Single-Step Process for Production of Branched, Cyclic, Aromatic, and Cracked Hydrocarbons from Fatty Acids

Abstract

A catalytic process is provided which produces in a single reaction branched, cyclic and aromatic hydrocarbons, or cracked straight-chain hydrocarbons, from fatty acids in which the fatty acids are reacted over a multifunctional catalyst and undergo both decarboxylation and a further transformation (isomerization, cyclization, aromatization, or cracking) to form reaction products useful as fuels and for other applications that require a source of energy, or as feedstock for hydrocarbon-based commercial products such as surfactants, solvents and lubricants.

What is claimed is: 
     
         1 . A process for a catalytic reaction for the production of hydrocarbons from at least one fatty acid forming hydrocarbon reaction products, comprising the steps of:
 contacting fatty acids reactants with a. supported catalyst, the catalyst comprising a. metal component over a support, the metal being chosen from the group platinum, palladium and nickel, the support being chosen from the group alumina, silicoalumina, aluminosilicate zeolite, and silicoaltiminophosphate, and mixtures thereof; and   isolating hydrocarbon reaction products;   wherein the metal comprises about 3% -5% by weight of the catalyst, and the surface area of the support is about 50 m 2 /g-480 m 2 /g.   
     
     
         2 . The process of  claim 1 , wherein decarboxylation and cracking both occur during the catalytic reaction to yield at least one reaction product having a carbon chain shorter by at least three carbons than the fatty acid from which it was derived, 
     
     
         3 . The process of  claim 1 , wherein decarboxylation and conversion both occur during the catalytic reaction to yield at least one branched reaction product, 
     
     
         4 . The process of  claim 1 , wherein decarboxylation and conversion both occur during the catalytic reaction to yield at least one cyclic reaction product, 
     
     
         5 . The process of  claim 1 , wherein at least one fatty acid is unsaturated, and decarboxylation and conversion both occur during the catalytic reaction to yield at least one aromatic reaction product. 
     
     
         6 . The process of  claim 1 , carried out at a reaction temperature between about 200° C. and about 325° C. 
     
     
         7 . The process of  claim 1 , carried out at a reaction temperature no greater than about 350° C. 
     
     
         8 . The process of  claim 1 , wherein the silicoaluminophosphate is SAPO-11, and the aluminosilicate zeolite is chosen from the group zeolite Y, mordenite, zeolite beta and MCM-22. 
     
     
         9 . The process of  claim 1 , wherein at least about 72.0% of fatty acids are converted to hydrocarbon reaction products. 
     
     
         10 . The process of  claim 1 , wherein the at least one fatty acid is obtained from a renewable source chosen from the group plant oils; animal fats, animal oils; algae oils; waste vegetable oils; and oils from heterotrophic microbes, and mixtures thereof 
     
     
         11 . The process of  claim 10 , wherein the heterotrophic microbe is chosen from the group heterotrophic algae and oleaginous yeast. 
     
     
         12 . The process of  claim 10 , wherein the plant oil is chosen from the group jatropha oil, camelina oil, pennycress oil, pongamia oil, and carinata oil, and mixtures thereof. 
     
     
         13 . A process for generating a feedstock for the manufacture of at least one commercial product, comprising the steps of:
 contacting fatty acids reactants with a supported catalyst, the catalyst comprising a metal component over a support, the metal being chosen from the group platinum, palladium and nickel, the support being chosen from the group alumina, silicoalumina, aluminosilicate zeolite, and silicoaluminophosphate, and mixtures thereof; and   isolating hydrocarbon reaction products,   wherein the metal comprises about 3% -5% by weight of the catalyst, and the surface area of the support is about 50 m 2 /g-480 m 2 /g; and   wherein decarboxylation and conversion both occur during the catalytic reaction to yield at least one reaction product chosen from the group branched hydrocarbon reaction product, cyclic hydrocarbon reaction product, and aromatic hydrocarbon reaction product.   
     
     
         14 . The process of  claim 13 , wherein the at least one commercial product is chosen from the group: (i) gasoline having an octane rating greater than about 85; (ii) aviation fuel meeting the standard set forth in ASTM D1655; (iii) cleaning fluid having a flash point above about 140° F. and VOC Content less than about 25 grains/liter; (iv) AOS detergent having between 9 and 18 carbons; (v) LAB detergent having between 9 and 18 carbons; (vi) lubricant; (vii) surfactant; and (viii) solvent. 
     
     
         15 . A process for generating a feedstock for the manufacture of at least one commercial product chosen from the group diesel fuel, aviation fuel, solvents, and cleaning fluids, comprising the steps of:
 contacting fatty acids reactants with a supported catalyst, the catalyst comprising a metal component over a support, the metal being chosen from the group platinum, palladium and nickel, the support being chosen from the group alumina, silicoalumina, aluminosilicate zeolite, and silicoaluminophosphate, and mixtures thereof; and   isolating hydrocarbon reaction products,   wherein the metal comprises about 3% -5% by weight of the catalyst, and the surface area of the support is about 50 m 2 /g-480 m 2 /g; and   wherein decarboxylation and cracking both occur during the catalytic reaction to yield at least one reaction product having a carbon chain shorter by at least three carbons than the fatty acid from which it was derived.