LOW TEMPERATURE PRESSURLESS HYDROGENATION
Preamble
As we know, hydrogenation and gasification are competitors since long time in the fuel production. Many combinations are developed for the hydrogenation with hydrogen and the gasification with air, oxygen and steam. In spite of the higher efficiency of the hydrogenation the gasification was more used than the hydrogenation.
The reason for was the high pressure of more than 90 bar for the hydrogenation with hydrogen gas and Nickel catalyst.
After the gasification showed many problems with sticky particles, dioxins and furans the competition with the hydrogenation is again discussed.
Discoveries in hydrogenation
Not expected was discovered a new way in the hydrogenation. When hydrogen in the reaction is substituted with biomass, than the necessary pressure for the reaction can be reduced from 90 bars to less than normal pressure. For this process we do not need nickel as the catalyst, we can use the much cheaper minerals of the biomass in form of cation-aluminium-silicate. Also the reaction temperature drops down to less than 300°C.
We have to take into account for this reaction the other energy input in the reaction. This reaction is not possible by heating from outside. This reaction takes place only by friction, by heating in a mixing chamber called as a friction turbine. Nobody heated a reaction by friction before. Nobody tried to heat a chemical reaction with a friction turbine. Therefore nobody before Alphakat could find this soft hydrogenation system.
Under the special condition of:
- Energy input in form a mixing chamber, called friction turbine
- Catalyst in the circulation medium for the system in form of cation-aluminium-silicate in the range of 5 to 20 %
We have a destruction of the biomass into a fuel molecule on the example of cellulose (1) and sugar (2) in form of
1. C6H11O5 = 2,5 CO2 + (CH2)n (3,5) + H (4)
2. C6H12O6 = 3 CO2 + (CH2)n (3) + H (6)
This 4 or 6 hydrogen (in stadium nascenti) hydrogenates the input material by normal pressure or under pressure all hydrocarbons including olefins, like plastic, oil, rubber and bitumen, to alkanes and substitute the catalyst in the reaction mass with hydrogen to realize such a low temperature of less than 300°C. This is a pure chemical reaction and has nothing to do with thermal splitting, pyrolysis or thermal destruction. Therefore the product is chemical with high quality, has no smell of pyrolysis and contains no ammonium, dioxins, furans and light components. Nobody went this way of the nature. All the crude oil is produced like this by lower temperature (14-19°C) and much
longer reaction time.
To get to know this reaction was not easy, because all the prejudgments of the chemical engineering show in the other direction. Only the consequences to continue looking for a 100 % dioxin free process lead the scientific activity to this process. Finally we found this reaction in a special mixing system with molecule fine powder of the cation-aluminium-silicate with addition lime in the reaction to hold the pH-value higher than 8,5. Than we found an unlimited life time of the catalyst.
Hydrogenation Test using Biomass
We discovered the process and the chemical structure in a special test series. A costumer wants to test residues from sun flower residue in the conversion to fuel. We tested several times 5 kg input and got 15 l diesel for each test. Therefore it was demonstrated, that the hydrogen of 5 kg press residue from sun flowers can hydrogenate 15 l waste oil to saturated hydrocarbons in the boiling range of 260°C. This is diesel. With other words, the hydrogen production of 1 kg biomass hydrogenates 3-4 kg mineral residues to diesel. In the case of coal we need another relation of biomass to coal with more biomass.
What is the efficiency of the biomass in mixing with other hydrocarbons?
- Hydrogenation of the oil and plastic to alkanes and
- Substitution of the catalyst for the CO2-extraction and depolimerization with hydrogen to make the product vaporizable, this means the chemical product diesel is not longer covered from catalyst and can evaporate in the product line.
Use of Catalyst
The catalyst which allows this reaction can be added to the process in the following way:
- We add cation-aluminium-silicate produced in the silicate ion of sodium-aluminate or
- We use biomass + lime for the production of diesel fuel and the ash is our catalyst we need for the industrial and municipal waste.
This molecule fine catalyst allows a new catalytic system:
- Not stored in a vessel in form of pellets or honeycomb,
- The catalyst is fine suspended in the circulation oil and goes to the input of Hydrocarbon to make the CO2-extraction and the depolimerization.
This is a new system with the opposite catalytic reaction, the catalyst coming to the input and not the reaction mass going to the catalyst. This is supported by the high friction in the friction turbine. This system of chemical conversion makes the high product quality of saturated hydrocarbons.
This is new and no other production system in the chemical industry uses the friction turbine for heating and reaction and uses the tanks only for the separation.
Technique improvements
In other words, up to now, on no other place of the technique of chemical plants is used the friction to heat and make the process. This is new in the technique and leads the fuel production in the direction of cheap catalytic hydrogenation with biomass and the minerals of the biomass as the catalyst.
When we compare the level of investment in the old processes with the new low pressure process with
- 90 bar hydrogen Nickel catalyst, higher temperature with heating from outside or
- under pressure, biomass as carrier for the hydrogen and heating with the friction turbine
we can realize that the low pressure hydrogenation with biomass is much cheaper than all the old processes of gasification, pyrolysis and high pressure hydrogenation with hydrogen gas.
The KDV process
This can be applied in the production of fuel, because the KDV-system is complete environmental friendly and the cheaper way to the hydrogenation. The efficiency is regarding to the low reaction temperature very high in the range of 70 - 91 %. All the dangerous materials, like chlorine, flour and molecule fine metals are absorbed by the lime with the high pH-value and the crystalline catalyst.
The hydrogen content of the biomass is about 20 %. This is going in the way of the hydrogenation and in the case of pure biomass in the way to the production water. This hydrogen is consumed in the mixing with technical production more for coal, transformer oil, PVC, Teflon, rubber, bitumen and refinery residue and less for plastic, waste oil and polymers like PE and PP.
All material, you can burn, you also can convert to diesel in the KDV
In summary we get the following results with the low hydrogenation process KDV:
- As long we have in the mixture enough biomass we get a unique product diesel with saturated hydrocarbons
- We do not need pressure
- The catalyst is coming from the biomass or synthetic from Alphakat and Partners
- We do not get any emission from the plant
- We use the vacuum system for inherent safety
- We do not form any poison hydrocarbons like Dioxins and Furans.
The KDV is therefore environmental friendly and has the highest efficiency from all known processes. |
