Zeolitic catalytic conversion of alcohols to hydrocarbons
Inventors
Narula, Chaitanya K. • Davison, Brian H. • Keller, Martin
Assignees
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Publication Number
US-12384973-B2
Publication Date
2025-08-12
Expiration Date
Abstract
A method for converting an alcohol to a hydrocarbon, the method comprising contacting said alcohol with a metal-loaded zeolite catalyst at a temperature of at least 100° C. and up to 550° C., wherein said alcohol can be produced by a fermentation process, said metal is a positively-charged metal ion, and said metal-loaded zeolite catalyst is catalytically active for converting said alcohol to said hydrocarbon.
Core Innovation
The invention relates to converting ethanol to a mixture of hydrocarbon compounds useful as a fuel or as a blendstock component of a fuel, including gasoline, kerosene, diesel, and jet propellant. The system includes a source of a feedstock comprising ethanol in an aqueous solution at a concentration of no more than about 20% (vol/vol), a boiler unit that volatilizes the feedstock, and a reactor unit that directly converts the ethanol to a mixture of hydrocarbons.
Direct converting is carried out in a reactor unit configured to house a catalyst that catalytically converts ethanol to a fuel-range hydrocarbon mixture. The catalyst consists of a zeolite loaded with at least one positively-charged metal ion selected from alkali metal ion, alkaline earth metal ion, lanthanide metal ion, copper ion, zinc ion, titanium ion, vanadium ion, cadmium ion, gallium ion, and indium ion.
The described system supports converting dilute aqueous ethanol, including alcohol streams derived from fermentation, without purification or concentration. The provided catalyst embodiments specify pentasil zeolites such as ZSM-5 loaded with metal ions, including Cu-ZSM-5, Fe-ZSM-5, CuFe-ZSM-5, and V-ZSM-5, and the resulting mixture substantially corresponds to a fuel selected from gasoline, kerosene, diesel, and jet propellant.
Claims Coverage
The independent claim covers a complete ethanol-to-fuel conversion system with volatilization of an aqueous ethanol feed of no more than about 20% vol/vol and direct conversion in a reactor using a zeolite loaded with selected positively-charged metal ions. Dependent claims refine the zeolite framework, narrow the metal-ion set, further narrow reactor configuration, and define feedstock generation by fermentation including biomass lignocellulosic matter.
Dilute aqueous ethanol feed converted to fuel-range hydrocarbons
A system for converting ethanol to a mixture of hydrocarbon compounds useful as a fuel or as a blendstock component of a fuel, wherein the ethanol is in an aqueous solution at a concentration of no more than about 20% (vol/vol), and wherein the mixture of hydrocarbon compounds substantially corresponds to a fuel selected from gasoline, kerosene, diesel, and jet propellant.
Boiler volatilizing the aqueous ethanol feed and reactor direct conversion
A boiler unit in fluidic communication with the source of the feedstock and configured to volatilize the feedstock, and a reactor unit in fluidic communication with the boiler unit and configured to house a catalyst catalytically active for directly converting the ethanol to a mixture of hydrocarbons.
Zeolite catalyst loaded with selected positively-charged metal ions
A catalyst consisting of a zeolite loaded with at least one positively-charged metal ion selected from alkali metal ion, alkaline earth metal ion, lanthanide metal ion, copper ion, zinc ion, titanium ion, vanadium ion, cadmium ion, gallium ion, and indium ion.
Pentasil zeolite comprising ZSM5
The pentasil zeolite comprises ZSM5.
Copper and vanadium metal-ion selection
The at least one positively charged metal ion is selected from copper and vanadium.
Ethanol produced by fermentation process
The ethanol is produced by a fermentation process.
Biomass comprising lignocellulosic matter
The biomass comprises lignocellulosic matter.
Single reactor unit
The reactor unit is a single reactor unit.
Across the independent and dependent claims, coverage centers on direct conversion of dilute aqueous ethanol to a fuel-range hydrocarbon mixture using a zeolite catalyst loaded with selected positively-charged metal ions. The dependent claims further narrow the zeolite framework, narrow metal-ion selections, limit configuration to a single reactor unit, and define ethanol provenance via fermentation including lignocellulosic biomass.
Stated Advantages
Converts an aqueous ethanol feed at a concentration of no more than about 20% (vol/vol) into a mixture of hydrocarbon compounds that substantially corresponds to fuels selected from gasoline, kerosene, diesel, and jet propellant.
Enables fuel-blend stock component production from ethanol via direct conversion using a zeolite loaded with selected positively-charged metal ions.
Documented Applications
Use of the produced hydrocarbon mixture as a fuel or as a blendstock component of a fuel selected from gasoline, kerosene, diesel, and jet propellant.
Integration with a fermentation process to generate ethanol for conversion.
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