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Fuel 231 (2018) 271–280

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Fuel
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Full Length Article

Total Acid Number (TAN) reduction of high acidic crude oil by catalytic T
esterification of naphthenic acids in fixed-bed continuous flow reactor
⁎ ⁎
Bharat Singh Rana, Dong-Woo Cho , Kanghee Cho, Jong-Nam Kim
Clean Fuel Laboratory, Climate Changing Research Division, Korea Institute of Energy Research, 152 Gajeong-ro, Yuseong-gu, Daejeon 305-343, Republic of Korea

A R T I C LE I N FO A B S T R A C T

Keywords: High acid crude oils contain large amount of naphthenic acids which cause serious corrosion problem in pet-
Acidic crude oil roleum industry. Therefore, the removal of naphthenic acids becomes a great concern and challenge for oil
TPA/γ-Al2O3 catalyst refineries. In this study, the naphthenic acids in high TAN crude oils were removed by esterification with low
Naphthenic acids consumption of methanol using a solid acid catalyst consisting of 12-tungstophosphoric acid (TPA) supported on
Esterification
γ-Al2O3 (TPA/γ-Al2O3) in a fixed-bed up-flow reactor. The catalyst was prepared by conventional wet impreg-
Methanol
nation method, and it possessed 25 wt% TPA with high dispersion, and large pore structure. TPA leaching
Total Acid Number
problem from catalyst support was not observed during the reaction. The effect of various reaction parameters
such as temperature and liquid hour space velocity (LHSV), and methanol to the crude oil ratio on TAN reduction
were investigated in detail to maximize TAN reduction. The results revealed that the TPA/γ-Al2O3 catalyst
effectively removed the naphthenic acids via esterification in high TAN crude oils. The TAN decreased with
increase in methanol/oil mass ratio, reaction temperature, but it increased with increase in LHSV. In a long-term
experiments (up to 100 h) running at a reaction temperature of 250 °C and LHSV of 3 h−1 using 2 wt% methanol
in acidic crude oil, the TANs of acidic crude oil reduced from 2.0 mg KOH/g to a value below 0.5 mg KOH/g
which is an acceptable TAN value of crude oil to process in the refineries without material upgrades.

1. Introduction crude oil has a higher concentration of naphthenic acids based on ASTM
D 664 by potentiometric titration. The obtained values are considered
The worldwide increasing oil demand and consumption forces many to be the TAN or neutralization number, expressed in mg of KOH, re-
countries to explore and utilize heavy and inferior crude oil due to the quired to neutralize the acid component parents in one gram of crude
unavoidable decline of conventional petroleum oil reserves [1]. Heavy oil. Crude oils with a TAN > 0.5 mg KOH/g are considered to be acidic
and inferior crude oil is highly acidic compared with conventional crude oils, whereas crude oils with a TAN > 1 mg KOH/g are con-
crude oil, which means it has a high total acid number (TAN). Refining sidered to be highly acidic crude oils in the petroleum industry [7,8].
acidic crude oils might be a good choice for some refineries due to the Due to the worldwide acidic crude oil increase, the processing of high-
increased production and relatively lower price [2]. Worldwide, the TAN crude oils before refining, for which new technology is needed, is a
high-TAN crude oil production has increased by 0.3% per year in recent great challenge for the refineries.
years [3]. The main contributors to different levels of TAN of acidic To reduce the corrosivity of high-TAN crude oil due to the presence
crude oil are different concentrations of naphthenic acids, which are the of naphthenic acids, the petroleum oil refineries use the blending of
main components responsible for a variety of serious corrosion pro- low- and high-TAN crude oils, injection of a corrosion inhibitor, and
blems in up- and downstream petroleum processing units in which metallurgy upgrading [9]. However, these approaches are not entirely
high-TAN crude oils are processed [4–6]. satisfactory. Blending of low-TAN crude oil can substantially reduce the
In the petroleum industry, the term “naphthenic acids” refers to all TAN of highly acidic crude oil but is limited by low-TAN crude oil
carboxylic acids present in crude oil. Naphthenic acids have the general suppliers, which might reduce the value of low-TAN crude oil. In most
formula RCOOH, where R represents the naphthene moiety consisting cases, metallurgy upgrading is based on high contents of chromium and
of cyclopentane and cyclohexane derivatives; the carboxylic acid group molybdenum that are recognized as corrosion-resistant materials but
is usually attached through a eCH2 group or chain, containing up to are expensive and require high investments, which might increase the
five or more eCH2 groups, rather than directly to the ring. High-TAN refining costs. Corrosion inhibitors provide good mitigation of


Corresponding authors.
E-mail addresses: dwcho@kier.re.kr (D.-W. Cho), jnkim@kier.re.kr (J.-N. Kim).

