On-line analysis of complex hydrocarbon mixtures using comprehensive two-dimensional gas chromatography

The merit of pressure dependent kinetic modelling in steam cracking

Renewable cracking feedstocks from plastic waste and the need for novel reactor designs related to electrification of steam crackers drives the development of accurate and fundamental kinetic models for this process, despite its large scale implementation for more than half a century. Pressure dependent kinetics have mostly been omitted in fundamental steam cracking models, while they are crucial in combustion models. Therefore, we have assessed the importance of pressure dependent kinetics for steam cracking via in-depth modelling and experimental studies. In particular we have studied the influence of considering fall-off on the product yields for ethane and propane steam cracking. A high-pressure limit fundamental kinetic model is generated, based on quantum chemical data and group additive values, and supplemented with literature values for pressure dependent kinetic parameters for β-scission reactions and homolytic bond scissions of C₂ and C₃ species. Model simulations with high-pressure limit rate coefficients and pressure dependent kinetics are compared to new experimental measurements. Steam cracking experiments for pure ethane and propane feeds are performed on a tubular bench-scale reactor at 0.17 MPa and temperatures ranging from 1058 to 1178 K. All important product species are identified using a comprehensive GC × GC-FID/q-MS. For homolytic bond scissions, the inclusion of pressure dependent kinetics has a significant effect on the conversion profile for ethane steam cracking. On the other hand, pressure dependence of C₂ β-scissions significantly influences conversion and product species profiles for both ethane and propane steam cracking. The C₃ β-scissions pressure dependence has a negligible effect in ethane steam cracking, while for propane steam cracking the effect is non-negligible on the product species profiles.

Maximizing olefin production via steam cracking of distilled pyrolysis oils from difficult-to-recycle municipal plastic waste and marine litter

Plastic waste is steadily polluting oceans and environments. Even if collected, most waste is still predominantly incinerated for energy recovery at the cost of CO₂. Chemical recycling can contribute to the transition towards a circular economy with pyrolysis combined with steam cracking being the favored recycling option for the time being. However, today, the high variety and contamination of real waste remains the biggest challenge. This is especially relevant for waste fractions which are difficult or even impossible to recycle mechanically such as highly mixed municipal plastic waste or marine litter. In this work, we studied the detailed composition and the steam cracking performance of distilled pyrolysis oil fractions in the naphtha-range of two highly relevant waste fractions: mixed municipal plastic waste (MPW) considered unsuitable for mechanical recycling and marine litter (ML) collected from the sea bottom. Advanced analytical techniques including comprehensive two-dimensional gas chromatography (GC × GC) coupled with various detectors and inductively coupled plasma - mass spectrometry (ICP-MS) were applied to characterize the feedstocks and to understand how their properties affect the steam cracking performance. Both waste-derived naphtha fractions were rich in olefins and aromatics (~70% in MPW naphtha and ~51% in ML naphtha) next to traces of nitrogen, oxygen, chlorine and metals. ICP-MS analyses showed that sodium, potassium, silicon and iron were the most crucial metals that should be removed in further upgrading steps. Steam cracking of the waste-derived naphtha fractions resulted in lower light olefin yields compared to fossil naphtha used as benchmark, due to secondary reactions of aromatics and olefins. Coke formation of ML naphtha was slightly increased compared to fossil naphtha (+ ~50%), while that of MPW naphtha was more than ~180% higher. It was concluded that mild upgrading of the waste-derived naphtha fractions or dilution with fossil feedstocks is sufficient to provide feedstocks suitable for industrial steam cracking.

