NATURAL OIL REFINING METHOD

专利摘要:
refining and fuel production processes starting from natural oil raw materials. The present invention relates to methods for refining natural oil feedstocks. The methods comprise reacting the raw material in the presence of a metathesis catalyst under conditions sufficient to form a metathesis product comprising olefins and esters. In certain embodiments, the methods further comprise separating the olefins from the esters in the metathesis product. In certain embodiments, the methods further comprise hydrogenating the olefins under conditions sufficient to form a fuel composition. In certain embodiments, the methods further comprise transesterification of the esters in the presence of an alcohol to form a transesterified product.
公开号:BR112012008608B1
申请号:R112012008608-1
申请日:2010-10-11
公开日:2019-04-02
发明作者:Steven A. Cohen；Melvin L. Luetkens；Chander Balakrishnan；Robert Snyder
申请人:Elevance Renewable Sciences, Inc.；
IPC主号:

专利说明:

Descriptive Report of the Invention Patent for NATURAL OIL REFINING METHOD.
CROSS REFERENCE TO RELATED APPLICATIONS [001] This patent application claims the benefit of United States of America Provisional Patent Application No. 61 / 250,743, filed on October 12, 2009, which is incorporated here by reference.
BACKGROUND [002] Metathesis is a catalytic reaction generally known in the art that involves the exchange of alkylidene units between compounds that contain one or more double bonds (eg olefinic compounds) through the formation and cleavage of carbon-double bonds carbon. Metathesis can occur between two similar molecules (often referred to as self-synthesis) and / or it can occur between two different molecules (often referred to as cross-metathesis). Self-synthesis can be represented schematically as shown in Equation I.
R ¹ -CH = CH-R ² + R ¹ -CH = CH-R ² θ R ¹ -CH = CH-R ¹ + R ² -CH = CH-R ² where R ¹ and R ² are organic groups.
[003] Cross metathesis can be represented schematically as shown in Equation II.
(II) R ¹ -CH = CH-R ² + R ³ -CH = CH-R ⁴ θ R ¹ -CH = CH-R ³ + R ¹ -CH = CH-R ⁴ + R ² -CH = CH- R ³ + R ² -CH = CH-R ⁴ + R ¹ -CH = CH-R ¹ + R ² -CH = CH-R ² + R ³ CH = CH-R ³ + R ⁴ -CH = CH-R ⁴ where R ¹ , R ² , R ³ and R ⁴ are organic groups.
[004] In recent years, there has been a greater demand for techniques that are not hostile to the environment for the production of materials typically derived from oil sources. For example, researchers studied the possibility of producing biofuels, waxes, plastics and the like, using natural oil raw materials, such as oils
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2/58 vegetable and seed based. In a non-limiting example, metathesis catalysts are used to produce candle wax, as described in PCT / US2006 / 000822, which is incorporated herein by reference in its entirety. Metathesis reactions involving natural oil raw materials offer promising solutions for the present and the future.
[005] The natural oil raw materials of interest include non-limiting examples such as natural oils (for example, vegetable oils, fish oil, animal fats) and derivatives of natural oils, such as fatty acids and alkyl acid esters fatty (for example, methyl). These raw materials can be converted into chemical reagents useful for industry (for example, waxes, plastics, cosmetics, biofuels etc.) through any number of different metathesis reactions. Significant reaction classes include, as non-limiting examples, self-synthesis, cross-metathesis with olefins and ring-opening metathesis reactions. Representative non-limiting examples of useful metathesis catalysts are provided below. Metathesis catalysts can be expensive and therefore it is desirable to improve the efficiency of the metathesis catalyst.
[006] In recent years, there has been a greater demand for petroleum-based transport fuels. There are concerns that world oil production may not be able to meet demand. In addition, the increased demand for petroleum-based fuels has resulted in greater production of greenhouse gases. In particular, the airline industry is responsible for more than 10% of greenhouse gases within the United States of America. Due to the increased demand for fuel and the increased production of greenhouse gases, there is a need to explore methods of producing alternative fuel sources that are not hostile to the environment. In
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3/58 In particular, there is a need to explore methods of producing combustible compositions that are not hostile to the environment and fine chemical reagents from a natural raw material.
SUMMARY [007] Methods for refining a natural oil raw material through a metathesis reaction of the natural oil raw material in the presence of a metathesis catalyst are described.
[008] In one embodiment, the method comprises the reaction of a raw material that comprises a natural oil in the presence of a metathesis catalyst under conditions sufficient to form a product submitted to metathesis, in which the product submitted to metathesis comprises olefins and esters. The method further comprises separating the olefins from the esters. The method further comprises the transesterification of esters in the presence of an alcohol to form a transesterified product.
[009] In certain modalities, the method also includes the treatment of the raw material before the reaction of the raw material, under conditions sufficient to reduce toxic agents of the catalysts in the raw material. In some embodiments, the raw material is chemically treated through a chemical reaction to decrease the toxic agents in the catalysts. In other embodiments, the raw material is heated to a temperature greater than 100 ° C in the absence of oxygen and kept at a temperature for a period of time sufficient to decrease the toxic agents of the catalysts.
[0010] In certain embodiments, the method further comprises separating the metathesis catalyst from the olefins and esters with a water-soluble phosphine reagent.
[0011] In certain embodiments, the metathesis catalyst is dissolved in a solvent before the metathesis reaction. In some embodiments, the solvent is toluene.
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4/58 [0012] In certain embodiments, the method further comprises hydrogenating the olefins to form a fuel composition. In some embodiments, the fuel composition comprises an aircraft fuel composition that has a carbon number distribution between 5 and 16. In other embodiments, the fuel composition comprises a diesel fuel composition that has a carbon number distribution. carbons between 8 and 25. In some embodiments, the fuel composition is: (a) a fuel for kerosene type airplanes that has a carbon number distribution between 8 and 16, a flash point between approximately 38 ° C and approximately 66 ° C, an auto-ignition temperature of approximately 210 ° C and a freezing point between approximately -47 ° C and approximately -40 ° C; (b) a fuel for naphtha-type airplanes that has a carbon number distribution between 5 and 15, a flash point between approximately -23 ° C and approximately 0 ° C, an auto-ignition temperature of approximately 250 ° C; and a freezing point of approximately -65 ° C; or (c) a diesel fuel that has a carbon number distribution between 8 and 25, a specific gravity of between approximately 0.82 and approximately 1.08 at approximately 15.6 ° C, a cetane number greater than approximately 40; and a distillation range between approximately 180 ° C and approximately 340 ° C.
[0013] In certain modalities, the method also comprises oligomerization of the olefins to form at least one of: poly-alphaolefins, poly-olefins-internal, mineral oil or biodiesel substitutions.
[0014] In certain modalities, the method also comprises the separation of glycerin from the transesterified product through a liquid-liquid separation, the washing of the transesterified product with
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5/58 water to further remove glycerin and drying the transesterified product to separate the water from the transesterified product. In some embodiments, the method further comprises distilling the transesterified product to separate at least one specialty fine chemical reagent selected from the group consisting of: 9-decenoic acid ester, 9-undecenoic acid ester, 9dodecenoic acid ester, individually or in combinations thereof. In some additional embodiments, the method further comprises the hydrolysis of at least one fine chemical reagent of specialty, thus forming at least one acid selected from the group consisting of: 9-decenoic acid, 9-undecenoic acid, 9-dodecenoic acid, individually or in combinations thereof. In certain embodiments, the hydrolysis step also provides alkali metal salts and alkaline earth metal salts, individually or in combinations thereof, of at least one acid.
[0015] In certain modalities, the method comprises the reaction of the transesterified product with itself to form a dimer.
[0016] In certain modalities, the reaction stage comprises a self-synthesis reaction between the raw material and itself. In other embodiments, the reaction step comprises a cross-metathesis reaction between a low molecular weight olefin and the raw material. In some embodiments, the low molecular weight olefin comprises at least one low molecular weight olefin selected from the group consisting of ethylene, propylene, 1-butene, 2-butene, individually or in combinations thereof. In some embodiments, the low molecular weight olefin is an alpha-olefin. In one embodiment, the low molecular weight olefin comprises at least one branched olefin having a number of carbons between 4 and 10.
[0017] In another modality, the method comprises the reaction of
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6/58 a raw material comprising a natural oil in the presence of a metathesis catalyst under conditions sufficient to form a product undergoing metathesis, in which the product undergoing metathesis comprises olefins and esters. The method further comprises separating the olefins from the esters. The method further comprises hydrogenating the olefins under conditions sufficient to form a fuel composition.
[0018] In certain embodiments, the fuel composition comprises an aircraft fuel composition that has a carbon number distribution between 5 and 16. In other embodiments, the fuel composition comprises a diesel fuel composition that has a distribution number of carbons between 8 and 25. In some embodiments, the fuel composition is: (a) a fuel for kerosene-type airplanes that has a carbon number distribution between 8 and 16, a flash point between approximately 38 ° C and approximately 66 ° C, an auto-ignition temperature of approximately 210 ° C and a freezing point between approximately -47 ° C and approximately -40 ° C; (b) a fuel for naphtha-type airplanes that has a carbon number distribution between 5 and 15, a flash point between approximately -23 ° C and approximately 0 ° C, an auto-ignition temperature of approximately 250 ° C; and a freezing point of approximately -65 ° C; or (c) a diesel fuel that has a carbon number distribution between 8 and 25, a specific gravity of between approximately 0.82 and approximately 1.08 at approximately 15.6 ° C, a cetane number greater than approximately 40; and a distillation range between approximately 180 ° C and approximately 340 ° C.
[0019] In certain modalities, the method also includes the instant separation of a light-end chain from the product
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7/58 subjected to metathesis before the separation of the olefins from the esters, the light end chain having a majority of hydrocarbons with a carbon number between 2 and 4.
[0020] In certain embodiments, the method further comprises separating a light end chain from the olefins prior to the hydrogenation of the olefins, the light end chain having a majority of hydrocarbons with carbon numbers between 3 and 8.
[0021] In certain embodiments, the method further comprises separating the heavy end stream C18 + from the olefins prior to hydrogenation of the olefins, the heavy end stream having a majority of hydrocarbons having a carbon number of at least 18.
[0022] In certain embodiments, the method further comprises separating a heavy end chain C18 + from the fuel composition, the heavy end chain having a majority of hydrocarbons having carbon numbers of at least 18.
[0023] In certain embodiments, the method further comprises the isomerization of the fuel composition, in which a fraction of normal paraffin compounds in the fuel composition is isomerized into isoparaffin compounds.
[0024] In certain modalities, the reaction stage comprises a self-synthesis reaction between the raw material and itself. In other embodiments, the reaction step comprises a cross-metathesis reaction between a low molecular weight olefin and the raw material.
[0025] In another modality, the method comprises the reaction of a raw material that comprises a natural oil in the presence of a metathesis catalyst under conditions sufficient to form a
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8/58 product submitted to metathesis, in which the product submitted to metathesis comprises olefins and esters. The method further comprises the hydrogenation of the product submitted to metathesis, thus producing a composition of fuel and esters at least partially saturated. The method further comprises separating the fuel composition from the at least partially saturated esters. The method may further comprise the isomerization of the fuel composition, wherein a portion of normal paraffins is isomerized into isoparaffins, forming an isomerized fuel composition there. The method may further comprise separating a fuel stream cut off at the center of the fuel composition or the isomerized fuel composition.