https://doi.org/10.1016/j.fuel.2018.05.074
Received 19 September 2017; Received in revised form 27 March 2018; Accepted 14 May 2018
Available online 29 May 2018
0016-2361/ © 2018 Elsevier Ltd. All rights reserved.
B.S. Rana et al. Fuel 231 (2018) 271–280

naphthenic acid corrosion if closely monitored and used for specific made more efficient, eco-friendly, and insoluble solid acid catalysts
fractions but will affect downstream processing and poison the catalyst with high thermal stability and high surface area and are expected to
that is used in the refinery. overcome the above-mentioned problems. The suitable support for
Reducing the TAN of highly acidic crude oils by removing naph- HPAs provides the opportunity to be dispersed over a high surface area,
thenic acids is considered to be one of the most important processes. which increases the catalytic performance [22–24].
Currently, a number of approaches have been proposed to remove Recently, researchers have reported that 12-tungstophosphoric acid
naphthenic acids from highly acidic crude oil involving the neu- (TPA) supported on acidic or neutral solids, such as SiO2, TiO2, SnO2,
tralization or caustic washing, solvent extraction, physical adsorption, active carbon, ZrO2, Al2O3, SBA-15, SBA-16, KIT-6, MCM-41, kaolin
thermal decomposition, catalytic decarboxylation, and esterification clay, and H-β zeolite, can be dispersed over the surface and/or in-
[10–13]. However, some of these approaches have drawbacks. For ex- troduced inside the pores of these supporting solid materials, thus al-
ample, neutralization or caustic washing might cause serious emulsion lowing for a significant increase in the thermal stability and surface
problems, the loss of crude oil products, and environmental pollution. area of TPA in addition to the enhancement of Bronsted acid sites
Solvent extraction techniques require a large amount of solvent and within the supporting materials [22,24–35]. Therefore, TPA-supported
high-energy consumption due to the multiple steps that are necessary to materials can provide potential heterogeneous acid catalysts with high
separate the solvent. Physical adsorption techniques are usually costly catalytic activity for various organic transformation reactions including
and applications are limited. Catalytic hydrogenation is commonly used esterification reactions [24,33,35,36]. The esterification reactions using
for industrial distillates or residual oils; it requires the large consump- these TPA supported catalysts were only used for lower aliphatic car-
tion of hydrogen and large investments in equipment modification. boxylic fatty acid, formic acid, oleic acid, lauric acid, and free fatty
Therefore, these techniques have not been used for the treatment of acids with different alcohols such as methanol, ethanol 1-butanol, and
acidic crude oil in industry. Furthermore the catalytic decomposition glycerol [32,36]. However, these catalysts were not used for the es-
employed for deacidification of naphthenic acids has been reported and terification of naphthenic acids that are present in the hydrocarbon
seems to be an alternative and effective method to remove naphthenic fraction and acidic crude oil to reduce the acidity. In this regard, TPA-
acids. Research has mainly focused on the development of base metal supported catalysts for the organic acid esterification have been proven
oxides and mixed oxide-based catalysts to improve the reaction speed of to be efficient and eco-friendly solid acid catalysts; approximately
the decomposition of naphthenic acids in the oil fraction or crude oil 20–30 wt% TPA on suitable support materials leads to the highest ac-
[14]. However, naphthenic acids possibly form insoluble metal-organic tivity [30,32]. Among the different mesoporous materials, such as
components through well-known acid–base neutralization reactions MCM-41 and SBA-16, γ-alumina (γ-Al2O3) is commercially available
when using base metal oxide catalysts, which are very difficult to re- and the most important amphoteric material. Based on the combination
move [15]. of its textural properties, such as surface area, pore volume, and pore
In recent years, heterogeneous catalytic esterification with alcohol size distribution, it has been directly used as a catalyst and catalyst
has been considered to be an interesting and novel method. It is thought support material in the automotive and petroleum industry [37,38].
to be capable of overcoming the disadvantages of homogeneous cata- The objective of this study was to develop an effective and eco-
lytic esterification and conventional deacidification methods. This friendly TPA supported solid acid catalyst which has been used for the
method has been employed for the esterification of naphthenic acids esterification of naphthenic acids in highly acidic crude oil with very
with alcohol in diesel, the second vacuum fraction, and vacuum gas oil less consumption of methanol to reduce the TAN of acidic crude oil to
(VGO) [6,16,17] using SnO/Al2O3, SnO, and Mg-Al hydrotalcite cata- an acceptable level for the refinery. The effect of various reaction
lysts, respectively. The TAN of diesel oil was lowered from 1.7 mg parameters on the acid removal, such as reaction temperature, me-
KOH/g to < 0.5 mg KOH/g at a reaction temperature of 250 °C, a me- thanol/oil ratio, and LHSV, was investigated using a fixed-bed con-
thanol/oil ratio of 0.010, and LHSV of 1.6 h−1 in a fixed-bed reactor tinuous up-flow reactor.
system. However, catalytic esterification to reduce the TAN of acidic
crude oil has rarely been reported. The Exxon Research and Engineering
2. Experimental section
Company used esterification to reduce the acidity of petroleum oil
without any catalyst in batch reactor systems [18]; however, this batch
2.1. Materials and reagents
process was not adopted in the industry due to long reaction times.
Wang et al. reported the esterification of naphthenic acids in highly
The naphthenic acids containing various carboxylic acids having
acidic crude oil using SnO–Al2O3 in a continuous flow fixed-bed reactor
TAN value of 200 mg KOH/g was purchased from Wako Chemical. The
system to lower the TAN [19] The TAN of acidic crude oil was reduced
boiling point range of naphthenic acids is 200–450 °C, as given in the
from 2.8 mg KOH/g to < 0.5 mg KOH/g at optimized conditions: tem-
Table 4. The heavy crude oil (Castilla Crude Oil) was received from
perature of 300 °C, a methanol to oil ratio of 2 wt%, and a space velo-
Venezuela, the basic properties are given in Table 1. Methanol, 2-pro-
city of 2.5 h−1. Thus, very few research has been carried out on re-
panol and toluene (HPLC grade) were purchased from SAMCHUN
grading and esterification of naphthenic acids in acidic crude oil using
Chemical. 12-Tungstophosphoric acid hydrate, H3[P(W3O10)4]·xH2O
solid acid catalysts. More efficient and eco-friendly solid acid catalysts
(TPA) was purchased from Sigma-Aldrich and γ-Al2O3 was purchased
are needed for the continuous flow reactor system, which is the most
from Sasol Germany.
promising solution to this problem.
In the recent years, solid acid catalysts have received considerable
Table 1
attention in many industrial organic transformations, which is mainly
Basic physical-chemical properties of Castilla Crude oil used in
due to the non-toxicity, non-corrosiveness, less costs, easy handling, this study.
recovery, and reusability [20]. Keggin-type heteropoly acids (HPA),
Density, kg/m3 (at 15 °C) 0.9445
particularly 12-tungstophosphoric acid (H3PW12O40·xH2O, TPA), are
API gravity (at 60 °F) 18.2
well known to pass the pure Brønsted acidity and have proven to be Kinetic Viscosity in cft (at 40 °C) 139.2
efficient catalysts when applied in acid-catalyzed reactions [21]. Sulfur content (wt%) 1.53
However, pure HPAs generally have a very low catalytic reactivity due Pour point (°C) −39.0
to their very low surface area (1–10 m2/g), their solubility in polar Nitrogen content (wt-ppm) 2787
MCR (wt%) 12.03
solvents, low thermal stability, and problems with respect to the se-
Salt Contents (PTB) 7.0
paration from the reaction mixture. Consequently, by impregnation of Acid Number (mg KOH/g) 0.203
HPAs on suitable high surface area-supported materials, HPAs can be