Assessing the feasibility of chemical recycling via steam cracking of untreated plastic waste pyrolysis oils: Feedstock impurities, product yields and coke formation

Chemical recycling of plastic waste to base chemicals via pyrolysis and subsequent steam cracking of pyrolysis oils shows great potential to overcome the limitations in present means of plastic waste recycling. In this scenario, the largest concern is the feasibility. Are plastic waste pyrolysis products acceptable steam cracking feedstocks in terms of composition, product yields and coke formation? In this work, steam cracking of two post-consumer plastic waste pyrolysis oils blended with fossil naphtha was performed in a continuous bench-scale unit without prior treatment. Product yields and radiant coil coke formation were benchmarked to fossil naphtha as an industrial feedstock. Additionally, the plastic waste pyrolysis oils were thoroughly characterized. Analyses included two dimensional gas chromatography coupled to a flame ionization detector for the detailed hydrocarbon composition as well as specific analyses for heteroatoms, halogens and metals. It was found that both pyrolysis oils are rich in olefins (∼48 wt%) and that the main impurities are nitrogen, oxygen, chlorine, bromine, aluminum, calcium and sodium. Steam cracking of the plastic waste derived feedstocks led to ethylene yields of ∼23 wt% at a coil outlet temperature of 820 °C and ∼28 wt% at 850 °C, exceeding the ethylene yield of pure naphtha at both conditions (∼22 wt% and ∼27 wt%, respectively). High amounts of heavy products were formed when steam cracking both pyrolysis oils, respectively. Furthermore, a substantial coking tendency was observed for the more contaminated pyrolysis oil, indicating that next to unsaturated hydrocarbons, contaminants are a strong driver for coke formation.

Opportunities and challenges for the application of post-consumer plastic waste pyrolysis oils as steam cracker feedstocks: To decontaminate or not to decontaminate?

Thermochemical recycling of plastic waste to base chemicals via pyrolysis followed by a minimal amount of upgrading and steam cracking is expected to be the dominant chemical recycling technology in the coming decade. However, there are substantial safety and operational risks when using plastic waste pyrolysis oils instead of conventional fossil-based feedstocks. This is due to the fact that plastic waste pyrolysis oils contain a vast amount of contaminants which are the main drivers for corrosion, fouling and downstream catalyst poisoning in industrial steam cracking plants. Contaminants are therefore crucial to evaluate the steam cracking feasibility of these alternative feedstocks. Indeed, current plastic waste pyrolysis oils exceed typical feedstock specifications for numerous known contaminants, e.g. nitrogen (∼1650 vs. 100 ppm max.), oxygen (∼1250 vs. 100 ppm max.), chlorine (∼1460vs. 3 ppm max.), iron (∼33 vs. 0.001 ppm max.), sodium (∼0.8 vs. 0.125 ppm max.)and calcium (∼17vs. 0.5 ppm max.). Pyrolysis oils produced from post-consumer plastic waste can only meet the current specifications set for industrial steam cracker feedstocks if they are upgraded, with hydrogen based technologies being the most effective, in combination with an effective pre-treatment of the plastic waste such as dehalogenation. Moreover, steam crackers are reliant on a stable and predictable feedstock quality and quantity representing a challenge with plastic waste being largely influenced by consumer behavior, seasonal changes and local sorting efficiencies. Nevertheless, with standardization of sorting plants this is expected to become less problematic in the coming decade.

Detailed Group-Type Characterization of Plastic-Waste Pyrolysis Oils: By Comprehensive Two-Dimensional Gas Chromatography Including Linear, Branched, and Di-Olefins