BRIEF DESCRIPTION OF THE DRAWINGS [0026] Figure 1 is a schematic diagram of a modality of a method for the production of a fuel composition and a transesterified product from a natural oil.
[0027] Figure 2 is a schematic diagram of a second modality of a method for the production of a fuel composition and a transesterified product starting from a natural oil.
DETAILED DESCRIPTION [0028] The present patent application relates to methods of refining a natural oil raw material through the metathesis reaction of the natural oil raw material.
[0029] As used here, the singular forms one, one, o and a include referents in the plural unless the context clearly determines otherwise. For example, reference to a substituent covers a single substituent as well as two or more substituents and the like.
[0030] As used here, the terms for example, in case
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9/58 of, such as or including are understood for the introduction of examples that further clarify the general purpose subject. Unless otherwise specified, these examples are provided only as an aid to understanding the patent applications illustrated in the present disclosure and are not intended to be limiting in any way.
[0031] As used here, the following terms have the following meanings unless expressly stated otherwise. It is understood that any term in the singular can include its corresponding in the plural and vice versa.
[0032] As used here, the term metathesis catalyst includes any catalyst or catalyst system that catalyzes a metathesis reaction.
[0033] As used here, the terms natural oils, natural raw materials or raw materials of natural oil can refer to oils derived from plant or animal origins. The term natural oil includes derivatives of natural oil, unless otherwise indicated. Examples of natural oils include, but are not limited to, vegetable oils, seaweed oils, animal fats, liquid resins, derivatives of these oils, combinations of any of these oils and the like. Representative non-limiting examples of vegetable oils include canola oil, rapeseed oil, coconut oil, corn oil, cottonseed oil, olive oil, palm oil, peanut oil, safflower oil, oil sesame oil, soybean oil, sunflower oil, flaxseed oil, palm oil, tung oil, Jatropha oil, mustard oil, Thlaspi oil, Camelina oil and castor oil. Representative non-limiting examples of animal fats include lard, tallow, poultry fat, yellow fat and fish oil. Liquid resins are by-products from the manufacture of wood pulp.
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10/58 [0034] As used herein, the term natural oil derivatives may refer to compounds or a mixture of compounds derived from natural oil using any or a combination of methods known in the art. Such methods include saponification, transesterification, esterification, hydrogenation (partial or complete), isomerization, oxidation and reduction. Representative non-limiting examples of natural oil derivatives include gums, phospholipids, soapstock, acidulated soapstock, distillate or distilled slurry, fatty acids and fatty acid alkyl ester (for example, non-limiting examples such as 2-ethylhexyl ester), variations substituted by hydroxy of the same ones of the natural oil. For example, the natural oil derivative may be a fatty acid methyl ester (FAME) derived from the natural oil glyceride. In some embodiments, the raw material includes canola or soy oil, as a non-limiting example, refined, bleached and deodorized soy oil (ie RDB soy oil). Soybean oil typically comprises approximately 95% by weight or more (for example, 99% by weight or more) triglycerides of fatty acids. The main fatty acids in soybean oil polyol esters include saturated fatty acids, as a non-limiting example, palmitic acid (hexadecanoic acid) and stearic acid (octadecanoic acid) and unsaturated fatty acids, as a non-limiting example, oleic acid ( 9-octadecenoic acid), linoleic acid (9, 12-octadecadienoic acid) and linolenic acid (9,12,15 octadecatrienoic acid).
[0035] As used here, the term low molecular weight olefin can refer to any or a combination of straight, branched or cyclic unsaturated hydrocarbons in the range of C2 to C14. Low molecular weight olefins include alpha-olefins or terminal olefins, where the unsaturated carbon-carbon bond is present at one end of the compound. Low soft weight olefins
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11/58 can also include dienes or trienes. Examples of low molecular weight olefins in the C2 to Ce range include, but are not limited to: ethylene, propylene, 1-butene, 2-butene, isobutene, 1pentene, 2-pentene, 3-pentene, 2-methyl- 1-butene, 2-methyl-2-butene, 3methyl-1-butene, cyclopentene, 1-hexene, 2-hexene, 3-hexene, 4hexene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 2-methyl-2-pentene, 3-methyl-2-pentene, 4-methyl-2-pentene, 2-methyl-3-pentene and cyclohexene. Other possible low molecular weight olefins include styrene and vinyl cyclohexane. In certain embodiments, it is preferable to use a mixture of olefins, the mixture comprising linear and branched low molecular weight olefins in the C4C10 range. In one embodiment, it may be preferable to use a mixture of C4 linear and branched olefins (i.e., combinations of: 1-butene, 2butene and / or isobutene). In other embodiments, a larger range of C11-C14 can be used.
[0036] As used here, the terms submission to metathesis and metatetization can refer to the reaction of the raw material in the presence of a metathesis catalyst to form a product submitted to metathesis that comprises a new olefinic compound. Metatetization can refer to cross-metathesis (also known as co-metathesis), self-metathesis, ring opening metathesis, ring opening metathesis polymerizations (ROMP), ring closing metathesis (RCM) and acyclic diene metathesis ( ADMET). As a non-limiting example, metatetization can refer to the reaction of two triglycerides present in a natural raw material (self-synthesis) in the presence of a metathesis catalyst, in which each triglyceride has an unsaturated carbon-carbon double bond, thus forming a new blend of olefins and esters that may include a triglyceride dimer. Such triglyceride dimers can have more than one olefinic bond, thus larger oligomers
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12/58 can also be formed. Additionally, metatetization can refer to the reaction of an olefin, such as ethylene and a triglyceride in a natural raw material that has at least one unsaturated carbon-carbon double bond, thus forming new olefinic molecules as well as new ester molecules (metathesis) cross).
[0037] As used here, the terms ester and esters can refer to compounds that have the general formula: R-COO-R ', where R and R' mean any alkyl or aryl group, including those that carry a substituent group . In certain embodiments, the term ester or esters can refer to a group of compounds with the general formula described above, in which the compounds have different lengths of carbon.
[0038] As used herein, the terms olefin and olefins can refer to hydrocarbon compounds that have at least one unsaturated carbon-carbon double bond. In certain embodiments, the term olefin or olefins can refer to a group of unsaturated carbon-carbon double bond compounds with different carbon lengths. It is noted that an olefin can also be an ester and an ester can also be an olefin, if the group R or R 'contains an unsaturated carbon-carbon double bond. Unless otherwise specified, an olefin refers to compounds that do not contain ester functionality, whereas an ester can include compounds that contain olefin functionality.
[0039] As used here, the terms paraffin and paraffins can refer to hydrocarbon compounds that have only simple carbon-carbon bonds, which have the general formula CnH2n + 2, where, in certain embodiments, n is greater than approximately 20 .
[0040] As used here, the terms isomerization, isomerizes or that isomerizes (m) can refer to the reaction and conversion of
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13/58 straight chain hydrocarbon compounds, such as normal paraffins, in branched hydrocarbon compounds, such as isoparaffins. Isomerization of an olefin or an unsaturated ester indicates a change in the carbon-carbon double bond to another location in the molecule or indicates a change in the geometry of the compound in the carbon-carbon double bond (for example, cis to trans). As a non-limiting example, n-pentane can be isomerized in a mixture of n-pentane, 2-methylbutane and 2,2-dimethylpropane. The isomerization of normal paraffins can be used to improve the general properties of a fuel composition. In addition, isomerization may refer to the conversion of branched paraffins into additionally more branched paraffins.
[0041] As used here, the term yield can refer to the total weight of fuel produced from the reactions of metathesis and hydrogenation. It can also refer to the total weight of the fuel after a separation step and / or an isomerization reaction. It can be defined in terms of a% yield, in which the total weight of the fuel produced is divided by the total weight of the raw material of natural oil and, in some modalities, combined low molecular weight olefin.
[0042] As used herein, the terms combustible and combustible compositions refer to materials that satisfy required specifications or to mixing components that are useful in the formulation of combustible compositions, but, by themselves, do not satisfy all the specifications required for a fuel.
[0043] As used here, the term jet fuel or aviation fuel can refer to kerosene or naphtha type fuel bands or military grade jet fuel compositions. Fuel for kerosene-type jets (including Jet A and Jet A-1) has a carbon number distribution between
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14/58 approximately 8 and approximately 16. Jet A and Jet A-1 typically have a flash point of at least approximately 38 ° C, an auto-ignition temperature of approximately 210 ° C, a freezing point less than or equal to approximately 40 ° C for Jet A and -47 ° C for Jet A-1, a density of approximately 0.8 g / cc at 15 ° C and an energy density of approximately 42.8-43.2 MJ / kg. Fuel for naphtha or wide-range jets (including Jet B) has a carbon number distribution between approximately 5 and approximately 15. Jet B typically comprises a flash point below approximately 0 ° C, an auto-ignition temperature of approximately 250 ° C, a freezing point of approximately -51 ° C, a density of approximately 0.78 g / cc and an energy density of approximately 42.8-43.5 MJ / kg. Fuel for military grade jets refers to the Jet Propulsion or JP numbering system (JP-1, JP-2, JP-3, JP-4, JP-5, JP-6, JP-7, JP- 8 etc.). Military grade jet fuels can comprise alternative or additional additives to have higher flash points than Jet A, Jet A-1 or Jet B in order to cope with the heat and stress suffered during supersonic flight.
[0044] As used here, the term diesel fuel can refer to a hydrocarbon composition that has the following property characteristics, including a carbon number distribution between approximately 8 and approximately 25. Diesel fuels also typically have a specific gravity of approximately 0.82-1.08 to 15.6 ° C (60 ° F), based on water that has a specific gravity of -17.22 to 15, 55 ° C (1 to 60 ° F ). Diesel fuels typically comprise a distillation range between approximately 180-340 ° C (356-644 ° F). In addition, diesel fuels have a number of
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15/58 minimum cetane number of approximately 40.
[0045] As used here, the term carbon number distribution can refer to the range of compounds present in a composition, where each compound is defined by the number of carbon atoms present. As a non-limiting example, a jet fuel of the naphtha type typically comprises a distribution of hydrocarbon compounds in which a majority of such compounds have between 5 and 15 carbon atoms each. A jet fuel of the kerosene type typically comprises a distribution of hydrocarbon compounds in which a majority of such compounds have between 8 and 16 carbon atoms each. A diesel fuel typically comprises a distribution of hydrocarbon compounds in which a majority of such compounds have between 8 and 25 carbon atoms each.
[0046] As used here, the term energy density can refer to the amount of energy stored in a certain system per unit of mass (MJ / kg) or per unit of volume (MJ / L), where MJ refers to a million Joules. As a non-limiting example, the fuel energy density for kerosene or naphtha jets is typically greater than approximately 40 MJ / kg.
[0047] A number of valuable compositions can be targeted through the self-synthesis reaction of a natural oil raw material or the cross-methane reaction of the natural oil raw material with a low molecular weight olefin, in the presence of a catalyst metathesis. Such valuable compositions may include combustible compositions, the non-limiting examples of which include jet, kerosene or diesel fuel. In addition, transesterified products can also be targeted, whose non-limiting examples include: fatty acid methyl esters; biodiesel; esters of 9-decenoic acid (9DA), esters of 9-undecenoic acid
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16/58 (9UDA) and / or esters of 9-dodecenoic acid (9DDA); 9 DA, 9UDA and / or 9DDA; alkali metal salts and alkaline earth metal salts of 9DA, 9UDA and / or 9DDA; dimers of transesterified products; and mixtures thereof.