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B.S. Rana et al. Fuel 231 (2018) 271–280

Fig. 1. Scheme of the experimental apparatus used for the continuous esterification.

2.1.1. Highly acidic crude oil (High TAN crude oil) preparation by increasing the temperature from 100 to 700 °C at the ramp rate of
Herein, the synthetic pseudo high acidic crude oil (High TAN crude 10 °C min−1; the temperature was held for two hours to remove
oil) as feedstock was prepared by mixing of the required amount of strongly bound species. Subsequently, the sample was cooled to 100 °C
0.952 g of naphthenic acids and 100 g of heavy crude oil. The me- in a He stream.
chanical stirrer was used for the proper mixing of naphthenic acids in Thermogravimetric analysis (TGA) was performed using a DuPont
crude oil. The TAN was determined according to ASTM D664 method, TGA51 thermogravimetric analyzer; 20–30 mg of the sample was
and reached to a values around 2.0 mg KOH/g. The TAN values of crude placed in a quartz basket, purged for 20 min at room temperature with
oils having > 1 are to be considered as highly acidic crude oil [3]. an N2-air mixture, and then heated from room temperature to 1000 °C
at a rate of 10 °C min−1 in the same gas mixture.
Scanning electron micrograph (SEM) images with EDS mapping
2.2. Catalyst preparation
were obtained with a Hitachi S-4800 at 2 kV, without metal coating.
To determine the chemical composition of the fresh and used cat-
The spherically extruded alumina (γ-Al2O3, Sasol Germany) as me-
alysts and possible leaching of TPA from the supported catalyst, X-ray
soporous support was preheated at 550 °C before use. The γ-Al2O3
fluorescence (XRF) analysis was performed using a Primus II (RIGAKU
supported TPA (25 wt% of TPA) as solid acid heterogeneous catalyst
Co., Japan).
was prepared by using conventional incipient wetness impregnation
method. In a typical procedure, a solution containing the required
amount of TPA in double distilled water was impregnated onto the
2.4. Reaction procedure
mesoporous γ-Al2O3 support and the excess water was then evaporated
using a rotary evaporator at 80 °C, and after that catalyst was dried at
The catalytic esterification of naphthenic acids with methanol in
120 °C in an oven for the overnight and then calcined at 300 °C for 4 h.
highly acidic crude oil for the TAN reduction was conducted in a fixed-
The prepared catalyst was denoted as TPA/γ-Al2O3.
bed reactor by using TPA/ γ-Al2O3 as the solid acid catalyst. The con-
tinuous flow fixed-bed reactor system comprises a feed tank with a
2.3. Catalyst characterization mechanical stirrer, feeding pump, furnace, fixed-bed type reactor
(material: SUS 316, inner diameter of 1.2 cm and length of 45 cm), and
The BET surface area, pore volume, and pore size of the support and gas/liquid separator combined with condenser. The schematic diagram
catalyst were obtained with the Micromeritics ASAP-2020 instrument at of the esterification reaction system is shown in Fig. 1.
77 K using liquid N2. Before the analysis, the catalyst was evacuated at The highly acidic heavy crude oil and methanol were uniformly
300 °C for 5 h to remove the adsorbed moisture from the catalyst sur- premixed according to a specified ratio at 20–30 °C and then poured
face and pores. Mesoporous size distributions were obtained with the into the feed tank. The feedstocks in the feed tank were constantly
Barret–Joyner–Halenda (BJH) method from the desorption branch of stirred using a mechanical stirrer during the experiment to prevent the
the isotherms. phase separation of the mixture. The catalyst was loaded in the middle
Powder X-ray diffraction (XRD) patterns of fresh and used catalysts section of the reactor. The remaining spaces of the reactor were filled
were measured using a Rigaku Multiflex diffractometer and CuKα ra- with spherical glass beads (2–3 mm). The mixture of the pseudo highly
diation (40 kV, 40 mA). acidic crude oil and methanol, as the feedstocks, was pumped into the
The acidity of catalyst was determined based on NH3-temperature- reactor through the preheating section and heated to the reaction
programmed desorption (NH3-TPD) using the Micrimetrics-720 instru- temperature. The esterification reaction was carried out in the catalyst
ment; the catalyst was degassed at 250 °C under He flow for 2 h before bed section at temperatures varying from 175 °C to 300 °C. During the
the analysis to remove the water vapor and avoid pore damage from reaction, produced oil was immediately cooled down to room tem-
steaming, which might alter the structure of the catalyst, and cooled to perature as mentioned in the reactor system after back pressure reg-
100 °C. The NH3 gas was adsorbed using 10% NH3 in Ar gas for 1 h. The ulator (BPR) to avoid the backward reaction and was collected in the
TPD (NH3-TPD) studies were carried out in a He stream of 30 ml min−1 product container.