Plastic-waste pyrolysis oils contain large amounts of linear, branched, and di-olefinic compounds. This makes it not obvious to determine the detailed group-type composition in particular to the presence of substantial amounts of N-, S-, and O-containing heteroatomic compounds. The thorough evaluation of different column combinations for two-dimensional gas chromatography (GC × GC), i.e., non-polar × polar and polar × non-polar, revealed that the second combination had the best performance, as indicated by the bi-dimensional resolution of the selected key compounds. By coupling the GC × GC to multiple detectors, such as the flame ionization detector (FID), a sulfur chemiluminescence detector (SCD), a nitrogen chemiluminescence detector (NCD), and a mass spectrometer (MS), the identification and quantification were possible of hydrocarbon, oxygen-, sulfur-, and nitrogen-containing compounds in both naphtha (C5–C11) and diesel fractions (C7–C23) originating from plastic-waste pyrolysis oils. Group-type quantification showed that large amounts of α-olefins (36.39 wt%, 35.08 wt%), iso-olefins (8.77 wt%, 9.06 wt%), and diolefins (4.21 wt%, 4.20 wt%) were present. Furthermore, oxygen-containing compounds (alcohols, ketones, and ethers) could be distinguished from abundant hydrocarbon matrix, by employing Stabilwax as the first column and Rxi-5ms as the second column. Ppm levels of sulfides, thiophenes, and pyridines could also be quantified by the use of selective SCD and NCD detectors.

The Effect of Refractory Wall Emissivity on the Energy Efficiency of a Gas-Fired Steam Cracking Pilot Unit

The effect of high emissivity coatings on the radiative heat transfer in steam cracking furnaces is far from understood. To start, there is a lack of experimental data describing the emissive properties of the materials encountered in steam cracking furnaces. Therefore, spectral normal emissivity measurements are carried out, evaluating the emissive properties of refractory firebricks before and after applying a high emissivity coating at elevated temperatures. The emissive properties are enhanced significantly after applying a high emissivity coating. Pilot unit steam cracking experiments show a 5% reduction in fuel gas firing rate after applying a high emissivity coating on the refractory of the cracking cells. A parametric study, showing the effect of reactor coil and furnace wall emissive properties on the radiative heat transfer inside a tube-in-box geometry, confirms that a non-gray gas model is required to accurately model the behavior of high emissivity coatings. Even though a gray gas model suffices to capture the heat sink behavior of a reactor coil, a non-gray gas model that is able to account for the absorption and re-emission in specific bands is necessary to accurately model the benefits of applying a high emissivity coating on the furnace wall.

Odorant Monitoring in Natural Gas Pipelines Using Ultraviolet-Visible Spectroscopy

The remote, timely and in-field detection of sulfured additives in natural gas pipelines is a challenge for environmental, commercial and safety reasons. Moreover, the constant control of the level of odorants in a pipeline is required by law to prevent explosions and accidents. Currently, the detection of the most common odorants (THT = tetrahydrothiophane; TBM = tertiary butyl mercaptan) added to natural gas streams in pipelines is made in situ by using portable gas chromatography apparatuses. In this study, we report the analysis of the ultraviolet spectra obtained by a customized ultraviolet spectrophotometer, named Spectra, for the in-field detection of thiophane and tertiary butyl mercaptan. Spectra were conceived to accomplish the remote analysis of odorants in the pipelines of the natural gas stream through the adoption of technical solutions aimed to adapt a basic bench ultraviolet spectrophotometer to the in-field analysis of gases. The remotely controlled system acquires spectra continuously, performing the quantitative determination of odorants and catching systemic or accidental variations of the gaseous mixture in different sites of the pipeline. The analysis of the experimental spectra was carried out also through theoretical quantum mechanical approaches aimed to detect and to correctly assign the nature of the intrinsic electronic transitions of the two odorants, thiophane and tertiary butyl mercaptan, that cause the ultraviolet absorptions. So far, these theoretical aspects have never been studied before. The absorption maxima of thiophane and tertiary butyl mercaptan spectra were computationally simulated through the usage of selected molecular models with satisfactory results. The good matches between the experimental and theoretical datasets corroborate the reliability of the collected data. During the tests, unexpected pollutants and accidental malfunctions have been detected and also identified by Spectra, making this instrument suitable for many purposes.