[0048] In certain modalities, before the metathesis reaction, the natural oil raw material can be treated to make the natural oil more suitable for the subsequent metathesis reaction. In certain embodiments, the natural oil is preferably a vegetable oil or a vegetable oil derivative, such as soybean oil.
[0049] In one embodiment, the treatment of natural oil involves the removal of toxic agents from catalysts, such as peroxides, which can potentially decrease the activity of the metathesis catalyst. Non-limiting examples of natural oil raw material treatment methods for reducing toxic agents from catalysts include those described in PCT / US2008 / 09604, PCT / US2008 / 09635 and U.S. Patent Applications Nos. 12 / 672,651 and 12 / 672,652, incorporated here as a reference in their entirety. In certain embodiments, the natural oil raw material is thermally treated by heating the raw material to a temperature greater than 100 ° C in the absence of oxygen and kept at a temperature for a period of time sufficient to decrease the toxic agents of the catalysts in the raw material. In other embodiments, the temperature is between approximately 100 ° C and 300 ° C, between approximately 120 ° C and 250 ° C, between approximately 150 ° C and 210 ° C or approximately between 190 and 200 ° C. In one embodiment, the absence of oxygen is achieved by purging the natural oil raw material with nitrogen, in which nitrogen gas is pumped into the raw material treatment vessel at a pressure of approximately 1013.24 Kpa ( 10 atm - 150 psig).
[0050] In certain modalities, the raw material for natural oil is
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17/58 chemically treated under conditions sufficient to decrease the toxic agents of the catalysts in the raw material through a chemical reaction of the toxic agents of the catalysts. In certain embodiments, the raw material is treated with a reducing agent or an inorganic cation-based composition. Non-limiting examples of reducing agents include bisulfate, borohydride, phosphine, thiosulfate, individually or combinations thereof.
[0051] In certain embodiments, the raw material of natural oil is treated with an adsorbent to remove toxic agents from the catalysts. In one embodiment, the raw material is treated with a combination of thermal and adsorbent methods. In another modality, the raw material is treated with a combination of chemical and adsorbent methods. In another modality, the treatment involves a partial hydrogenation treatment to modify the reactivity of the natural oil raw material with the metathesis catalyst. Additional non-limiting examples of the treatment of the raw material are also described below when discussing the various metathesis catalysts.
[0052] Additionally, in certain modalities, low molecular weight olefin can also be treated before the metathesis reaction. Like natural oil treatment, low molecular weight olefin can be treated to remove toxic agents that can impact or decrease catalyst activity.
[0053] As shown in figure 1, after this optional treatment of the raw material of natural oil and / or low molecular weight olefin, natural oil 12 is obtained with itself or combined with a low molecular weight olefin 14 in one metathesis reactor 20 in the presence of a metathesis catalyst. Metathesis catalysts and metathesis reaction conditions are discussed in more detail below. In certain modalities, in the presence of a ca
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18/58 metathesis talisator, natural oil 12 undergoes a self-synthesis reaction with itself. In other modalities, in the presence of the metathesis catalyst, natural oil 12 undergoes a cross metathesis reaction with low molecular weight olefin 14. In certain modalities, natural oil 12 undergoes both self-synthesis and cross reactions in metathesis reactors in parallel. The self-and / or cross-metathesis reaction forms a product submitted to metathesis 22 in which the product submitted to metathesis 22 comprises olefins 32 and esters 34.
[0054] In certain embodiments, the low molecular weight olefin 14 is in the range of C2 to Ce. As a non-limiting example, in one embodiment, the low molecular weight olefin 14 may comprise at least one of the following: ethylene, propylene, 1-butene, 2-butene, isobutene, 1-pentene, 2-pentene, 3-pentene , 2-methyl-1-butene, 2-methyl2-butene, 3-methyl-1-butene, cyclopentene, 1-hexene, 2-hexene, 3hexene, 4-hexene, 2-methyl-1-pentene, 3-methyl -1-pentene, 4-methyl-1-pentene, 2-methyl-2-pentene, 3-methyl-2-pentene, 4-methyl-2-pentene, 2-methyl-3-pentene and cyclohexene. In another embodiment, the low molecular weight olefin 14 comprises at least one of styrene and vinyl cyclohexane. In another embodiment, the low molecular weight olefin 14 may comprise at least one of ethylene, propylene, 1-butene, 2-butene and isobutene. In another embodiment, the low molecular weight olefin 14 comprises at least one alpha-olefin or terminal olefin in the range of C2 to C10.
[0055] In another embodiment, the low molecular weight olefin 14 comprises at least one low molecular weight olefin branched in the range of C4 to C10. Non-limiting examples of branched low molecular weight olefins include isobutene, 3-methyl-1-butene, 2-methyl-3-pentene and 2,2-dimethyl-3-pentene. Through the use of these low molecular weight olefins branched in the metathesis reaction, the
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19/58 product undergoing metathesis will include branched olefins, which can subsequently be hydrogenated to isoparaffins. In certain embodiments, branched low molecular weight olefins can help achieve the desired performance properties for a fuel composition, such as jet, kerosene or diesel fuel.
[0056] As noted, it is possible to use a mixture of several linear or branched low molecular weight olefins in the reaction to achieve the desired metathesis products distribution. In one embodiment, a mixture of butenes (1-butene, 2-butenes and, optionally, isobutene) can be employed as the low molecular weight olefin, offering a low-cost commercially available raw material instead of a purified source of a particular butene. Such low-cost mixed butene raw materials are typically diluted with n-butane and / or isobutane.
[0057] In certain embodiments, the recycled streams from downstream separation units can be introduced into the metathesis reactor 20 in addition to natural oil 12 and, in some embodiments, low molecular weight olefin 14. For example, in some embodiments, a C2-C6 recycling olefin stream or a C3-C4 bottom stream from a top separation unit can be returned to the metathesis reactor. In one embodiment, as shown in Figure 1, a lightweight olefin chain 44 from an olefin separation unit 40 can be returned to the metathesis reactor 20. In another embodiment, the bottom current of C3-C4 and the lightweight olefin chain 44 is combined and returned to the metathesis reactor 20. In another embodiment, a bottom current of C15 + 46 from olefin separation unit 40 is returned to the metathesis reactor 20. In another embodiment , all recycling chains men
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Previously entered 20/58 are returned to the metathesis reactor 20. [0058] The metathesis reaction in the metathesis reactor 20 produces a product submitted to metathesis 22. In one embodiment, the product submitted to metathesis 22 enters a torrent vessel operated under temperature and pressure conditions that target C2 or C2-C3 compounds for instant extraction and be removed at the top. The light ends of C2 or C2-C3 are comprised of a majority of hydrocarbon compounds having a carbon number of 2 or 3. In certain embodiments, the light ends of C2 or C2-C3 are then sent to a separation unit top, where the C2 or C2-C3 compounds are further separated on top of the heavier compounds that were instantly extracted with the C2-C3 compounds. These heavier compounds are typically C3-C5 compounds carried at the top with C2 or C2-C3 compounds. After separation in the top separation unit, the top C2 or C2-C3 stream can then be used as a fuel source. These hydrocarbons have their own value outside the scope of a fuel composition and can be used or separated at this stage for other compositions and patent applications of value. In certain embodiments, the bottom stream from the top separation unit containing mainly the C3-C5 compounds is returned as a recycle stream to the metathesis reactor. In the torrent vessel, the product submitted to metathesis 22 not extracted at the top is sent downstream for separation in a separation unit 30, such as a distillation column.
[0059] Before the separation unit 30, in certain modalities, the product submitted to metathesis 22 can be introduced into an adsorbent bed to facilitate the separation of the product submitted to metathesis 22 starting from the metathesis catalyst. In one modality, the ad
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21/58 sorbent is a bed of clay. The clay bed will adsorb the metathesis catalyst and after a filtration step, the product submitted to metathesis 22 can be sent to the separation unit 30 for further processing. In another embodiment, the adsorbent is a water-soluble phosphine reagent such as tris hydroxymethyl phosphine (THMP). The catalyst can be separated with a water-soluble phosphine using liquid-liquid extraction mechanisms known by decanting the aqueous phase from the organic phase. In other embodiments, the product submitted to metathesis 22 can be placed in contact with a reagent to deactivate or to extract the catalyst.
[0060] In the separation unit 30, in certain modalities, the product submitted to metathesis 22 is separated into at least two product streams. In one embodiment, the product submitted to metathesis 22 is sent to the separation unit 30 or the distillation column, to separate the olefins 32 from the esters 34. In another embodiment, a chain of by-products comprising Cz's and cyclohexadiene can be removed in a side chain from the separation unit 30. In certain embodiments, the separate olefins 32 may comprise hydrocarbons having carbon numbers of up to 24. In certain embodiments, esters 34 may comprise glycerides subjected to metathesis. In other words, the lighter-ended olefins 32 are preferably separated or distilled at the top for processing into olefin compositions, while esters 34, comprised mainly of compounds having carboxylic acid / ester functionality, are attracted into a bottom stream. Based on the quality of the separation, it is possible for some ester compounds to be carried into the top olefin stream 32 and it is also possible for some heavier olefin hydrocarbons to be carried to
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22/58 into the ester chain 34.
[0061] In one embodiment, olefins 32 can be collected and sold for any number of known uses. In other embodiments, olefins 32 are further processed in an olefin separation unit 40 and / or a hydrogenation unit 50 (wherein the olefinic bonds are saturated with hydrogen gas 48, as described below). In other embodiments, esters 34 comprising heavier-ended glycerides and free fatty acids are separated or distilled in the form of a bottom product for further processing into various products. In certain embodiments, further processing may be aimed at producing the following non-limiting examples: fatty acid methyl esters; biodiesel; 9DA esters, 9UDA esters and / or 9DDA esters; 9DA, 9UDA and / or 9DDA; alkali metal salts and alkaline earth metal salts of 9DA, 9UDA and / or 9DDA; diacids and / or diesters of transesterified products; and mixtures thereof. In certain embodiments, further processing may target the production of C15-C18 fatty acids and / or esters. In other embodiments, further processing may be aimed at producing diacids and / or diesters. In yet other modalities, further processing may be aimed at producing compounds that have molecular weights greater than the molecular weights of stearic acid and / or linolenic acid.
[0062] As shown in figure 1, considering the top olefins 32 of the separation unit 30, the olefins 32 can be further separated or distilled in the olefin separation unit 40 to separate the various components from the chain. In one embodiment, light-ended olefins 44 consisting mainly of C2-C9 compounds can be distilled into a top stream from the olefin separation unit 40. In certain embodiments, the light-ended olefins 44 are comprised of
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23/58 of a majority of C3-C8 hydrocarbon compounds. In other embodiments, heavier olefins that have larger numbers of carbons can be separated at the top into the chain of light-ended olefins 44 to assist in targeting a specific fuel composition. Light-ended olefins 44 can be recycled in the metathesis reactor 20, purged from the system for further processing and sold or a combination of the two. In one embodiment, the light-ended olefins 44 can be partially purged from the system and partially recycled in the metathesis reactor 20. With respect to the other chains in the olefin separation unit 40, a chain of compounds C16 +, C18 +, C20 +, C22 + or heavier C24 + can be separated in the form of a bottom olefin chain 46. This bottom olefin chain 46 can be purged or recycled in the metathesis reactor 20 for further processing or a combination of the two. In another embodiment, a central cut olefin stream 42 can be separated from the olefin distillation unit for further processing. Center-cut olefins 42 can be designed to target a selected carbon number range to a specific fuel composition. As a non-limiting example, a C5-C15 distribution can be targeted for further processing in a naphtha jet fuel. Alternatively, a distribution of C5-C16 can be targeted for further processing in a jet fuel of the kerosene type. In another embodiment, a distribution of C8-C25 can be targeted for further processing on a diesel fuel.