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B.S. Rana et al. Fuel 231 (2018) 271–280

2.5. Analytical methods Table 2


Physical properties of the catalysts.
The TAN of the feed and product oil was measured using an auto- Catalyst BET Microspore Total Mesoporous Average
matic potentiometer with a glass electrode (Metrohm Titrando Plus surface volume (cm3/ pore volume (cm3/ pore
Model 904, Metrohm Ltd., Switzerland) based on a standard method area g) volume g) diameter
(ASTM D664, standard test method for the acid number of petroleum (m2/g) (cm3/g) (Å)

products by potentiometric titration). A required known amount of feed TPA/γ- 178.43 0.002 0.392 0.383 68.71
and product oil was diluted with 125 ml of the titration solvent (iso- Al2O3
propanol, toluene, and water in a ratio of 45:50:5 by volume). The TPA/γ- 116.26 0.013 0.237 0.229 55.66
electrode was washed with the titration solvent before use. The Al2O3
(use-
homogenous solution was then titrated using 0.1 N of methanolic po-
d)
tassium hydroxide solution as titrant until it reached an end point. The
TAN is calculated based on the following equation [6]:
TAN (mgKOH /g ) = (A−B ) × M × 56.1/w (1)
where A is the volume of KOH used to reach the equilibrium point, B is
the volume of KOH for blank titration, M is the concentration of the
KOH solution, and w is the sample mass. The accuracy of the method
depends on the mass of the oil used. For a 10 g sample, each sample was
measured twice; the average of two TAN values was then calculated. If
the measurement error of the two TAN values was larger than ± 5%,
additional measurements were performed until the measurement error
was within ± 5% or less. The extent of acid removal was determined
using the following equation:
TANFO−TANPO
Acid Removal = × 100
TANFO (2)
where TANFO refers to the TAN of the feed oil and TANPO refers to the
TAN of the produced oil. It should be noted that the electrode must be
immersed in a buffer solution with pH of 4 (Metrohm US) for a
minimum of 10 min between the measurements. After five measure-
ments, the electrode was washed with 18 MX water and reconditioned
overnight in the electrolyte solution (3.0 M potassium chloride in Fig. 2. N2 adsorption-desorption isotherm and the corresponding BJH pore-size
ethanol). distribution (inset) of fresh and used TPA/γ-Al2O3 based catalyst.
The water content after the esterification reaction of the naphthenic
acids was measured by Karl Fischer titration (877 KF Titrino, desorption branches of the isotherms (Fig. 2, inset) clearly shows that
Metrohm). Physical and chemical analyses of naphthenic acids were the catalysts have a narrow pore size distribution with a mean pore
conducted to obtain information on the carbon number distribution diameter of 68.71 Å for the fresh TPA/γ-Al2O3 catalyst and 55.66 Å for
estimated from the boiling point and chemical mapping. The analysis of the used catalyst. It is well known that the surface area, pore volume,
the carbon number and boiling point distributions was conducted using and pore diameter decrease after impregnation of the supported cata-
simulated distillation (SIMDIS) based on the extended ASTM D 2887. In lyst in which oxides are used as support due to the strong interaction of
addition, two-dimensional gas chromatography (GC) with a flame io- TPA with the oxide support material [39]. The decrease of the BET
nization detector (2D-GC/FID, Leco GC X GC with LN2-cooled thermal surface area, pore volume, and pore diameter due to the TPA in-
modulator), 1st Rtx-1 column (length: 60 m, inner diameter: 0.25 mm, corporation into the γ-Al2O3 support indicates that the TPA might be
phase film thickness: 0.25 μm), and 2nd Rxi-17Si column (length: dispersed in the support material [22], which is evidence for the che-
1.2 m, inner diameter: 0.15 mm, phase film thickness: 0.15 μm) was mical interaction between the TPA and support material. The N2
conducted for chemical mapping. The main oven temperature for GC sorption and XRD studies reveal that the impregnation of TPA does not
was programmed from 40 °C to 300 °C, with a ramp of 2 °C/min, and the affect the mesoporosity of the support material. Mesoporous support is
detector temperature was maintained at 300 °C. The sample (0.2 μL) needed, specifically for large molecular reactions, to overcome diffu-
was injected into the column at a 100:1 split ratio. sion limitations and better diffuse large molecules and for lower deac-
The used catalyst was washed with hot toluene, dried, and calci- tivation by pore blocking.
nated. The regenerated catalyst was characterized using XRF, TGA, The XRD patterns of the support material and synthesized catalyst
SEM, and BET surface area analyses. are shown in Fig. 3. The XRD pattern of the TPA/γ-Al2O3 catalyst
clearly indicates that the synthesized catalyst is the typical γ-phase of
3. Results and discussion Al2O3 at 2θ of ∼36.5°, 45.9°, and 66.6° corresponding to the (3 1 1),
(4 0 0), and (4 4 0) reflections, respectively [40]. A characteristic peak
3.1. Catalyst characterization of the crystalline phase corresponding to TPA was not observed. The
absence of diffraction peaks due to the crystalline phase of TPA in the
The BET surface area, pore volume, and average pore diameter of Al2O3 support material could be attributed to the good dispersion of
the fresh and used TPA/γ-Al2O3 catalysts were analyzed using N2 ad- this phase in the matrix of the γ-Al2O3 support material, forming very
sorption-desorption isotherms. The physicochemical properties of the small crystallites, which cannot be detected by XRD [41].
catalysts are summarized in Table 2. Fig. 2 shows the N2 sorption iso- The NH3-TPD is a useful technique to investigate acidic properties
therm of the fresh and used TPA/γ-Al2O3 catalysts, which is typical for including the amount of acidic sites and acid strength of acidic cata-
type IV due to the mesoporous structure, and a clear step in the ad- lysts. The amount of acidic sites can be determined based on the
sorption curves at the partial pressure P/P0 of 0.6–0.9 due to well-de- amount of desorbed NH3 and the acid strength can be determined based
fined mesoporosity. The BJH pore size distribution calculated from the