Combustion in the future: The importance of chemistry

Combustion involves chemical reactions that are often highly exothermic. Combustion systems utilize the energy of chemical compounds released during this reactive process for transportation, to generate electric power, or to provide heat for various applications. Chemistry and combustion are interlinked in several ways. The outcome of a combustion process in terms of its energy and material balance, regarding the delivery of useful work as well as the generation of harmful emissions, depends sensitively on the molecular nature of the respective fuel. The design of efficient, low-emission combustion processes in compliance with air quality and climate goals suggests a closer inspection of the molecular properties and reactions of conventional, bio-derived, and synthetic fuels. Information about flammability, reaction intensity, and potentially hazardous combustion by-products is important also for safety considerations. Moreover, some of the compounds that serve as fuels can assume important roles in chemical energy storage and conversion. Combustion processes can furthermore be used to synthesize materials with attractive properties. A systematic understanding of the combustion behavior thus demands chemical knowledge. Desirable information includes properties of the thermodynamic states before and after the combustion reactions and relevant details about the dynamic processes that occur during the reactive transformations from the fuel and oxidizer to the products under the given boundary conditions. Combustion systems can be described, tailored, and improved by taking chemical knowledge into account. Combining theory, experiment, model development, simulation, and a systematic analysis of uncertainties enables qualitative or even quantitative predictions for many combustion situations of practical relevance. This article can highlight only a few of the numerous investigations on chemical processes for combustion and combustion-related science and applications, with a main focus on gas-phase reaction systems. It attempts to provide a snapshot of recent progress and a guide to exciting opportunities that drive such research beyond fossil combustion.

Symoens S, Olahova N, Reyniers MF, B. Marin G, M. Van Geem K. Alumina-based Coating for Coke Reduction in Steam Crackers

Alumina-based coatings have been claimed as being an advantageous modification in industrial ethylene furnaces. In this work, on-line experimentally measured coking rates of a commercial coating (CoatAlloy™) have pointed out its superiority compared to an uncoated reference material in an electrobalance set-up. Additionally, the effects of presulfiding with 500 ppmw DMDS per H₂O, continuous addition of 41 ppmw S per HC of DMDS, and a combination thereof were evaluated during ethane steam cracking under industrially relevant conditions (T_gasphase = 1173 K, P_tot = 0.1 MPa, X_C2H6 = 70%, dilution δ = 0.33 kg_H2O/kg_HC). The examined samples were further evaluated using online thermogravimetry, scanning electron microscopy and energy diffractive X-ray for surface and cross-section analysis together with X-ray photoelectron spectroscopy and wavelength-dispersive X-ray spectroscopy for surface analysis. The passivating coating illustrated a better performance than the reference Ni-Cr Fe-base alloy after application of an improved pretreatment, followed by piddling changes on the product distribution. Presulfiding of the coating affected negatively the observed coking rates in comparison with the reference alloy, so alternative presulfiding and sulfur addition strategies are recommended when using this barrier coating.

Compositional Analysis of Heavy Petroleum Distillates by Comprehensive Two-dimensional Gas Chromatography, Field Ionization and High-resolution Mass Spectrometry

We report recent progresses of combining comprehensive two-dimensional gas chromatography (2DGC or GC × GC) separation, field ionization (FI), and time-of-flight mass spectrometry (TOF MS) for the detailed analysis of vacuum gas oil distillation (VGO) cuts. 2DGC separates petroleum molecules by the combination of boiling point and polarity. FI generates molecule ions-only mass spectra. TOF MS allows accurate mass analysis of hydrocarbon molecules. A new data analysis strategy is implemented for compositional analysis. First, all masses were separated into nominal mass classes. Since petroleum homologues have unique Kendrick mass defects (KMD), KMD plots were generated for easy recognition of homologues series within each nominal mass class. Finally, KMD windows were imposed for complete resolution of petroleum molecules. Using this approach, a total of 16 hydrocarbon types, 14 sulfur types, and their carbon number distributions were determined in the three VGO distillation cuts. Two series of geological biomarkers were also revealed by the analysis.