[0063] In certain embodiments, olefins 32 can be oligomerized to form poly-alpha-olefins (PAOs) or internal poly-olefins (PIOs), mineral oil and / or diesel biofuel substitutes. THE
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The oligomerization reaction can occur after the distillation unit 30 or after the olefin top separation unit 40. In certain embodiments, by-products of the oligomerization reactions can be recycled back to the metathesis reactor 20 for further processing.
[0064] As mentioned, in one embodiment, the olefins 32 of the separation unit 30 can be sent directly to the hydrogenation unit 50. In another embodiment, the central cut olefins 42 from the olefin top separation unit 40 can be sent to the hydrogenation unit 50. The hydrogenation can be carried out according to any method known in the art for the hydrogenation of compounds containing double bonds such as olefins 32 or central cut olefins 42. In certain embodiments, in the hydrogenation unit hydrogenation 50, hydrogen gas 48 is achieved with olefins 32 or central cut olefins 42 in the presence of a hydrogenation catalyst for the production of a hydrogenated product 52.
[0065] In some embodiments, olefins are hydrogenated in the presence of a hydrogenation catalyst comprising nickel, copper, palladium, platinum, molybdenum, iron, ruthenium, osmium, rhodium or iridium, individually or in combinations thereof. The useful catalyst can be heterogeneous or homogeneous. In some embodiments, catalysts are catalysts of the type supported by nickel or nickel sponge.
[0066] In some embodiments, the hydrogenation catalyst comprises nickel which has been chemically reduced with hydrogen to an active state (ie reduced nickel) supplied on a support. The support may comprise porous silica (for example, diatomite, infusory, diatomaceous earth or silica) or alumina. The catalysts are characterized by a high nickel surface area by grade 870190001430, from 07/01/2019, p. 30/72
25/58 ma of nickel.
[0067] Commercial examples of hydrogenation catalysts with nickel support include those available under the trade names NYSOFACT, NYSOSEL and Nl 5248 D (from BASF Catalysts LLC, Iselin, NJ). Additional nickel-supported hydrogenation catalysts include those commercially available under the trade names PRICAT 9910, PRICAT 9920, PRICAT 9908, PRICAT 9936 (from Johnson Matthey Catalysts, Ward Hill, MA).
The nickel supported catalysts can be of the type described in U.S. Patent No. 3,351,566, U.S. Patent No. 6,846,772, EP 0168091 and EP 0167201, incorporated by reference in their entirety here. Hydrogenation can be carried out in a batch or continuous process and can be partial or complete hydrogenation. In certain embodiments, the temperature ranges from approximately 50 ° C to approximately 350 ° C, approximately 100 ° C to approximately 300 ° C, approximately 150 ° C to approximately 250 ° C or approximately 100 ° C to approximately 150 ° C. The desired temperature can vary, for example, with the pressure of the hydrogen gas. Typically, a higher gas pressure will require a lower temperature. The hydrogen gas is pumped into the reaction vessel to achieve a desired H2 gas pressure. In certain embodiments, the H2 gas pressure ranges from approximately 101.32 Kpa (15 psig - 1 atm) to approximately 20680.43 Kpa (3000 psig -204.1 atm), approximately 101.32 Kpa (15 psig - 1 atm) ) to approximately 618.08 Kpa (90 psig - 6.1 atm) or approximately 689.01 Kpa (100 psig - 6.8 atm) to approximately 3445.05 Kpa (500 psig - 34 atm). As the gas pressure increases, more specialized high pressure processing equipment may be required. In certain modali
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26/58, reaction conditions are mild, where the temperature is approximately between approximately 50 ° C and approximately 100 ° C and the pressure of the H2 gas is less than approximately 689.01 Kpa (100 psig). In other embodiments, the temperature is between approximately 100 ° C and approximately 150 ° C and the pressure is between approximately 689.01 Kpa (100 psig - 6.8 atm) and approximately 3445.05 Kpa (500 psig - 34 atm). When the desired degree of hydrogenation is reached, the reaction mass is cooled to the desired filtration temperature.
[0069] The amount of hydrogenation catalyst is typically selected in view of a number of factors including, for example, the type of hydrogenation catalyst used, the amount of hydrogenation catalyst used, the degree of unsaturation in the material that will be hydrogenated, the desired hydrogenation rate, the desired degree of hydrogenation (for example, which is measured by the iodine (IV) value), the purity of the reagent and the pressure of the H2 gas. In some embodiments, the hydrogenation catalyst is used in an amount of approximately 10% by weight or less, for example, approximately 5% by weight or less or approximately 1% by weight or less.
[0070] During hydrogenation, compounds containing carbon-carbon double bonds in olefins are partially even completely saturated by hydrogen gas 48. In one embodiment, the resulting hydrogenated product 52 includes hydrocarbons with a centralized distribution between approximately C10 and C12 hydrocarbons for fuel compositions for naphtha and kerosene jets. In another embodiment, the distribution is centralized between approximately C16 and C18 for a diesel fuel composition.
[0071] In certain embodiments, after hydrogenation, the catalyst
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Hydrogenation 27/58 can be removed from the hydrogenated product 52 using techniques known in the art, for example, by filtration. In some embodiments, the hydrogenation catalyst is removed using a plate and frame filter such as those commercially available from Sparkler Filters, Inc., Conroe TX. In some embodiments, filtration is performed with the aid of pressure or a vacuum. In order to improve filtration performance, a filtration aid can be used. A filtration aid can be added to the product directly or can be applied to the filter. Present non-limiting examples of filtration aids include diatomaceous earth, silica, alumina and carbon. Typically, the filter aid is used in an amount of approximately 10% by weight or less, for example, approximately 5% by weight or less or approximately 1% by weight or less. Other filtration techniques and filtration aids can also be employed to remove the used hydrogenation catalyst. In other embodiments, the hydrogenation catalyst is removed using centrifugation followed by product decantation.
[0072] In certain embodiments, based on the quality of the hydrogenated product 52 obtained in the hydrogenation unit 50, it may be preferable to isomerize the hydrogenated olefin product 52 to assist in targeting the desired combustible properties such as flash point, freezing point, energy density, cetane number or end point distillation temperature, among other parameters. Isomerization reactions are well known in the art, as described in U.S. Patent Nos. 3,150,205; 4,210,771; 5,095,169; and 6,214,764, incorporated here as a reference in their entirety. In one embodiment, the isomerization reaction at this stage can also disrupt part of the remaining C15 + compounds, which can additionally assist in the production of a
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28/58 fuel that has compounds within the desired carbon number range, such as 5 through 16 for a jet fuel composition.
[0073] In certain modalities, the isomerization can occur concurrently with the hydrogenation step in the hydrogenation unit 50, thus turning to a desired fuel product. In other embodiments, the isomerization step can take place before the hydrogenation step (i.e., olefins 32 or central cut olefins 42 can be isomerized before the hydrogenation unit 50). In still other modalities, it is possible that the isomerization step can be avoided or reduced in scope based on the selection of low molecular weight olefin (s) 14 used in the metathesis reaction.
[0074] In certain embodiments, the hydrogenated product 52 comprises approximately 15-25% by weight of C7, approximately <5% by weight of C8, approximately 20-40% by weight of C9, approximately 20-40% by weight of C10 , approximately <5% by weight of C11, approximately 15-25% by weight of C12, approximately <5% by weight of C13, approximately <5% by weight of C14, approximately <5% by weight of C15, approximately <1 % by weight of C16, approximately <1% by weight of C17 and approximately <1% by weight of C18 +. In certain embodiments, the hydrogenated product 52 comprises a heat of combustion of at least approximately 40, 41.42, 43 or 44 MJ / kg (which is measured by ASTM D3338). In certain embodiments, hydrogenated product 52 contains less than approximately 1 mg of sulfur per kg of hydrogenated product (which is measured by ASTM D5453). In other embodiments, the hydrogenated product 52 comprises a density of approximately 0.70-0.75 (which is measured by ASTM D4052). In other modalities, the hydrogenated product has a final boiling point of
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29/58 approximately 220-240 ° C (which is measured by ASTM D86).
[0075] The hydrogenated product 52 obtained from the hydrogenation unit 50 can be used as a fuel composition, the non-limiting examples of which include jet, kerosene or diesel fuel. In certain embodiments, the hydrogenated product 52 may contain by-products from hydrogenation, isomerization and / or metathesis reactions. As shown in figure 1, hydrogenated product 52 can be further processed in a fuel composition separation unit 60, removing any remaining by-products from hydrogenated product 52, such as hydrogen gas, water, C2-C9 hydrocarbons or C15 + hydrocarbons, producing thus a target fuel composition. In one embodiment, the hydrogenated product 52 can be separated into the desired C9-C15 fuel product 64 and a C2-C9 light-end fraction 62 and / or a C15 + 66 heavy-end fraction. Distillation can be used to separate the fractions. Alternatively, in other embodiments, such as for a jet fuel composition of the naphtha or kerosene type, the heavy-end fraction 66 can be separated from the desired fuel product 64 by cooling the hydrogenated product 52 to approximately -40 ° C, -47 ° C or -65 ° C and then removing the solid heavy tip fraction 66 by techniques known in the art such as filtration, decantation or centrifugation.
[0076] Regarding the esters 34 from the distillation unit 30, in certain embodiments, the esters 34 can be entirely eliminated in the form of a stream of ester product 36 and further processed or sold at their own value, as shown in the figure 1. As a non-limiting example, esters 34 can comprise various triglycerides that could be used as a lubricant. Based on the quality of separation between
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30/58 olefins and esters, esters 34 can comprise some heavier olefin components loaded with triglycerides. In other embodiments, esters 34 can be further processed in a biorefinery or other chemical reagent or fuel processing unit known in the art, thus producing various products such as biodiesel or fine chemical reagents that have a higher value than that of triglycerides, for example . Alternatively, in certain embodiments, esters 34 can be partially eliminated from the system and sold, with the remainder further processed at the biorefinery or another chemical or fuel reagent processing unit known in the art.
[0077] In certain embodiments, the ester stream 34 is sent to a transesterification unit 70. Within the transesterification unit 70, esters 34 are reacted with at least one alcohol 38 in the presence of a transesterification catalyst. In certain embodiments, the alcohol comprises methanol and / or ethanol. In one embodiment, the transesterification reaction is conducted at approximately 60-70 ° C and approximately 1 atm. In certain embodiments, the transesterification catalyst is a homogeneous sodium methoxide catalyst. Variable amounts of catalyst can be used in the reaction and, in certain embodiments, the transesterification catalyst is present in the amount of approximately 0.51.0% by weight of the esters 34.
[0078] The transesterification reaction can produce transesterified products 72 including saturated and / or unsaturated fatty acid methyl esters (FAME), glycerin, methanol and / or free fatty acids. In certain embodiments, transesterified products 72, or a fraction thereof, may comprise a source for biodiesel. In certain embodiments, transesterified products 72 comprise
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31/58 with 9DA esters, 9UDA esters and / or 9DDA esters. Non-limiting examples of 9DA esters, 9UDA esters and 9DDA esters include methyl 9-decenoate (9-DAME), methyl 9undecenoate (9-UDAME) and methyl 9-dodecenoate (9DDAME), respectively. As a non-limiting example, in a transesterification reaction, a 9DA group of a glyceride subjected to metathesis is removed from the glycerol structure to form a 9DA ester.