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B.S. Rana et al. Fuel 231 (2018) 271–280

Fig. 5. TGA profile of fresh and used TPA/γ-Al2O3 catalysts.


Fig. 3. XRD pattern of γ-Al2O3 support and TPA/γ-Al2O3 catalyst.
and TPA/γ-Al2O3 catalyst are presented in Fig. 4. The desorption tem-
peratures and amount of NH3 desorbed from each of the TPD peaks are
given in Table 3. The TPD profile of the TPA/γ-Al2O3 catalyst shows
two desorption peaks in the temperature range of 100–250 °C (in-
dicating weak acid sites) and 250–700 °C (indicating strong acid sites)
[42]. It was clear from Fig. 4 that weak acid sites of the catalyst (TPA/γ-
Al2O3) surface decreased with the addition of TPA, while increased in
the numbers of strong acid site. The nature of a solid acid catalyst is
mainly determined by the strongest acidic sites on its surface [31].
Thermo-gravimetric analyses of TPA/γ-Al2O3 fresh and used cata-
lyst are shown in Fig. 5. Two distinct regions of weight loss are shown
in the temperature ranges of 50–250 °C and 250–500 °C. The first
weight loss of 1.45% for fresh TPA/γ-Al2O3 catalyst and 2.72% for used
TPA/γ-Al2O3 catalysts in the temperature ranges of 50–250 °C corre-
sponds to desorption and removal of physisorbed water. The second
notable weight loss of 7.63% for fresh TPA/γ-Al2O3 catalyst and 7.73%
for regenerated used TPA/γ-Al2O3 catalysts in the temperature ranges
of 250–500 °C corresponds to the loss of water during the crystallization
of the Keggin ion of TPA. The results are in good agreement with the
reported one [43]. In the case of used catalyst, broad peak at
250–550 °C corresponds to relatively slow weight loss due to release of
Fig. 4. NH3-TPD profile of the γ-Al2O3 support and TPA/γ-Al2O3 catalyst. heavy hydrocarbon from the catalyst surface. In the temperature range
550–750 °C, the slight weight loss in the both fresh and used catalysts
Table 3 are associated with the decomposition of TPA to WO3 and P2Ox species
Acidity of pure-TPA, γ-Al2O3 support and TPA/ γ-Al2O3 catalyst from NH3-TPD. [44]. Herein, TGA analysis of catalyst reveals that the catalyst is stable
Sample Surface acidity (mmol/g NH3) up to 500 °C. This may be due to the formation of strong intermolecular
bonding between the TPA and the γ-Al2O3.
Weak acidity Strong acidity Total SEM with Energy-dispersive X-ray spectroscopy mapping (EDS-
(100–250 °C) (250–700 °C) acidity mapping) of the fresh and used TPA/γ-Al2O3 catalysts was carried out
Pure-TPA 0.224 0.973 1.197 to examine the elemental composition and its distribution (Fig. 6). The
γ-Al2O3 (Pretreated at 0.465 0.231 0.696 SEM with EDS mapping shows the expected elemental constituents: Al,
550 °C) O, P, and W., and the SEM with EDS mapping also indicates that the P
TPA/γ-Al2O3 catalyst 0.309 0.637 0.946 and W elemental species are homogeneous and well distributed on the
γ-Al2O3 surface. Furthermore, EDX measurements were carried out to
determine the chemical composition of the fresh and used catalysts. The
on the desorption temperature. The NH3 molecules adsorbed on the
quantitative analysis of different elements shows that the fresh TPA/γ-
catalyst are desorbed at lower temperature from weakly acidic sites and
Al2O3 catalyst contains 24.51 wt% W, 0.34 wt% P, and 33.58 wt% Al,
at high temperature from strongly acid sites. The γ-Al2O3 support
while the used TPA/γ-Al2O3 catalyst consists of 23.68 wt% W, 0.36 wt%
showed a broad distribution of the desorption peak in the temperature
P, and 30.05 wt% Al. The surface morphology of the fresh and the used
range of 100–700 °C, with a peak maxima at around 230 °C, indicating
catalysts (TPA/γ-Al2O3) is almost same. And from the SEM with EDS
that γ-Al2O3 support have only weak acid sites on the surface. However,
elemental mapping confirms that the surface morphology of fresh and
the TPD profile of pure TPA showed two desorption peak in the tem-
used catalysts indicates TPA species are well dispersed inside the γ-
perature range of 100–250 °C, indicating weak acid sites (mmol/g) and
Al2O3 pores. Further, no separate crystallites of bulk phase of TPA were
250–700 °C with peak maxima at 550 °C, indicating strong acid sites
found in both samples, and this can be also clearly observed by XRD
(mmol/g). The results are in good agreement with the reported one
diffraction pattern. Thus XRD pattern, SEM with EDS elemental map-
[42]. The NH3-TPD profiles of the γ-Al2O3 support material, pure TPA
ping are in good agreement with each other and confirms the uniform