Uniformity and Sensitivity Improvements in Comprehensive Two-Dimensional Gas Chromatography Using Flame Ionization Detection with Post-Column Reaction

A 3D-printed microreactor for post-column reactions was successfully integrated with comprehensive two -dimensional  gas chromatography. A two-stage post-column reaction provided a carbon-independent response, enhanced the flame ionization detection uniformity, and improved the detector sensitivity. These enhancements are critical to overcome challenges in analyses using comprehensive two-dimensional gas chromatography and flame ionization detection, which aim to separate and quantify multiple components. Post-column reaction flame ionization detection eliminated the requirement of multilevel and multicompound calibration, it enabled the determination of target analytes with a single-carbon-containing calibration compound with an accuracy of ±10%, and it improved the sensitivity for compounds that were not efficiently ionized by flame ionization detection. Extra column band-broadening caused by the incorporation of the 3D-printed microreactor was minimized using optimized reactor operating parameters and intercolumn connectivity. Chromatographic fidelity was in the practical domain of comprehensive 2D gas chromatography. Typical peak widths at half-height using the described approach ranged from 165 to 235 ms for probe compounds with retention factors spanning 5 < k < 40.

Inverse Opal Photonic Crystals as an Optofluidic Platform for Fast Analysis of Hydrocarbon Mixtures

Most of the reported optofluidic devices analyze liquid by measuring its refractive index. Recently, the wettability of liquid on various substrates has also been used as a key sensing parameter in optofluidic sensors. However, the above-mentioned techniques face challenges in the analysis of the relative concentration of components in an alkane hydrocarbon mixture, as both refractive indices and wettabilities of alkane hydrocarbons are very close. Here, we propose to apply volatility of liquid as the key sensing parameter, correlate it to the optical property of liquid inside inverse opal photonic crystals, and construct powerful optofluidic sensors for alkane hydrocarbon identification and analysis. We have demonstrated that via evaporation of hydrocarbons inside the periodic structure of inverse opal photonic crystals and observation of their reflection spectra, an inverse opal film could be used as a fast-response optofluidic sensor to accurately differentiate pure hydrocarbon liquids and relative concentrations of their binary and ternary mixtures in tens of seconds. In these 3D photonic crystals, pure chemicals with different volatilities would have different evaporation rates and can be easily identified via the total drying time. For multicomponent mixtures, the same strategy is applied to determine the relative concentration of each component simply by measuring drying time under different temperatures. Using this optofluidic sensing platform, we have determined the relative concentrations of ternary hydrocarbon mixtures with the difference of only one carbon between alkane hydrocarbons, which is a big step toward detailed hydrocarbon analysis for practical use.

On-line Analysis of Nitrogen Containing Compounds in Complex Hydrocarbon Matrixes

The shift to heavy crude oils and the use of alternative fossil resources such as shale oil are a challenge for the petrochemical industry. The composition of heavy crude oils and shale oils varies substantially depending on the origin of the mixture. In particular they contain an increased amount of nitrogen containing compounds compared to the conventionally used sweet crude oils. As nitrogen compounds have an influence on the operation of thermal processes occurring in coker units and steam crackers, and as some species are considered as environmentally hazardous, a detailed analysis of the reactions involving nitrogen containing compounds under pyrolysis conditions provides valuable information. Therefore a novel method has been developed and validated with a feedstock containing a high nitrogen content, i.e., a shale oil. First, the feed was characterized offline by comprehensive two-dimensional gas chromatography (GC × GC) coupled with a nitrogen chemiluminescence detector (NCD). In a second step the on-line analysis method was developed and tested on a steam cracking pilot plant by feeding pyridine dissolved in heptane. The former being a representative compound for one of the most abundant classes of compounds present in shale oil. The composition of the reactor effluent was determined via an in-house developed automated sampling system followed by immediate injection of the sample on a GC × GC coupled with a time-of-flight mass spectrometer (TOF-MS), flame ionization detector (FID) and NCD. A novel method for quantitative analysis of nitrogen containing compounds using NCD and 2-chloropyridine as an internal standard has been developed and demonstrated.

