The_Catalyst_Review_February_2024 - 6

SPECIAL FEATURE
Naphtha-to-Olefins
Conversion
Maximum Propylene with Ultralow GHG Emissions
By Ray Fletcher
Inovacat™ has developed a catalytic-driven naphtha-to-olefins technology -
Gasolfin™ - which converts conventional and bio-derived naphthas into light
olefins (ethylene, propylene, and butylene). Propylene selectivities are up to 46 wt%
depending upon feedstock composition. The Gasolfin process also reduces CO2
emissions by 50% or more when compared with polymer-grade propylene produced
from the fluid catalytic cracking (FCC) and propane dehydrogenation (PDH) processes.
The Gasolfin catalyst converts naphtha boiling range hydrocarbons - excluding
aromatics - from butane through undecane (C4
- C11
pentane, recognized as the lowest valued and most refractive of gasoline
components.
). The catalyst also converts
The definition of highly valued
chemical (HVC) for Gasolfin is the
sum of ethylene, propylene and
butylene. HVC for PDH and FCC
is propylene and ethylene for
steam cracking.
InovaCat's technology is based upon a novel catalyst system protected by multiple patents. This technology has been in development since
2017 and has successfully passed both bench and pilot plant scale testing.
Inovacat is currently in collaboration with an Asian refiner to build and operate an 800 liter/day demonstration plant. This plant is expected to
go into construction in mid-2024 and to be in production in late-2025. Inovacat anticipates having the technology ready for deployment in
2027.
A Novel Process
What makes the Gasolfin™ process special?
* Light-ends Conversion Process. Gasolfin is the first-ever catalytic light ends conversion process capable of converting low molecular
weight paraffins, such as pentane, into high-value ethylene, propylene, and butylene.
* Conversion of Conventional and Bio-derived Naphthas. Gasolfin converts fossil-derived and bio-derived naphthas into, respectively,
light olefins and light bio-olefins. Gasolfin is a competitive transition technology for today's refineries and for future anticipated
renewable fuels and chemicals refineries.
* Gasolfin Produces Light Olefin with 50-66% Lower CO2
ethylene at 1.231 tCO2
low 0.45 tons CO2/ton Olefin ratio. An FCC unit produces propylene at 0.783-0.869 tCO2
/tOlefin.
Emissions. Gasolfin produces polymer-grade propylene and ethylene at a very
/tOlefin, while a steam cracker produces
* Gasolfin Improves the Flexibility of the Fuels-based Refinery and the Steam Cracker-based Chemical Plant. Gasolfin converts any
naphtha regardless of the source (crude unit, hydrotreater, coker, etc.) and petrochemical plant intermediate and by-product streams.
* Gasolfin Enables Reduced Severity in Other Catalytic Operations. Depending upon crude slate, a refiner employing a Gasolfin unit to
convert light straight run (LSR) naphtha will observe up to a 1.5 research octane number (RON) octane increase by elimination of this
stream into the gasoline pool.
Ultralow CO2
Emissions
The Gasolfin process sets a new benchmark for the industry with respect to producing light olefin with significantly lower CO2
than the three leading propylene producing technologies: FCC, steam cracking, and PDH. See Chart 1.
Gasolfin produces 0.45 tons of CO2
for every ton of total olefin produced, annotated as " tCO2
emissions
/tHVC, " where tHVC abbreviates " ton
highly valued chemical. " This excellent metric enables a side-by-side comparison of an FCC and a steam cracker.
6
The Catalyst Review
February 2024

The_Catalyst_Review_February_2024

Table of Contents for the Digital Edition of The_Catalyst_Review_February_2024