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B.S. Rana et al. Fuel 231 (2018) 271–280

Fig. 6. SEM and corresponding elemental mapping of (a) and (b) TPA/γ-Al2O3 fresh catalyst and (C and D) TPA/γ-Al2O3 used catalyst.

and high dispersion of TPA in a non-crystalline form due to the inter- oil (LVGO), mainly diesel fuel oil and LVGO hydrocarbon fractions. The
action with the support matrix. results reveals that most of the naphthenic acids consists in the middle
distillates hydrocarbon fractions. And accordingly choice of the effec-
tive heterogeneous solid acid catalysts becomes more important for
3.2. Physical and chemical analysis of naphthenic acid TAN reduction of high acidic crude oils.
In addition, two-dimensional gas chromatography with a flame io-
Before the experiments, physical and chemical analyses of naph- nization detector (2D-GC/FID; Leco GC X GC with LN2 cooled thermal
thenic acids mixture, having TAN value of 200 mg KOH/g (Received modulator) was conducted for chemical mapping. The analysis results
from Wako Chemicals) were conducted to obtain information on the are shown in Fig. 7. It is clear from Fig. 7 that the chemical mapping
carbon number distribution estimated from the boiling point and the showed strong peaks due to cyclo-paraffins with alkyl side chain ending
chemical mapping. The analyses of the carbon number and boiling with carboxylic acids (naphthenic acids), which indicates that
point distributions were conducted using SIMDIST based on the ex-
tended ASTM D 2887 method. The analysis results for the naphthenic
acids used in this study is shown in the Table 4. The boiling point of
naphthenic acids ranges from 213 °C (IBP) to 449 °C (FBP). Compared Cycloaliphatic carboxylic acids
(Naphthenic Acids) Acids)
with the common fraction of petroleum oil, naphthenic acids consists in
the mixture of jet, kerosene, diesel fuel, fuel oil, and light vacuum gas
Mono and di-aromatics within NA
Table 4
Boiling point distribution of naphthenic acids using in this study (analyzed by
SIMDIS ASTM D2887 Extended).
Mass% Boiling point (°C) Mass% Boiling point (°C)

0.5 213 50 333.5


1 223.5 55 338.5
5 258.5 60 344
10 276 65 348.5
15 287.5 70 353.5
20 296.5 75 358.5
25 303.5 80 364
30 310.5 85 371
35 316.5 90 379
40 322.5 95 380.5
Fig. 7. Two-dimensional gas chromatogram (GC × GC-FID) of naphthenic acids
45 328 99.5 449
reagent.