[0079] In another embodiment, a glycerin alcohol can be used in the reaction with a glyceride stream. This reaction can produce monoglycerides and / or diglycerides.
[0080] In certain embodiments, the transesterified products 72 of the transesterification unit 70 can be sent to a liquid-liquid separation unit, in which the transesterified products 72 (ie, FAME, free fatty acids and / or alcohols) are separated of glycerin. In addition, in certain embodiments, the glycerin by-product stream can be further processed in a secondary separation unit, where the glycerin is removed and any remaining alcohols are recycled back to the transesterification unit 70 for further processing.
[0081] In one embodiment, the transesterified products 72 are additionally processed in a water washing unit. In this unit, transesterified products undergo a liquid-liquid extraction when washed with water. Excess alcohol, water and glycerin are removed from the transesterified products 72. In another embodiment, the water washing step is followed by a drying unit in which the excess water is additionally removed from the desired ester mixture (ie ie, fine chemical reagents). Such fine chemical reagents include non-limiting examples such as 9DA, 9UDA and / or 9DDA, alkali metal salts and
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32/58 alkaline earth metals from the previous ones, individually or in combinations thereof.
[0082] In one embodiment, the specialty fine chemical reagent (eg 9DA) can be further processed in an oligomerization reaction to form a lactone, which can serve as a precursor to a surfactant.
[0083] In certain embodiments, the transesterified products 72 from the transesterification unit 70 or the fine chemical reagents from the water wash unit or the drying unit are sent to an ester distillation column 80 for further separation of several individual compounds or groups of compounds, as shown in figure 1. This separation can include, but is not limited to, the separation of 9DA esters, 9UDA esters and / or 9DDA esters. In one embodiment, the 9DA ester 82 can be individually distilled or separated from the rest of the mixture 84 of transesterified products or fine chemical reagents. Under certain process conditions, the 9DA 82 ester should be the lightest component in the transesterified product or stream of specialty fine chemicals and leave at the top of the ester 80 distillation column. In another embodiment, the rest of the mixture 84 or heavier compounds, transesterified products or fine chemical reagents can be separated from the lower end of the column. In certain embodiments, this bottom chain 84 can potentially be sold as biodiesel.
[0084] 9DA esters, 9UDA esters and / or 9DDA esters can be further processed after the distillation step in the ester distillation column. In one embodiment, under known operating conditions, the 9DA ester, the 9UDA ester and / or the 9DDA ester can then undergo a hydrolysis reaction with water to form 9DA, 9UDA and / or 9DDA, alkali metal salts and salts of
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33/58 alkaline earth metals from the previous ones, individually or in combinations thereof.
[0085] In certain embodiments, the fatty acid methyl esters of the transesterified products 72 can be reacted with each other to form other fine chemical reagents such as dimers.
[0086] Figure 2 shows another modality for processing natural oil in combustible compositions and fine chemical reagents. As previously described, the raw material of natural oil and / or the low molecular weight olefin in figure 2 can undergo a pre-treatment step before the metathesis reaction. In figure 2, the raw material of natural oil 112 is obtained with itself or combined with a low molecular weight olefin 114 in a metathesis reactor 120 in the presence of a metathesis catalyst. In certain embodiments, in the presence of a metathesis catalyst, natural oil 112 undergoes a self-synthesis reaction with itself. In other modalities, in the presence of the metathesis catalyst, natural oil 112 undergoes a cross metathesis reaction with low molecular weight olefin 114. In certain modalities, natural oil 112 undergoes both self-synthesis and cross reactions in metathesis reactors in parallel. The self-and / or cross-metathesis reaction forms a product subjected to metathesis 122 in which the product subjected to metathesis 122 comprises olefins 132 and esters 134.
[0087] In certain embodiments, the low molecular weight olefin 114 is in the range of C2 to C6. As a non-limiting example, in one embodiment, the low molecular weight olefin 114 may comprise at least one of the following: ethylene, propylene, 1-butene, 2butene, isobutene, 1-pentene, 2-pentene, 3-pentene, 2 -methyl-1-butene,
2-methyl-2-butene, 3-methyl-1-butene, cyclopentene, 1-hexene, 2-hexene,
3-hexene, 4-hexene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 2-methyl-2-pentene, 3-methyl-2-pentene, 4-methyl- 2-pentene, 2
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34/58 methyl-3-pentene and cyclohexene. In another embodiment, the low molecular weight olefin 114 comprises at least one of styrene and vinyl cyclohexane. In another embodiment, the low molecular weight olefin 114 may comprise at least one of ethylene, propylene, 1-butene, 2-butene and isobutene. In another embodiment, the low molecular weight olefin 114 comprises at least one alpha-olefin or terminal olefin in the range of C2 to C10.
[0088] In another embodiment, the low molecular weight olefin 114 comprises at least one low molecular weight olefin branched in the range of C2 to C10. Non-limiting examples of branched low molecular weight olefins include isobutene, 3-methyl-1-butene, 2-methyl-3-pentene and 2,2-dimethyl-3-pentene. In certain embodiments, branched low molecular weight olefins can help achieve the desired performance properties for fuel composition, such as jet fuel, kerosene or diesel fuel.
[0089] As noted, it is possible to use a mixture of several linear or branched low molecular weight olefins in the reaction to achieve the distribution of desired metathesis products. In one embodiment, a mixture of butenes (1-butene, 2-butene and isobutene) can be used as the low molecular weight olefin 114.
[0090] In certain embodiments, recycled chains from downstream separation units can be introduced into the metathesis reactor 120 in addition to natural oil 112 and, in some embodiments, the low molecular weight olefin 114 to improve the yield of the composition of target fuel and / or the targeted transesterification products.
[0091] After the metathesis unit 120 and before the hydrogenation unit 125, in certain modalities, the product submitted to meth
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35/58 tothesis 122 can be introduced into an adsorbent bed to facilitate the separation of the product submitted to metathesis 122 from the metathesis catalyst. In one embodiment, the adsorbent is a clay. The clay will adsorb the metathesis catalyst and after a filtration step, the product submitted to metathesis 122 can be sent to the hydrogenation unit 125 for further processing. In another embodiment, the adsorbent is a water-soluble phosphine reagent such as tris hydroxymethyl phosphine (THMP). The catalyst can be separated from the reaction mixture with a water-soluble phosphine through liquid-liquid extraction mechanisms known through the decantation of the aqueous phase starting from the organic phase. In other embodiments, the addition of a reagent to deactivate or extract the catalyst can be used.
[0092] As shown in figure 2, the metathesis product 122 is sent to a hydrogenation unit 125, in which the carbon-carbon double bonds in the olefins and esters are partially to completely saturated with hydrogen gas 124. As previously described , hydrogenation can be conducted according to any method known in the art for hydrogenation of compounds containing double bonds such as olefins and esters present in metathesis product 122. In certain embodiments, in hydrogenation unit 125, hydrogen gas 124 is achieved with metathesis product 122 in the presence of a hydrogenation catalyst for the production of a hydrogenated product 126 which comprises partially to completely hydrogenated paraffins / olefins and partially to completely hydrogenated esters.
[0093] Typical hydrogenation catalysts have already been described with reference to the modalities in figure 1. The reaction conditions have also been described. In certain embodiments, the temperature ranges from approximately 50 ° C to approximately 350 ° C, approximately
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36/58 at about 100 ° C to approximately 300 ° C, approximately 150 ° C to approximately 250 ° C or approximately 50 ° C to approximately 150 ° C. The desired temperature can vary, for example, with hydrogen gas pressure. Typically, a higher gas pressure could allow the use of a lower reaction temperature. The hydrogen gas is pumped into the reaction vessel to achieve a desired H2 gas pressure. In certain embodiments, the pressure of the H2 gas ranges from approximately 101.32 Kpa (15 psig - 1 atm) to approximately 20680.43 Kpa (3000 psig 204.1 atm) or approximately 101.32 Kpa (15 psig - 1 atm) up to approximately 3445.05 Kpa (500 psig - 34 atm). In certain embodiments, the reaction conditions are mild, where the temperature is approximately between approximately 50 ° C and approximately 150 ° C and the pressure of the H2 gas is less than approximately 2757.903 Kpa (400 psig). When a desired degree of hydrogenation is reached, the reaction mass is cooled to the desired filtration temperature. [0094] During hydrogenation, the carbonocarbon double bonds are partially to completely saturated by hydrogen gas 124. In one embodiment, the olefins in the metathesis product 122 are reacted with hydrogen to form a fuel composition that comprises only or mainly paraffins. In addition, the esters from the metathesis product are completely or almost completely saturated in the hydrogenation unit 125. In another embodiment, the resulting hydrogenated product 126 includes only partially saturated paraffins / olefins and partially saturated esters.
[0095] In figure 2, the hydrogenated product 126 is sent to a separation unit 130 to separate the product into at least two product streams. In one embodiment, the hydrogenated product 126 is sent to the separation unit 130 or distillation column
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37/58 tion, to separate the partially to fully saturated paraffins / olefins or fuel composition 132, from the partially to fully saturated esters 134. In another embodiment, a by-product stream comprising C7's and cyclohexadiene can be removed in one side chain of separation unit 130. In certain embodiments, the fuel composition 132 may comprise hydrocarbons having carbon numbers of up to 24. In one embodiment, the fuel composition 132 consists essentially of saturated hydrocarbons.
[0096] In certain embodiments, esters 134 may comprise partially to completely hydrogenated glycerides subjected to metathesis. In other words, paraffins / olefins with a lighter end 132 are preferably separated or distilled at the top for processing into combustible compositions, while esters 134, comprised mainly of compounds that have carboxylic acid / ester functionality, are extracted in the form of a bottom stream. Based on the quality of the separation, it is possible for some ester compounds to be carried into the top paraffin / olefin stream 132 and it is also possible for some heavier paraffin / olefin hydrocarbons to be carried into the ester stream 134.
[0097] In certain embodiments, it may be preferable to isomerize the fuel composition 132 to increase the quality of the product stream and target the desired fuel properties such as flash point, freezing point, energy density, cetane number or distillation temperature of the end point, among other parameters. Isomerization reactions are well known in the art, as described in U.S. Patent Nos. 3,150,205; 4,210,771; 5,095,169; and 6,214,764, incorporated here as a reference in their entirety. In one embodiment, as shown
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38/58 in figure 2, the fuel composition 132 is sent to an isomerization reaction unit 150 in which an isomerized fuel composition 152 is produced. Under typical reaction conditions, the isomerization reaction at this stage can also disrupt part of the compounds present in stream 132, which can further assist in the production of an improved fuel composition that has compounds within the desired range of carbon numbers, such as 5 to 16 for a jet fuel composition.
