Recent advances in co-processing biomass feedstock with petroleum feedstock: A review

doi:10.1007/s11708-024-0920-1

Front. Energy

Cong Wang, Tan Li, Wenhao Xu, Shurong Wang(

), Kaige Wang(

)

State Key Laboratory of Clean Energy Utilization, Zhejiang University, Hangzhou 310027, China

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Abstract

Co-processing of biomass feedstock with petroleum feedstock in existing refineries is a promising technology that enables the production of low-carbon fuels, reduces dependence on petroleum feedstock, and utilizes the existing infrastructure in refinery. Much effort has been dedicated to advancing co-processing technologies. Though significant progress has been made, the development of co-processing is still hindered by numerous challenges. Therefore, it is important to systematically summarize up-to-date research activities on co-processing process for the further development of co-processing technologies. This paper provides a review of the latest research activities on co-processing biomass feedstock with petroleum feedstock utilizing fluid catalytic cracking (FCC) or hydrotreating (HDT) processes. In addition, it extensively discusses the influence of different types and diverse physicochemical properties of biomass feedstock on the processing of petroleum feedstock, catalysts employed in co-processing studies, and relevant projects. Moreover, it summarizes and discusses co-processing projects in pilot or larger scale. Furthermore, it briefly prospects the research trend of co-processing in the end.

Keywords co-processing biomass bio-oil petroleum feedstock fluid catalytic cracking hydrotreating

Corresponding Author(s): Shurong Wang,Kaige Wang

Online First Date: 16 January 2024

Cite this article:

Cong Wang,Tan Li,Wenhao Xu, et al. Recent advances in co-processing biomass feedstock with petroleum feedstock: A review[J]. Front. Energy, 16 January 2024. [Epub ahead of print] doi: 10.1007/s11708-024-0920-1.

URL:

https://academic.hep.com.cn/fie/EN/10.1007/s11708-024-0920-1
https://academic.hep.com.cn/fie/EN/Y/V/I/0

Tab.1 Characteristics of typical petroleum feedstock and biomass feedstock

Fig.1 Schematic view of typical co-processing routes.

Fig.3 Schematic depiction of FCC process (adapted from Ref. [103] under the terms of CC BY-NC license).

Fig.4 Pretreatment scheme of low-grade bio-oil before co-processed in refinery.

