Automotive e-Fuels via Hydrocracking of FT-Wax: e-Gasoline and e-Diesel Production

The main goal of this research is the production of e-fuels in gasoline- and diesel-range hydrocarbons via the hydrocracking of wax from Fischer–Tropsch (FT-wax) synthesis. The hydrogen for the hydrocracking process originated from solar energy via water electrolysis, thus, the produced fuels were called e-fuels. The FT-wax was produced via the Fischer–Tropsch synthesis of syngas stream from the chemical looping gasification (CLG) of biogenic residues. For the hydrocracking tests, a continuous-operation TRL3 (Technology Readiness Level) pilot plant was utilized. At first, hydrocracking catalyst screening was performed for the upgrading of the FT-wax. Three hydrocracking catalysts were investigated (Ni-W, Ni-W zeolite-supported, and Ni-W Al2O3-supported catalyst) via various operating conditions to identify the optimal operating window for each one. These three catalysts were selected, as they are typical catalysts that are used in the petroleum refinery industry. The optimal catalyst was found to be the NiW catalyst, as it led to high e-fuel yields (38 wt% e-gasoline and 47 wt% e-diesel) with an average hydrogen consumption. The optimum operating window was found at a 603 K reactor temperature, 8.3 MPa system pressure, 1 hr−1 LHSV, and 2500 scfb H2/oil ratio. In the next phase, the production of 5 L of hydrocracked wax was performed utilizing the optimum NiW catalyst and the optimal operating parameters. The liquid product was further fractionated to separate the fractions of e-gasoline, e-diesel, and e-heavy fuel. The e-gasoline and e-diesel fractions were qualitatively assessed, indicating that they fulfilled almost all EN 228 and EN 590 for petroleum-based gasoline and diesel, respectively. Furthermore, a 12-month storage study showed that the product can be stored for a period of 4 months in ambient conditions. In general, green transportation e-fuels with favorable properties that met most of the fossil fuels specifications were produced successfully from the hydrocracking of FT-wax.