[0098] In certain embodiments, the fuel composition 132 or the isomerized fuel composition 152 comprises approximately 15-25% by weight of C7, approximately <5% by weight of C8, approximately 20-40% by weight of C9, approximately 20-40% by weight of C10, approximately <5% by weight of C11, approximately 15-25% by weight of C12, approximately <5% by weight of C13, approximately <5% by weight of C14, approximately <5% by weight of C15, approximately <1% by weight of C16, approximately <1% by weight of C17 and approximately <1% by weight of C18 +. In certain embodiments, the fuel composition 132 or the isomerized fuel composition 152 comprises a heat of combustion of at least approximately 40, 41, 42, 43 or 44 MJ / kg (which is measured by ASTM D3338). In certain embodiments, the fuel composition 132 or the isomerized fuel composition 152 contains less than approximately 1 mg of sulfur per kg fuel composition (which is measured by ASTM D5453). In other embodiments, the fuel composition 132 or the isomerized fuel composition 152 comprises a density of approximately 0.70-0.75 (which is measured by ASTM D4052). In other embodiments, the fuel composition 132 or the isomerized fuel composition 152 has a pon
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39/58 final boiling temperature of approximately 220-240 ° C (which is measured by ASTM D86).
[0099] Fuel composition 132 or isomerized fuel composition 152 can be used as jet, kerosene or diesel fuel, depending on the characteristics of the fuel. In certain embodiments, the fuel composition may contain by-products from hydrogenation, isomerization and / or metathesis reactions. The fuel composition 132 or the isomerized fuel composition 152 can be further processed in a fuel composition separation unit 160 as shown in figure 2. The separation unit 160 can be operated to remove any remaining by-products from the mixture, such as hydrogen gas, water, C2-C9 hydrocarbons or C15 + hydrocarbons, thus producing a desired fuel product 164. In one embodiment, the mixture can be separated into the desired C9-C15 fuel product 164 and a fraction of C2-C9 (or C3- C8) of light extremities 162 and / or a fraction of heavy extremities of C18 + 166. Distillation can be used to separate the fractions. Alternatively, in other embodiments, such as for a jet fuel composition of the naphtha or kerosene type, the heavy tip fraction 166 can be separated from the desired fuel product 164 by cooling the paraffins / olefins to approximately -40 ° C, -47 ° C or -65 ° C and then removing the solid heavy tip fraction 166 by techniques known in the art such as filtration, decantation or centrifugation. [00100] Regarding the partially to fully saturated esters 134 of the separation unit 130, in certain embodiments, the esters 134 can be entirely eliminated in the form of a stream of partially to fully hydrogenated ester product 136 and further processed or sold by your eigenvalue,
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40/58 as shown in figure 2. As a non-limiting example, esters 134 can comprise various partially to fully saturated triglycerides that could be used as a lubricant. Based on the quality of separation between paraffins / olefins (fuel composition 132) and esters, esters 134 may comprise some heavier paraffin and olefin components loaded with triglycerides. In other embodiments, esters 134 can be further processed in a biorefinery or other chemical or fuel reagent processing unit known in the art, thereby producing various products such as biodiesel or fine chemical reagents that have greater value than those of triglycerides, for example. example. Alternatively, esters 134 can be partially eliminated from the system and sold, with the remainder further processed at the biorefinery or another chemical or fuel reagent processing unit known in the art.
[00101] In certain embodiments, ester stream 134 is sent to a transesterification unit 170. Within transesterification unit 170, esters 134 are reacted with at least one alcohol 138 in the presence of a transesterification catalyst. In certain embodiments, the alcohol comprises methanol and / or ethanol. In one embodiment, the transesterification reaction is conducted at approximately 60-70 ° C and 1 atm. In certain embodiments, the transesterification catalyst is a homogeneous sodium methoxide catalyst. Variable amounts of catalyst can be used in the reaction and, in certain embodiments, the transesterification catalyst is present in the amount of approximately 0.5-1.0% by weight of the esters 134.
[00102] The transesterification reaction can produce transesterified products 172 including saturated fatty acid methyl esters
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41/58 and / or unsaturated (FAME), glycerin, methanol and / or free fatty acids. In certain embodiments, transesterified products 172, or a fraction thereof, may comprise a source for biodiesel. In certain embodiments, transesterified products 172 comprise esters of decenoic acid, esters of decanoic acid, esters of undecenoic acid, esters of undecanoic acid, esters of dodecenoic acid and / or esters of dodecanoic acid. In one embodiment, in a transesterification reaction, a group of the decanoic acid of a glyceride submitted to metathesis is removed from the glycerol structure to form an ester of the decanoic acid. In another embodiment, a group of decenoic acid from a glyceride submitted to metathesis is removed from the glycerol structure to form an ester of decenoic acid.
[00103] In another embodiment, a glycerin alcohol can be used in the reaction with a triglyceride stream 134. This reaction can produce monoglycerides and / or diglycerides.
[00104] In certain embodiments, the transesterified products 172 of the transesterification unit 170 can be sent to a liquid-liquid separation unit, in which the transesterified products 172 (i.e., FAME, free fatty acids and / or alcohols) are separated of glycerin. Additionally, in certain embodiments, the glycerin by-product stream can be further processed in a secondary separation unit, where the glycerin is removed and any remaining alcohols are recycled back to the transesterification unit 170 for further processing.
[00105] In one embodiment, the transesterified products 172 are further processed in a water washing unit. In this unit, transesterified products undergo a liquid-liquid extraction when washed with water. Excess alcohol, water and glycerin is removed from transesterified products 172. In
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In another embodiment, the water washing step is followed by a drying unit in which the excess water is additionally removed from the desired ester mixture (i.e., fine chemical reagents). Such fine hydrogenated chemical reagents include non-limiting examples such as decenoic acid, decanoic acid, undecenoic acid, undecanoic acid, dodecenoic acid, dodecanoic acid and mixtures thereof.
[00106] As shown in figure 2, transesterified products 172 from transesterification unit 170 or fine chemical reagents from the water wash unit or drying unit can be sent to an ester distillation column 180 for further separation of several individual compounds or groups of compounds. This separation may include, but is not limited to, the separation of esters of decenoic acid, esters of decanoic acid, esters of undecenoic acid, esters of undecanoic acid, esters of dodecenoic acid and / or dodecanoic acid esters. In one embodiment, a decanoic acid ester or a decenoic acid ester 182 can be distilled or individually separated from the rest of the mixture 184 of transesterified products or fine chemical reagents. Under certain process conditions, the decanoic acid ester or the decenoic acid ester 182 should be the lightest component in the transesterified product or in the stream of specialty chemicals and come out at the top of the 180 distillation column. In this embodiment, the remainder of mixture 184 or the heavier compounds, transesterified products or fine chemical reagents can be separated from the lower end of the column. In certain embodiments, this bottom chain 184 can potentially be sold as biodiesel.
[00107] Decenoic acid esters, decanoic acid esters, undecenoic acid esters, undeca acid esters
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43/58 noico, dodecenoic acid esters and / or dodecanoic acid esters can be further processed after the distillation step on the ester distillation column. In one embodiment, under known operating conditions, the decenoic acid ester, the decanoic acid ester, the undecenoic acid ester, the undecanoic acid ester, the dodecenoic acid ester and / or the dodecanoic acid ester can then undergo a hydrolysis reaction with water to form decenoic acid, decanoic acid, undecenoic acid, undecanoic acid, dodecenoic acid and / or dodecanoic acid.
[00108] As noted, the self-synthesis of natural oil or the cross-metathesis between natural oil and low molecular weight olefin occurs in the presence of a metathesis catalyst. As previously mentioned, the term metathesis catalyst includes any catalyst or catalyst system that catalyzes the metathesis reaction. Any metathesis catalyst known or developed in the future can be used, individually or in combination with one or more additional catalysts. Non-limiting examples of metathesis catalysts and process conditions are described in PCT / US2008 / 009635, pp. 18-47, incorporated herein by reference. A number of metathesis catalysts that are shown are manufactured by Materia, Inc. (Pasadena, CA).
[00109] The metathesis process can be conducted under any conditions suitable for the production of the desired metathesis products. For example, stoichiometry, atmosphere, solvent, temperature and pressure can be selected by one skilled in the art to obtain a desired product and to minimize undesirable by-products. The metathesis process can be carried out under an inert atmosphere. Similarly, if a reagent is provided in the form of a gas, an inert gas diluent can be used. The inert atmosphere or the inert gas diluent is typically a gas
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44/58 inert, meaning that the gas does not interact with the metathesis catalyst to substantially prevent catalysis. For example, particular inert gases are selected from the group consisting of helium, neon, argon, nitrogen, individually or in combinations thereof.
[00110] In certain embodiments, the metathesis catalyst is dissolved in a solvent before the metathesis reaction is carried out. In certain embodiments, the chosen solvent can be selected to be substantially inert to the metathesis catalyst. For example, substantially inert solvents include, without limitation, aromatic hydrocarbons, such as benzene, toluene, xylenes, etc .; halogenated aromatic hydrocarbons, such as chlorobenzene and dichlorobenzene; aliphatic solvents, including pentane, hexane, heptane, cyclohexane etc .; and chlorinated alkanes, such as dichloromethane, chloroform, dichloroethane, etc. In a particular embodiment, the solvent comprises toluene.
[00111] The metathesis reaction temperature can be a variable that controls the speed at which the temperature is selected to provide a desired product at an acceptable speed. In certain embodiments, the metathesis reaction temperature is greater than approximately -40 ° C, greater than approximately -20 ° C, greater than approximately 0 ° C or greater than approximately 10 ° C. In certain embodiments, the metathesis reaction temperature is less than approximately 150 ° C or less than approximately 120 ° C. In one embodiment, the metathesis reaction temperature is between approximately 10 ° C and approximately 120 ° C.
[00112] The metathesis reaction can be performed under any desired pressure. Typically, it will be desirable to maintain a total pressure that is high enough to keep the cross-metering reagent in solution. Therefore, as the molecular weight of the area
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45/58 cross-metathesis people increase, the lower pressure range typically decreases as the boiling point of the cross-metathesis reagent increases. The total pressure can be selected to be greater than approximately 0.1 atm (10 kPa), in some embodiments greater than approximately 0.3 atm (30 kPa) or greater than approximately 1 atm (100 kPa). Typically, the reaction pressure is not greater than approximately 70 atm (7000 kPa), in some embodiments it is not greater than approximately 30 atm (3000 kPa). A non-limiting example of the pressure range for the metathesis reaction is approximately 1 atm (100 kPa) to approximately 30 atm (3000 kPa).
[00113] Although the invention that is described may have modifications and alternative forms, several modalities of it have been described in detail. It should be understood, however, that the description contained here of these various modalities is not intended to limit the invention, but rather the intention is to cover all modifications, equivalents and alternatives that fit within the spirit and scope of the invention that are defined by the claims. In addition, although the invention is also described with reference to the following non-limiting examples, it will be understood, of course, that the invention is not limited to them since modifications can be made by those skilled in the art, particularly in light of the above teachings.
