affiliations

  • Desavath Viswanatha Naik
    • 1
  • Vimal Kumar
    • 2
  • Basheshwar Prasad
    • 2
  1. 1.Conversions and Catalysis DivisionCSIR-Indian Institute of PetroleumDehradunIndia
  2. 2.Department of Chemical EngineeringIndian Institute of Technology RoorkeeRoorkeeIndia

Personalised recommendations