Recent advances in the application of 2-dimensional gas chromatography with soft and hard ionisation time-of-flight mass spectrometry in environmental analysis

Two-dimensional gas chromatography has huge power for separating complex mixtures. The principles of the technique are outlined together with an overview of detection methods applicable to GC × GC column effluent with a focus on selectivity. Applications of GC × GC techniques in the analysis of petroleum-related and airborne particulate matter samples are reviewed. Mass spectrometric detection can be used alongside spectral libraries to identify eluted compounds, but in complex petroleum-related and atmospheric samples, when used conventionally at high ionisation energies, may not allow differentiation of structural isomers. Available low energy ionisation methods are reviewed and an example given of the additional structural information which can be extracted by measuring mass spectra at both low and high ionisation energies, hence greatly enhancing the selectivity of the technique.

Petroleum crude oil analysis using low-temperature plasma mass spectrometry

RATIONALE

The analysis of crude oil is a challenging task due to sample complexity. In mass spectrometry, several ionization techniques can be used to perform this task. Herein, we report the use of an atmospheric pressure low-temperature plasma (LTP) probe to desorb and ionize compounds of petroleum crude oil from different sources and residual fuel oil standard reference materials (SRMs). LTP is used to perform rapid screening of low molecular weight and relatively volatile components enabling characterization and differentiation of crude oil samples relying solely on mass spectrometric data.

METHODS

Crude oil samples were analyzed without sample preparation or dilution directly from sampling surfaces of different materials such as polytetrafluorethylene, glass and polyethylene. Analyses were performed using Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS) with high mass accuracy and high resolving power of 400,000 at m/z 400 to estimate the elemental composition of the ions produced by LTP. Principal components analysis (PCA) was performed on the LTP data for statistical analysis.

RESULTS

LTP was found to generate positive ions of lower mass compounds of low to moderate polarity. Three-dimensional PCA plots efficiently differentiated between SRMs and Azerbaijan crude oil samples. Standards of alkanes, nitrogen heterocycles, sulfur heterocycles, hydrocarbon polycyclic aromatics and saturated acids were investigated for their behavior in LTP ionization. Alkanes were found to form oxidized products to some extent. The LTP probe worked particularly well in the characterization of sulfur compounds.

CONCLUSIONS

LTP ionization of crude oils was found to advantageously complement analysis by electrospray ionization. The LTP probe in combination with miniaturized mass spectrometers has the potential to provide direct composition analysis and source identification of crude oil contaminations in the future.

Wood-derived olefins by steam cracking of hydrodeoxygenated tall oils

Tall oil fractions obtained from Norwegian spruce pulping were hydrodeoxygenated (HDO) at pilot scale using a commercial NiMo hydrotreating catalyst. Comprehensive two dimensional gas chromatography (GC×GC) showed that HDO of both tall oil fatty acids (TOFA) and distilled tall oil (DTO) produced highly paraffinic hydrocarbon liquids. The hydrotreated fractions also contained fatty acid methyl esters and norabietane and norabietatriene isomers. Steam cracking of HDO-TOFA in a pilot plant revealed that high light olefin yields can be obtained, with 35.4 wt.% of ethene and 18.2 wt.% of propene at a coil outlet pressure (COP) of 1.7 bara, a dilution of 0.45 kg(steam)/kg(HDO-TOFA) and a coil outlet temperature (COT) of 820 °C. A pilot plant coking experiment indicated that cracking of HDO-TOFA at a COT of 850 °C results in limited fouling in the reactor. Co-cracking of HDO tall oil fractions with a typical fossil-based naphtha showed improved selectivity to desired light olefins, further demonstrating the potential of large scale olefin production from hydrotreated tall oil fractions in conventional crackers.