EXAMPLES
Example 1 [00114] A 5 gallon (~ 19 L) Parr reactor vessel with a clean dry stainless steel liner equipped with an immersion tube, a surface stirrer, internal cooling / heating coils, temperature probe, pressure valve sampling and gas release valve in the upper space was purged with argon at
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101.32 Kpa (15 psig). Soybean oil (SBO, 2.5 kg, 2.9 moles, Costco, PM = 864.4 g / mol, 85% by weight of unsaturation as determined by GC, argon purged for 1 hour in the 5-gallon container) was added to the Parr reactor. The Parr reactor was sealed and the SBO was purged with argon for 2 hours while being cooled to 10 ° C. After 2 hours, the reactor was ventilated until the internal pressure reached 68.95 Kpa (10 psig). The valve of the immersion tube in the reactor was connected to a 1-butene cylinder (Airgas, CP grade, head space pressure of 227.53 Kpa (33 psig),> 99% by weight) and repressurized to 101.32 Kpa (15 psig) of 1-butene. The reactor was re-ventilated to 68.95 Kpa 10 psig to remove residual argon in the upper space. The SBO was stirred at 350 rpm and 9-15 ° C under 1-butene at 124.10 to 193.05 Kpa (18-28 psig) until 3 moles of 1-butene per bonded SBO olefin were transferred into the reactor ( 2.2 kg of 1butene over approximately 4-5 hours). A toluene solution of [1,3-bis- (2,4,6-trimethylphenyl) -2-imidazolidinylidene] dichloroructene (3-methyl-2-butenylidene) (tricyclohexylphosphine) (C827, Materia) was prepared in the container of FischerPorter pressure by dissolving 130 mg of catalyst in 30 grams of toluene in the form of a catalyst carrier (10 moles ppm per SBO olefin attached) and was added to the reactor through the reactor immersion tube by pressurizing the space higher into the Fischer-Porter container up to 344.505 to 413.69 Kpa (5060 psig) with argon. The Fischer-Porter vessel and the immersion tube were washed with an additional 30 g of toluene. The reaction mixture was stirred for 2.0 hours at 60 ° C. The reaction mixture was allowed to cool to room temperature while the gases in the upper space were vented. After the pressure was released, the reaction mixture was transferred to a 3-necked round bottom flask containing 58 g of bleaching clay (2% w / w SBO,
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Pure Flow B80 CG) and a magnetic stir bar. The reaction mixture was treated by stirring at 85 ° C under argon. After 2 hours, during such period of time any remaining 1-butene was allowed to vent, the reaction mixture was allowed to cool to 40 ° C and was filtered through a sintered glass filter. It was observed by gas chromatography analysis (after transesterification with 1% w / w NaOMe in methanol at 60 ° C) that an aliquot of the product mixture contained approximately 22% by weight of methyl 9-decenoate, approximately 16% by weight of methyl 9-dodecenoate, approximately 3% by weight of dimethyl 9-octadecenedioate and approximately 3% by weight of methyl 9-octadecenoate (per gc). These results compare favorably with the calculated equilibrium yields of 23.4% by weight of methyl 9-decenoate, 17.9% by weight of methyl 9-dodecenoate, 3.7% by weight of 9-octadecenedioate of dimethyl and 1.8% by weight of methyl 9octadecenoate.
Example 2 [00115] Through the general procedures described in example 1, a reaction was carried out using 1.73 kg of SBO and 3 moles of double bond of 1-butene / SBO. It was observed that an aliquot of the product mixture by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 24% by weight of methyl 9-decenoate, approximately 18% by weight of methyl 9-dodecenoate, approximately 2% by weight of dimethyl 9-octadecenedioate and approximately 2% by weight of methyl 9-octadecenoate (as determined by gc). Example 3 [00116] Through the general procedures described in example 1, a reaction was carried out using 1.75 kg of SBO and 3 moles of double bond of 1-butene / SBO. It was observed that a rate of mis
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48/58 ture of the product by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 24% by weight of methyl 9-decenoate, approximately 17% by weight of 9- methyl dodecenoate, approximately 3% by weight of dimethyl 9-octadecenedioate and approximately 2% by weight of methyl 9-octadecenoate (as determined by gc). Example 4 [00117] Through the general procedures described in example 1, a reaction was carried out using 2.2 kg of SBO, 3 moles of double bond of 1-butene / SBO and the 60 g of toluene used for the transfer of the catalyst were replaced by SBO. It was observed that an aliquot of the product mixture by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 25% by weight of methyl 9-decenoate, approximately 18% by weight of methyl 9-dodecenoate, approximately 3% by weight of dimethyl 9-octadecenedioate and approximately 1% by weight of methyl 9-octadecenoate (as determined by gc).
Example 5 [00118] A rounded glass bottom flask with 3 12 liter necks that was equipped with a magnetic stir bar, a heating blanket and a temperature controller was loaded with 8.42 kg of the combined reaction products from examples 1-4. A cooling condenser with a vacuum inlet was connected to the central neck of the bottle and a collection bottle was connected to the condenser. The hydrocarbon olefins were removed from the reaction product by vacuum distillation in relation to the following range of conditions: 22 - 130 ° C temperature of the vessel, top temperature of the distillation of 19 - 70 ° C and pressure of 266.64 21 , 33 Kpa (2000 - 160 torr). The weight of the rest of the material after
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49/58 volatile hydrocarbons having been removed was 5.34 kg. It was observed that an aliquot of the mixture of non-volatile products by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 32% by weight of methyl 9-decenoate, approximately 23% by weight of methyl 9dodecenoate, approximately 4% by weight of dimethyl 9octadecenedioate and approximately 5% by weight of methyl 9octadecenoate (as determined by gc).
Example 6 [00119] A round-bottomed flask with 3 12-liter necks that was fitted with a magnetic stir bar, a condenser, a heating mantle, a temperature probe and a gas adapter was loaded with 4 liters of 1 % w / w NaOMe in MeOH and 5.34 kg of the mixture of non-volatile products produced in example 5. The resulting light yellow heterogeneous mixture was stirred at 60 ° C. After approximately one hour, the mixture became a homogeneous orange color (detected pH = 11.) After a total reaction time of 2 hours, the mixture was cooled to room temperature and two layers were observed. The organic phase was washed twice with 3 L of 50% (v / v) aqueous MeOH, separated and neutralized by washing with glacial HOAc in MeOH (1 mol of HOAc / mol of NaOMe) to a detected pH of 6.5 , providing 5.03 kg. Example 7 [00120] A round bottomed flask with 3 12 L glass necks mounted with a magnetic stirrer, a packaged column and a temperature controller was loaded with the methyl ester mixture (5.03 kg) produced in example 6 and placed on the heating mat. The column attached to the flask was a 5.08 cm x 91.44 cm (2 in x 36 in) glass column containing 0.16 Pro-Pak®® stainless steel saddles. The distillation column was connected to a top of
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50/58 fractional distillation to which a pre-weighed rounded 1 L flask was assembled to collect the distillation fractions. Distillation was carried out under vacuum at 13.33 to 15.99 Kpa (100-120 torr). A reflux ratio of 1: 3 was used for the isolation of both methyl 9-decenoate (9-DAME) and methyl 9-dodecenoate (9-DDAME). A reflux ratio of 1: 3 referred to as 1 drop collected for every 3 drops sent back to the distillation column. The samples collected during the distillation, the vacuum distillation conditions and the fractions 9-DAME and 9-DDAME content, as determined by gc, are shown in Table 1. The combination of fractions 2-7 produced 1.46 kg of methyl 9-decenoate with 99.7% purity. After collecting fraction 16, 2.50 kg of material remained in the distillation container: it was observed by gc that contained approximately 14% by weight of 9-DDAME, approximately 42% by weight of methyl palmitate and approximately 12% by weight methyl stearate.
Table 1
Distillation Fractions # Temp. Top (° C) Temp. ofContainer(° C) Vacuum fotoor) Weight(g) 9-DAME (% by weight) 9-DDAME(% by weight) 1 40-47 104-106 110 6.8 80 0 2 45-46 106 110 32.4 99 0 3 47-48 105-110 120 223.6 99 0 4 49-50 110-112 120 283 99 0 5 50 106 110 555 99 0 6 50 108 110 264 99 0 7 50 112 110 171 99 0 8 51 114 110 76 97 1 9 65-70 126-128 110 87 47 23 10 74 130-131 110 64 0 75 11 75 133 110 52.3 0 74 12 76 135-136 110 38 0 79
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Distillation Fractions # Temp. Top (° C) Temp. of the Container(° C) VacuumGtoor) Weight(g) 9-DAME (% by weight) 9-DDAME(% by weight) 13 76 136-138 100 52.4 0 90 14 76 138-139 100 25.5 0 85 15 76-77 140 110 123 0 98 16 78 140 100 426 0 100
Example 8 [00121] A reaction was carried out using the general procedures described in example 1 with the following changes: 2.2 kg of SBO, 7 moles of propene / mol of double bond of SBO and 200 mg of [1,3- Bis (2,4,6-trimethylphenyl) -2imidazolidinylidene] dichlororutene (benzylidene) (tricyclohexyl-phosphine) [catalyst C848, Materia Inc., Pasadena, California, USA, 90 ppm (w / w) vs. SBO] at a reaction temperature of 40 ° C were used. The catalyst removal step using bleaching clay was also replaced by the following: after venting the excess propene, the reaction mixture was transferred into a 3-necked round bottom flask to which tris (hydroxymethyl) phosphine (THMP, 1.0 M in isopropanol, 50 moles THMP / mole of C848) was added. The resulting cloudy yellow mixture was stirred for 20 hours at 60 ° C, transferred to a 6 L separating funnel and extracted with 2 x 2.5 L deionized H2O. The organic layer was separated and dried over anhydrous Na2SO4 for 4 hours, and then filtered through a sintered glass filter containing a bed of silica gel.
Example 9 [00122] A reaction was carried out using the general procedures described in example 8, except that 3.6 kg of SBO and 320 mg of catalyst C848 were used. After removing the catalyst, the reaction product of example 9 was combined with that of example 8, producing 5.12 kg of material. It was observed that a
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52/58 aliquot of the combined product mixture by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 34% by weight of methyldecenoate, approximately 13% by weight of 9undecenoate methyl, <1% by weight of dimethyl 9-octadecenedioate and <1% by weight of methyl 9-octadecenoate (as determined by gc).
[00123] The hydrocarbon olefins were removed from the 5.12 kg of the combined reaction product described above by vacuum distillation using the general procedure described in example 5. The weight of the rest of the material after the volatile olefins were removed was 4 , 0 kg. It was observed that an aliquot of the mixture of non-volatile products by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 46% by weight of methyl 9-decenoate, approximately 18% by weight of methyl 9-undecenoate, approximately 2% by weight of dimethyl 9-octadecenedioate and approximately 1% by weight of methyl 9-octadecenoate (as determined by gc). Example 10 [00124] Two reactions were performed using the general procedures described in example 8, except for the fact that for each reaction, 3.1 kg of SBO and 280 mg of catalyst C848 were used. After removing the catalyst, the reaction products of the two preparations were combined, producing 5.28 kg of material. It was observed that an aliquot of the combined product mixture by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 40% by weight of methyl 9-decenoate, approximately 13% in weight of methyl 9undecenoate, approximately 2% by weight of dimethyl 9octadecenedioate and approximately 1% by weight of 9 Petition 870190001430, from 07/01/2019, p. 58/72
53/58 methyl octadecenoate (as determined by gc).
[00125] The hydrocarbon olefins were removed from the 5.28 kg of combined reaction product by vacuum distillation using the general procedure described in example 5. The weight of the rest of the material after the volatile olefins had been removed was 4.02 kg. It was observed that an aliquot of the mixture of non-volatile products by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 49% by weight of methyl 9-decenoate, approximately 16% by weight of methyl 9-undecenoate, approximately 2% by weight of dimethyl 9octadecenedioate and approximately 3% by weight of methyl 9octadecenoate (as determined by gc).
Example 11 [00126] Through the general procedures described in example 10, two metathesis reactions were performed using SBO, 7 moles of cis-2-butene / mol double bonded SBO and 220 mg of C848 catalyst / kg SBO. After removing the catalyst, the reaction products of the two preparations were combined, producing 12.2 kg of material. It was observed that an aliquot of the combined product mixture by gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 49% by weight of methyl 9-undecenoate, approximately 2% in weight of dimethyl 9-octadecenoidate and approximately 1% by weight of methyl 9-octadecenoate (as determined by gc).