276
B.S. Rana et al. Fuel 231 (2018) 271–280

Fig. 8. Effect of reaction temperature on the TAN change of product oil using
TPA/γ-Al2O3 catalyst. Fig. 9. Effect of the LHSV on the TAN change of product oil.

naphthenic acids are mainly derivatives of cyclo-paraffins carboxylic 0.5 mg KOH/g required for the acid removal in the petroleum industry
acids. A weak peak derived from isomers and derivatives of cyclo- when the LHSV was 2–4 h−1 at a reaction temperature of 250 °C. The
paraffin can be observed near the strong group peak of cyclo-paraffins processing at higher LHSVs facilitates more production and less in-
carboxylic acids. The peaks due to aromatics (mono and di-aromatics) vestment costs. The low consumption of methanol and processing at
within the naphthenic acids are grouped together away from that due to lower temperatures are other parameters that can reduce the processing
cyclo-paraffin carboxylic acids. The aromatics within the naphthenic cost and might be economically feasible for the industry. The reaction
acids content is too small compared with that of cyclo-paraffins deri- was also conducted at a lower reaction temperature of 200 °C for 1 wt%
vative carboxylic acids. methanol. The favorable condition for the low consumption of me-
thanol at a LHSV of 1 h−1 is 200 °C, which also leads to a TAN reduction
3.3. Catalytic performance to < 0.5 mg KOH/g and reduces the investment costs. The optimum
LHSV (h−1) at a temperature of 250 °C was determined to be between 3
3.3.1. Effect of the reaction temperature on the TAN reduction and 4 h−1 for 2 wt% methanol; at a temperature of 200 °C it is 1 h−1 for
The effect of the reaction temperature on the TAN reduction of 1 wt% methanol. In both cases, the TAN was reduced to < 0.5 mg KOH/
highly acidic crude oil was studied at temperatures ranging from 175 to g.
300 °C, a fixed LHSV of 5 h−1, and 2 wt% methanol in acidic crude oil
as feedstock represented in Fig. 8. It can be clearly seen from Fig. 8 that
3.3.3. Effect of the methanol concentration in crude oil
the TAN of the produced oil decreases sharply with increasing reaction
The effect of the methanol content in acidic crude oil, varying from
temperature (between 175 °C and 250 °C). At higher temperatures, a
0.5 to 2 wt%, on the acid removal was determined at temperatures of
high TAN reduction was obtained due to the enhanced, subsequent
250 °C and 200 °C for a LHSV of 3 h−1 and 1 h−1, respectively. Fig. 10
endothermic esterification of naphthenic acid with methanol. With
shows that 2 wt% methanol leads to the most effective results at 250 °C
further increasing reaction temperature (> 250 °C), the TAN slowly
for a LHSV of 3 h−1; however, 1 wt% methanol at 200 °C for a LHSV of
decreases due to the attainment of the chemical equilibrium and fast
reaction rate. Palani and Pandurangan also report that an increasing
reaction temperature promotes the removal of water formed as by-
product during the esterification reaction. This water acts as a poison by
adsorption on the hydrophilic sites of the solid acid catalyst; hence, the
removal of the water can improve the catalytic activity with increasing
temperature [45]. The reaction temperature for the esterification of
naphthenic acids in acidic crude oil with 2 wt% methanol should be
higher than 270 °C to reduce the TAN of crude oil to a values < 0.5 mg
KOH/g (the upper limit of low acid crude oil), where LHSV is 5 h−1.
The TAN was reduced < 0.5 mg KOH/g at temperature of 275 °C and
300 °C. In the present study, we achieved the required target for low-
ering of TAN to a values < 0.5 at temperature of < 300 °C. Above the
300 °C, however, the corrosion problem may become more serious on
processing units and the other catalytic systems [46].

3.3.2. The effect of LHSV (h−1)


The effect of different LHSVs on the TAN reduction at 250 °C and
200 °C using 2 and 1 wt% methanol in the acidic crude oil as feedstock,
respectively, were investigated as represented in Fig. 9. The TAN values
of the crude oil increases as the LHSV increases. This means that the
time for the reactant molecules at catalytic active sites is not sufficient Fig. 10. The TAN change of product oil with effect of methanol wt% in acidic
for a reaction to occur. Fig. 9 also shows that the TAN reduced to < crude oil.

277
B.S. Rana et al. Fuel 231 (2018) 271–280

work
work
work
work
work
Reference

Present
Present
Present
Present
Present
[18]

[16]
[17]
[19]
[6]

Stable up to 100 h
Stable up to 60 h
Catalyst stability









Acid removal (%)

81.00
95.00
89.50

79.25
82.55
80.90

79.25
> 80
Feed TAN (mg KOH/g)

Fig. 11. The TAN changes of product oil as a function of reaction time (h) at
different reaction conditions.

1 h−1 shows comparative results with respect to the TAN reduction to a


4.10
0.59

2.00
2.00
2.00
2.00
2.00
4.2
1.7

2.8

value acceptable for the petroleum industry.


Fig. 10 also shows that 0.5 and 1 wt% methanol result in an effective
acid removal; however, the most effective acid removal is favorable by
T = 300 °C, RT = 2 h Methanol/oil(w/w) = 0.05 4 wt% SnO

using 2 wt% methanol in acidic crude oil as feedstock. It can be noted


T = 280 °C, LHSV = 1.2 h−1 Methanol/oil(w/w) = 0.010

LHSV = 2.5 h−1 Methanol/oil(w/w) = 0.02

that using 1 wt% methanol at a lower LHSV and temperature reduced


LHSV = 5 h−1 Methanol/oil(w/w) = 0.02
LHSV = 3 h−1 Methanol/oil(w/w) = 0.01
LHSV = 1 h−1 Methanol/oil(w/w) = 0.01
LHSV = 1 h−1 Methanol/oil(w/w) = 0.01
LHSV = 3 h−1 Methanol/oil(w/w) = 0.02
T = 250 °C, RT = 7.5 h, Methanol/oil(w/w) = 0.024

the acid removal to an acceptable value to process acidic crude oil in


the petroleum industry. These results are much more effective than the
results reported by Wang et al. using a SnO-Al2O3 catalyst for the es-
Comparative study of esterification of naphthenic acids in acidic crude oil or its fractions over various catalysts.