Feedstock						Operation parameters for co-processing					Product yield/wt.%			Ref
Biomass					Petroleum	Reactor	Feeding quantity	Operation time	T/°C	Catalyst	Gasoline	LCO	Coke
Type	Process	HHV/ (MJ?kg^–1)	Oxygen/ wt.%	Ratio/%	Petroleum	Reactor	Feeding quantity	Operation time	T/°C	Catalyst	Gasoline	LCO	Coke
Palm oil	Extraction	NM	11.8	100	None	MAT	1.5 g/batch	12 s	565	E-CAT	38.2	9.9	5.4	Melero et al. [97]
Palm oil	Extraction	NM	11.8	30	VGO	MAT	1.5 g/batch	12 s	565	E-CAT	42.7	16.6	4.2	Melero et al. [97]
Animal fats	Extraction	NM	12.4	30	VGO	MAT	1.5 g/batch	12 s	565	E-CAT	43.9	16.4	NM	Melero et al. [97]
Soybean oil	Extraction	NM	11.7	30	VGO	MAT	1.5 g/batch	12 s	565	E-CAT	46.4	16.6	NM	Melero et al. [97]
WCO	Extraction	NM	11.8	30	VGO	MAT	1.5 g/batch	12 s	565	E-CAT	44.1	16.6	NM	Melero et al. [97]
Soybean oil	Extraction	NM	10.5	100	None	Pilot-scale	NM	NM	521–528	E-CAT	44.5	22.0	4.6	Bryden et al. [92]
Soybean oil	Extraction	35.85	11.0	0–100	VGO	Pilot-scale	3 L/h	At least 6 h	550	E-CAT	40–46	NM	5.6	Bielansky et al. [38]
Rapeseed oil	Extraction	36.54	10.9	0–100	VGO	Pilot-scale	3 L/h	At least 6 h	550	E-CAT	40–43	NM	5.6	Bielansky et al. [38]
Palm oil	Extraction	35.97	11.3	0–100	VGO	Pilot-scale	3 L/h	At least 6 h	550	E-CAT	40–46	NM	5.6	Bielansky et al. [38]
Microalgae	HTL	30.02	12.54	10	HVGO	MAT	NM	12 s	520	NM	27–42.5	22.9–23.1	4.0–5.8	Santillan-Jimenez et al. [98]
Black liquor	HTL +HDO	NM	4.7	10–30	VGO	MAT	0.57–2 g/batch	30 s	560	E-CAT	43–45	NM	5.3–6.6	van Dyk et al. [9]
Forest residue	HTL	NM	1	5–15	VGO	ACE	0.9–2.25 g/batch	45–112.5 s	510	E-CAT	46–50	17.6–23.2	3.1–6.6	van Dyk et al. [9]
Forest thinning	FP	22.1	36.5	20	VGO	MAT	3.33 g/batch	188 s	482	E-CAT	17	16	10	Lindfors et al. [41]
Wheat straw	FP	30.5	21.4	20	Atmospheric residue	MAT	0.75–1.0 g/batch	30 s	525	Residue FCC catalyst	41.2–45.0	11.7–14.8	12.2–17.0	Eschenbacher et al. [76]
Pine	FP	26.8	29.7	20	Atmospheric residue	MAT	0.75–1.2 g/batch	30 s	525	Residue FCC catalyst	41.8–45.4	12.2–15.2	10.2–14.5	Eschenbacher et al. [76]
Pine	FP	NM	38.0	3	VGO	Pilot-scale	NM	NM	521 (riser outlet)	E-CAT	47.9	13.3	6.65	Bryden et al. [92]
Pine	FP	NM	NM	5	VGO	Pilot-scale	2 kg/h	< 2.5 h (Riser residence time ~1 s)	550	E-CAT	36.3	5.0	5.7	Lutz et al. [114]
Pine	FP	NM	50.7	5, 10	VGO	Demonstration-scale	200 kg/h	2–3 h	540	E-CAT	37–42	17–21	5.6–7.2	Pinho et al. [39]
Pine	FP	21.36	51.2	10, 20	VGO	Demonstration-scale	150 kg/h	NM	540	E-CAT	37.7–40.7	16.5–17.4	7.5–8.5	de Rezende Pinho et al. [91]
Forest residue	HDO	25.2–35.8	16.9–28.0	20	Long residue	MAT	2.3–2.9 g/batch	60 s	520	E-CAT	43.7–46.0	23.1–25.0	5.5–7.8	de Miguel Mercader et al. [115]
Forest residue	HDO	31.3–35.8	16.9–22.6	100	None	MAT	0.50–0.83 g/batch	60 s	520	E-CAT	22.3–36.2	10.9–19.3	21.9–37.5	de Miguel Mercader et al. [115]
Forest thinning	HDO	29.6	22	20	VGO	MAT	3.33 g/batch	188 s	482	E-CAT	18	16	8	Lindfors et al. [41]
Pine	HDO	NM	21	10	VGO	MAT	0.33–0.67 g/batch	60 s	500	E-CAT	45.5–47.7	15.1–23.9	4.1–6.8	Thegarid et al. [86]
Pine	HDO	NM	NM	10	VGO	MAT	NM	30 s	560	USY	29.3–41.0	15.6–24.2	1.2–5.5	Gueudré et al. [113]
Wood	HDO	33.3	22.8	5–20	Atmospheric residue	MAT	1.75 g/batch	12 s	520	E-CAT	44.2–54.2	11.0–15.7	3.5–4.2	Huynh et al. [85]
Wood	HDO	33.3	22.8	5–20	Atmospheric residue	MAT	1.75 g/batch	12 s	520	E-CAT	52.6-55.5	10.9–13.8	3.8–4.5	Huynh et al. [85]
Beech wood	HDO	NM	4.9	2.5	VGO	Pilot-scale	NM	0.8 s	520	E-CAT	42–46.4	17.3–20.6	3.7–5.7	Wang et al. [121]
Pine	HDO	NM	Mild HDO	5	VGO	Pilot-scale	2 kg/h	2.5 h(Riser residence time ~1 s)	550	E-CAT	38.6	5.7	5.6	Lutz et al. [114]
Pine	HDO	NM	Severe HDO	5	VGO	Pilot-scale	2 kg/h	2.5 h (Riser residence time ~1 s)	550	E-CAT	41.5	6.8	5.6	Lutz et al. [114]
Pine	CFP	27.7	22	20	VGO	MAT	3.33 g/batch	188 s	482	E-CAT	19	17	10	Lindfors et al. [41]
Wheat straw	CFP	36.2	8.8	20	Atmospheric residue	MAT	0.75–1.2 g/batch	30 s	525	Residue FCC catalyst	43.2–46.8	13.3–17.6	8.8–16.2	Eschenbacher et al. [76]
Poplar wood	CFP	30.5	20–25	15	SRGO	ACE	1.5 g/batch	NM	538	E-CAT	44.4	17.2	6.8	Agblevor et al. [122]
Beech wood	CFP	NM	27	10	VGO	MAT	0.36–0.69 g/batch	60 s	500	E-CAT	55.7–58.0	14.8–19.9	4.1–6.0	Thegarid et al. [86]
Beech wood	CFP	NM	19.5	10	VGO	Pilot-scale	NM	NM	525	E-CAT	40.6–42.1	15.6–17.8	7.5–8.4	Wang et al. [121]

Tab.2 Research activities on co-processing biomass feedstock with petroleum feedstock via catalytic cracking

Fig.5 FCC catalysts in macro and micro perspectives.