[00127] The hydrocarbon olefins were removed from the 12.2 kg of combined reaction product by vacuum distillation using the general procedure described in example 5. The weight of the rest of the material after the volatile olefins were removed was 7.0 kg. It was observed that an aliquot of the mixture of non-volatile products per
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54/58 gas chromatography analysis after transesterification with 1% w / w NaOMe in methanol at 60 ° C contained approximately 57% by weight of methyl 9-undecenoate, approximately 4% by weight of
Dimethyl 9-octadecenoidate and approximately 2% by weight of methyl 9-octadecenoate (as determined by gc).
Example 12 [00128] Through the general procedures described in example 1, approximately 7 kg of cross-metathesis product were obtained by the reaction of SBO with 3 moles of 1-butene / mol of double bond SBO using 43 mg of catalyst C827 / kg of SBO after removing the catalyst with THMP. An initial 2.09 kg portion of the metathesis product was hydrogenated at 136 ° C and 2757.903 Kpa (400 psig) of H2 until hydrogen uptake ceased in a 3.78 L (one gallon) batch autoclave using 105 g of JohnsonMatthey A-7000 Sponge Metal® catalyst. The resulting mixture was filtered heated (22-55 ° C), producing 1.40 kg of filtrate and 350 g of a mixture consisting of the catalyst and the hydrogenated product. The entire mixture containing catalyst was returned to the 3.78 L (one gallon) reactor with a 2.18 kg second portion of the metathesis product and a second hydrogenation reaction was similarly carried out until the hydrogen uptake ceased. The catalyst was allowed to settle and most of the organic product was decanted and filtered, producing 1.99 kg of filtrate and 380 g of mixture of hydrogenated products with catalyst. The remainder of approximately 3 kg of metathesis product was hydrogenated in two additional batch reactions that were performed in a similar manner using the catalyst from the previous reaction, producing 1.65 kg and 1.28 kg of hydrogenated product, respectively. The total weight of hydrogenated product that was isolated after filtration was 6.32 kg. It was observed that the aliquots of the hydrogenated product by gas chromatography analysis
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55/58 contained approximately 30% by weight of C6-C18 n-paraffins and approximately 70% by weight of triglycerides. The relative distribution of C8-C18 n-paraffins contained in the hydrogenated product compares well with the calculated distribution of olefins by carbon number: observed (calculated) 2.3 (0.6)% by weight of C8, 35.6 ( 36.2)% by weight of Cg, 30.0 (27.6)% by weight of C10, 0.6 (0.1)% by weight of C11, 22.2 (23.6)% by weight of C12, 3.4 (3.7)% by weight of C13, 0.1 (0.0)% by weight of C14, 4.4 (6.3)% by weight of C15, 0.4 (0, 4)% by weight of C16, 0.1 (0.0)% by weight of C17 and 1.0 (1.6)% by weight of C18.
[00129] The paraffin components were separated by evaporation with agitated film starting from a 4.84 kg aliquot of the hydrogenated paraffin / triglyceride product. An initial stirred film evaporation was carried out at 75 ° C, 13.33 Kpa (100 torr), 300 rpm and condensing temperature of 15 ° C using a feed rate of 300 g / h and produced a condensate which was subjected to a second evaporation with stirred film at 125 ° C, 11.99 Kpa (90 torr), 300 rpm and 10 ° C condensing temperature to remove the lightest alkanes. It was observed that the resulting residual liquid by gas chromatography contained the following distribution of n-alkanes: 17.5% by weight of C7, 1.7% by weight of C8, 31.0% by weight of Cg, 28, 3% by weight of C10, 0.6% by weight of C11, 17.4% by weight of C12, 2.1% by weight of C13, 0.1% by weight of C14, 1.2% by weight of C15, 0.1% by weight of C16, 0.0% by weight of C17 and 0.1% by weight of C18. It was observed that the material had a heat of combustion of 43.86 MJ / kg (ASTM D3338), less than 1 mg / kg of sulfur (ASTM D5453), density of 0.7247 (ASTM D4052) and a final boiling point 232.3 ° C (ASTM D86), indicating that most of this material would be suitable as a mixing stock in a fuel application such as diesel or jet fuel.
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Example 13 [00130] A 1-olefin / 1,4-diene oligomerization reaction (92% by weight of 1-decene, 4.5% by weight of 1,4-decadiene, 2% by weight of 1.4 -undecadiene) which was produced from the cross metathesis of palm oil with 1-octene was performed on a 550 g scale using 1.1 mol% ethyl aluminum dichloride (1 M solution in hexane) / 1.1 mol % tert-butyl chloride for 3 hours at 10 ° C. The reaction mixture was quenched with water and 1 M sodium hydroxide solution and stirred until colorless. Hexane (300 ml) was added and the mixture was transferred to a separatory funnel. The organic layer was washed with water and brine and then concentrated on a rotary evaporator to remove hexane. The oligomeric mixture was devolatilized through short-distillation vacuum distillation (100 ° C and 5 Torr) and the product distribution was determined to be 97% of oligomers mixed by gc / MS. The dynamic viscosity (Brookfield, axis # 34, 100 rpm, 22 ° C) of the sample is 540 cps. The kinematic viscosity for the sample at 40 ° C is 232 cSt.
[00131] The previously mentioned examples used the analytical methods described below:
[00132] The volatile products were analyzed by gas chromatography and flame ionization detector (FID). Alken analyzes were performed using Agilent 6890 equipment and the following conditions:
Column: Restek Rtx-5, 30m x 0.25mm (ID) x 0.25pm film thickness
Injector temperature: 250 ° C
Detector temperature: 280 ° C
Oven temperature: 35 ° C starting temperature, holding time 4 minutes, lifting rate 12 ° C / min to 260 ° C, holding time 8 minutes
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Carrier gas: Helium
Average gas velocity: 31.3 ± 3.5% cm / s (calculated) Separation ratio: ~ 50: 1 [00133] The products were characterized by comparing the peaks with the known standards, in association with supporting data from mass spectrum analysis (GCMS-Agilent 5973N). GCMS analysis was performed with a second column of GC Rtx-5, 30m x 0.25mm (ID) x 0.25pm film thickness, using the same method as above. The alkane analyzes were performed using an Agilent 6850 equipment and the following conditions:
Column: Restek Rtx-65, 30m x 0.32mm (ID) x 0.1 pm film thickness
Injector temperature: 250 ° C
Detector temperature: 350 ° C
Oven temperature: 55 ° C starting temperature, retention time 5 minutes, elevation rate 20 ° C / min to 350 ° C, retention time 10 minutes
Carrier gas: Hydrogen
Flow rate: 1.0 mL / min
Separation ratio: 40: 1 [00134] The products were characterized by comparing the peaks with known standards. The fatty acid methyl ester (FAME) analyzes were performed using an Agilent 6850 equipment and the following conditions:
Column: J&W Scientific, DB-Wax, 30m x 0.32mm (ID) x
0.5pm film thickness
Injector temperature: 250 ° C
Detector temperature: 300 ° C
Oven temperature: 70 ° C starting temperature, holding time of 1 minute, rise rate of 20 ° C / min to
Petition 870190001430, of 01/07/2019, p. 63/72
58/58
180 ° C, rise rate from 3 ° C / min to 220 ° C, retention time 10 minutes
Carrier gas: Hydrogen
Flow rate: 1.0 mL / min [00135] The examples above demonstrate collectively the main steps described in the method diagrams, showing the production of olefins, paraffins, triglycerides submitted to metathesis, esters of unsaturated fatty acids and acids and compounds diacid from natural oils that are useful as chemical reagents, solvents and fuel mix stocks.

权利要求:
Claims (13)
[1]
1. Method of refining a natural oil, characterized by the fact that it comprises:
providing (a) a raw material comprising a natural oil glyceride; and (b) low molecular weight olefin comprising 1butene;
the cross metathesis of natural glyceride oil with low molecular weight olefin in the metathesis reactor in the presence of a metathesis catalyst to form a product undergoing metathesis comprising olefins and esters;
separating the olefins in the product undergoing the metastasis of esters in the product undergoing the metathesis to form a separate olefin stream, wherein the separate olefin stream comprises C2-C6 olefins; and recycling C2-C6 olefins in the separate olefin stream to the metathesis reactor.
[2]
2. Method according to claim 1, characterized by the fact that it additionally comprises the transesterification of esters in the product submitted to metathesis in the presence of an alcohol to form a transesterified product.
[3]
3. Method according to claim 2, characterized by the fact that it additionally comprises:
the separation of glycerin from the transesterified product by liquid-liquid separation;
after separation of the glycerin, washing the transesterified product with water to further remove the glycerin; and after washing, drying the transesterified product to separate water from the transesterified product.
Petition 870190001430, of 01/07/2019, p. 65/72
2/3
[4]
Method according to claim 3, characterized in that it additionally comprises the distillation of the transesterified product to separate at least one specialty fine chemical reagent selected from the group consisting of: 9-decenoic acid ester, 9-acid ester -undecenoic, ester of 9dodecenoic acid, individually or in combinations thereof.
[5]
Method according to claim 4, characterized in that it additionally comprises the hydrolysis of at least one specialty fine chemical reagent, thus forming at least one acid selected from the group consisting of: 9decenoic acid, 9-undecenoic acid, 9-dodecenoic acid, individually or in combinations thereof.
[6]
Method according to claim 5, characterized in that the hydrolysis step further provides alkali metal salts and alkaline earth metal salts, individually or in combinations thereof, of at least one acid.
[7]
Method according to claim 2, characterized in that it additionally comprises the reaction of the transesterified product with itself to form a dimer.
[8]
8. Method according to any of the claims
1 to 7, characterized by the fact that it additionally comprises the treatment of the raw material, before the reaction of the raw material in the presence of a metathesis catalyst, under conditions sufficient to decrease toxic agents of the catalysts in the raw material.
[9]
9. Method according to claim 8, characterized by the fact that the raw material is chemically treated through a chemical reaction to reduce the toxic agents of the catalysts.
[10]
10. Method according to claim 8, characterized by the fact that the raw material is heated to a temperature
Petition 870190001430, of 01/07/2019, p. 66/72
3/3 greater than 100 ° C in the absence of oxygen and maintained at temperature for a period of time sufficient to decrease the toxic agents of the catalysts.
[11]
Method according to any one of claims 1 to 5, characterized in that it further comprises separating the metathesis catalyst from the olefins and esters with a water-soluble phosphine reagent.
[12]
Method according to any one of claims 1 to 6, characterized in that the metathesis catalyst is dissolved in a solvent.
[13]
13. Method according to claim 12, characterized in that the solvent is toluene.

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法律状态:
2018-10-09| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2019-01-22| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2019-04-02| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/10/2010, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/10/2010, OBSERVADAS AS CONDICOES LEGAIS |

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2021-05-18| B25A| Requested transfer of rights approved|Owner name: WILMAR TRADING PTE LTD (SG) |

优先权:

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申请号 | 申请日 | 专利标题

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US25074309P| true| 2009-10-12|2009-10-12|

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US61/250,743|2009-10-12|

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PCT/US2010/052174|WO2011046872A2|2009-10-12|2010-10-11|Methods of refining and producing fuel from natural oil feedstocks|

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