terification of naphthenic acids in crude oil in a fixed-bed catalytic


reactor system [19], using a SnO catalyst for the esterification of the
second vacuum fraction in a batch reactor system [16], and in the U.S.
patent No. 6251305 using batch reactor system at high temperature for
longer reaction times (without catalyst) [18]. A detailed comparison of
different catalysts is shown in Table 5.
Operating conditions

3.4. Stability of the catalyst


T = 300 °C,
T = 275 °C,
T = 250 °C,
T = 200 °C,
T = 200 °C,
T = 250 °C,

To investigate the catalyst stability as a function of time-on-stream


(TOS), a long-term experiments were conducted under two different
reaction conditions as represented in Fig. 11. It is clear that the activity
Process reactor

of catalyst remains basically unchanged up to near 100 h of time-on-


stream at a reaction temperature of 250 °C and LHSV of 3 h−1 using
Fixed Bed

Fixed Bed
Fixed Bed

Fixed Bed

2 wt% methanol in acidic crude oil as feedstock, where the TAN was
Batch

Batch
Batch

reduced to a value below 0.5 mg KOH/g. Furthermore, the catalyst


stability at a reaction temperature of 200 °C and LHSV of 1 h−1 using
1 wt% methanol in acidic crude oil is unchanged up to 60 h of time-on-
Acidic crude oil (Gryphon Crude)

stream, where the TAN was also reduced to a value below 0.5 mg KOH/
g. However, after 60 h of time-on-stream, the catalyst activity for TAN
reduction was decreased at 200 °C of the reaction temperature. The
Second vacuum fraction

main reason for low long-term catalytic stability as a function of time-


on-stream at low reaction temperature (200 °C) might be attributed to
Acidic crude oil
Acidic crude oil

Acidic crude oil


Dewaxed VGO

slow diffusion rate of the product molecules and the product species
including bulky molecules of asphaltenes which can block pores of the
Feedstock

Diesel oil

catalyst. Thus, improving the catalyst longevity of TPA/γ-Al2O3 is big


challenge for future applications.
Mg-Al hydrotalcite

3.5. Reaction mechanism


Without Catalyst

TPA/γ-Al2O3

Esterification of naphthenic acids with methanol is an equilibrium,


TPA/Al2O3
SnO/Al2O3

SnO/Al2O3
Catalyst

limited, and electrophilic reaction, which is considered to be relatively


Table 5

SnO

slow and requires the activation by either a suitable catalyst or a higher


reaction temperature to achieve higher acid removal rates. A possible

278
B.S. Rana et al. Fuel 231 (2018) 271–280

Fig. 12. Proposed mechanism for the esterification of naphthenic acids with methanol over TPA/γ-Al2O3 catalyst.

reaction mechanism that is involved in the esterification of naphthenic The TPA/γ-Al2O3 catalyst promotes the esterification reaction at
acids with methanol over solid acid catalysts (TPA/γ-Al2O3) is shown in lower reaction temperatures and under low consumption of methanol,
Fig. 12. This esterification reaction follows the Eley–Rideal mechanism, as compared to other previous catalysts. In addition, the removal of
which takes place between naphthenic acid and protons chemisorbed water which is side product in the continuous flow reactor and im-
on the active site (Bronsted acid sites) of the solid acid catalyst surface mediate cooling systems improve both the esterification reaction speed
by donating a proton to the carboxylic acid group of naphthenic acids, and equilibrium. The TAN reduction of high acidic crude oils with very
resulting in stable carbocation. The carbocation-possessing positive low consumption of methanol at moderate temperatures in continuous
charge is then nucleophilically attacked by one of the lone pairs of the flow reactor is a prospectively economically-viable option for extensive
oxygen of the methanol to form an unstable intermediate molecule. In utilization of lower price high TAN Crude oils without material mod-
the last step, the elimination of the water molecule from the unstable ifications in existing petroleum refineries.
intermediate molecule leads to the methyl naphthenate as final product
accompanied by water and the regeneration of the solid acid catalyst. Acknowledgements

3.6. Comparative study of the catalysts This work was supported by the Industrial Strategic Technology
Development Program (No. 10045068, Title: Development of flow as-
The TAN reduction performance of the currently studied catalyst surance and organic acid/calcium removal process for the production of
was compared with that of catalysts reported in the literature for the offshore opportunity crude) of Korea Evaluation Institute of Industrial
esterification of naphthenic acids in acidic crude oils or its fractions Technology funded by the Ministry of Trade, Industry and Energy (MI.
using batch or fixed-bed reactor systems (Table 5). These comparisons Korea).
have been performed at optimal reaction conditions for each catalyst. It
can be observed that using a TPA/γ-Al2O3 catalyst results in a larger References
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