Single-step catalytic processes 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 further conversion(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 conducting a single 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 platinum metal component over a support, the support being chosen from the group SAPO-34, SAPO-11, DNL-6, RHO, and hydrotalcite, and mixtures thereof; and   isolating hydrocarbon reaction products;   wherein the metal comprises about 1% to about 10% by weight of the catalyst, and the surface area of the support is between about 50 m 2 /g and about 490 m 2 /g.   
     
     
         2 . The process of  claim 1 , wherein the metal comprises about 3% to about 5% by weight of the catalyst. 
     
     
         3 . 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. 
     
     
         4 . The process of  claim 1 , wherein decarboxylation and conversion both occur during the catalytic reaction to yield at least one branched reaction product. 
     
     
         5 . The process of  claim 1 , wherein decarboxylation and conversion both occur during the catalytic reaction to yield at least one cyclic reaction product. 
     
     
         6 . The process of  claim 2 , 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. 
     
     
         7 . The process of  claim 1 , carried out at a reaction temperature between about 200° C. and about 450° C. 
     
     
         8 . The process of  claim 7 , carried out at a reaction temperature no greater than about 325° C. 
     
     
         9 . The process of  claim 1 , wherein the at least one fatty acid has between about 7 and 24 carbons. 
     
     
         10 . The process of  claim 2 , wherein at least about 80% of fatty acids are converted to hydrocarbon reaction products. 
     
     
         11 . The process of  claim 2 , wherein at least about 95% of fatty acids are converted to hydrocarbon reaction products. 
     
     
         12 . 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. 
     
     
         13 . The process of  claim 12 , wherein the plant oil is chosen from the group jatropha oil, camelina oil, pennycress oil, pongamia oil, and carinata oil, and mixtures thereof. 
     
     
         14 . A process for generating a feedstock, comprising the steps of:
 contacting fatty acids reactants with a supported catalyst, the catalyst comprising a platinum metal component over a support, the support being chosen from the group SAPO-34, SAPO-11, DNL-6, RHO, and hydrotalcite, and mixtures thereof; and   isolating hydrocarbon reaction products,   wherein the metal comprises about 1% to about 10% by weight of the catalyst, and the surface area of the support is between about 50 m 2 /g and about 490 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.   
     
     
         15 . The process of  claim 14 , wherein the metal comprises about 3% to about 5% by weight of the catalyst. 
     
     
         16 . The process of  claim 15 , wherein the feedstock is suitable for the manufacture of at least one commercial product, and the at least one commercial product is chosen from the group: gasoline having an octane rating greater than about 85; aviation fuel meeting the standard set forth in ASTM D1655; cleaning fluid having a flash point above about 140° F. and VOC Content<25 grams/liter; AOS detergent having between 9 and 18 carbons; and LAB detergent having between 9 and 18 carbons; lubricant; surfactant, and solvent.