Fig.6 Comparison of pore sizes of catalyst with kinetic diameters (based on atomic radii) of some oxygenated compounds and hydrocarbon molecules (adapted with permission from Ref. [126], copyright 2013, Elsevier).

Fig.8 Reaction pathways in HDN-HDO of DEDAD and rate constants k (mol/(100g_cat·h)) in reaction network at 270 °C and 5.0 MPa H₂ in absence (black numbers above the brackets) and presence (red numbers in the brackets) of 30 kPa H₂S (adapted with permission from Ref. [161], copyright 2022, Elsevier).

Fig.9 Reaction pathways (a) in HDO of dodecanoic acid; (b) in HDO of 4-propylphenol (b); (c) in HDS of dibenzothiophene; (d) in HDN of quinoline as well as rate constants k (mol/(100g_cat·h)) in reaction network at 270 °C and 5.0 MPa H₂ (adapted with permission from Ref. [161], copyright 2022, Elsevier).

Feedstock					Operation parameters for co-HDT						Results	Ref
Biomass				Petroleum	Reactor	T/°C	Pressure (MPa H₂)	H₂/oil ratio (NL/L)	LHSV/h^?1	Catalyst
Type	Process	Oxygen/ wt%	Ratio/%	Petroleum	Reactor	T/°C	Pressure (MPa H₂)	H₂/oil ratio (NL/L)	LHSV/h^?1	Catalyst
WCO	Extraction	NM	0, 5, 10, 15	LCO, SRGO	Continuous flow tubular down-flow reactor	320–380	3	420	1.0–3.0	CoMo/Al₂O₃	HDS efficiency decreased after blending WCO	Tóth et al. [151]
WCO	Extraction	11.95	0–30	Heavy atmospheric gas oil	Continuous flow tubular down-flow reactor	350	5.6	500	1.0	NiMo/Al₂O₃	Hydrogen consumption of co-HDT system is an important economical factor that need to be considered. The blending ratio of WCO below 10% is suggested since the hydrogen consumption only increased by 6.5%	Bezergianni et al. [152]
Pine woodchips	HTL	12	2, 10, 20	SRGO	Continuous fixed bed reactor	350	7	100 NmL/min	1.0 (WHSV)	NiMo/Al₂O₃	From a density perspective, the diesel obtained by co-HDT meets the specifications of road diesel	Sauvanaud et al. [162]
Woody biomass	HTL	10.6	5, 10, 15	VGO	Continuous pilot reactor	350, 360, 370 and 380	6.9	800	1.5	NiMo/Al₂O₃	Blending ratio and temperature had a significant effect on the HDS and HDN efficiency. A blending ratio below 10% and a temperature above 370 °C are recommended	Xing et al. [164]
Canola meal and wheat flour	HTL	NM	10	Heavy gas oil	Batch reactor	300	5	None	None	CoMo/Al₂O₃ and NiMo/Al₂O₃	Miscibility between bio-oil and crude oil is an important factor that should be considered for co-HDT	Borugadda et al. [172]
Canola meal and wheat flour	HTL	13.2	10	VGO	Batch reactor	375	9.7	None	1.6 (WHSV)	NiMo/Al₂O₃	HDS (69.7%) and HDN (41.2%) efficiencies were well under the HDS (90.0%) and HDN (84.4%) efficiencies of the pure VGO HDT	Badoga et al. [165]
Canola meal and wheat flour	HTL	3.5	10	VGO	Batch reactor	375	9.7	None	1.6 (WHSV)	NiMo/Al₂O₃	HDS (81.6%) and HDN (75.3%) efficiencies were slightly lower than that of the pure VGO HDT	Badoga et al. [165]
Hardwoods	FP	41.9	2.4	SRGO	Down-flow pilot-scale fixed-bed reactor	330	5	400	1.0	CoMo/Al₂O₃	HDS (97.1%) and HDN (90.6%) efficiencies were under the HDS (97.7%) and HDN (93.0%) efficiencies of the pure SRGO HDT	Pinheiro et al. [166]
Barley and wheat straw at 50 wt.% each	HDO	2.1	10, 20, 30	LCO	Continuous pilot reactor	320–390	7	500	1.0	CoMo/Al₂O₃	Continuous tests for up to 37 days were successfully conducted	Dimitriadis et al. [171]
Forest residue	HDO	31.0–38.9	30	SRGO	Trickle bed reactor	380	NM	NM	2.0	CoMo/Al₂O₃	Some cracking reaction existed during HDT	de Miguel Mercader et al. [116]

Tab.3 Research activities on co-processing biomass feedstock with petroleum feedstock in HDT processes

Fig.10 Schematic diagram of experimental unit used for HDT experiments (ORLEN UniCRE) (adapted from Ref. [179] under the terms of CC BY-NC-ND license).

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