Synthetic diesel fuel compositions, and systems and methods of making the same

A CO2-derived, synthetic paraffinic diesel fuel composition comprising:

• 0% to about 5 wt % monocyclic aromatics;
• 0% to about 1 wt % polycyclic aromatics
• 0% to about 5 wt % cyclo-paraffins;
• greater than about 95 wt % of n-paraffins and iso-paraffins;
• and
• 0 wt % to about 15 wt % oxygenates;
• and
• wherein the composition comprises over about 80 wt % C9-C20 hydrocarbons;
• and
• wherein the composition comprises less than about 5 ppm total sulfur.

A method of making a diesel fuel composition comprising:

• i) contacting a first reduction gas and a first carbon source gas with a reduction catalyst to afford:
• a light hydrocarbon product mixture comprising one or more C2-4 paraffins and/or olefins;
• a medium hydrocarbon product mixture comprising one or more C5-8 paraffins and/or olefins;
• and a target hydrocarbon product mixture comprising one or more C9-20 paraffins and/or olefins;
• ii) contacting a first portion of the light hydrocarbon product mixture, optionally a second reduction gas, and optionally a second carbon source gas, with an aromatic catalyst to afford a light aromatic product mixture comprising one or more C6-8 aromatics;
• iii) contacting a second portion of the light hydrocarbon product mixture and the light aromatic product mixture with an alkylation catalyst to afford a target alkyl arene product mixture comprising one or more C9+ aromatics;
• iv) contacting the medium hydrocarbon product mixture with an oligomerization catalyst to afford a target oligomerized product mixture comprising one or more C9+ olefins and/or paraffins;
• v) hydrogenating the target hydrocarbon product mixture, the target alkyl arene product mixture, and the target oligomerized product mixture to yield a target paraffin product mixture, a target cycloparaffin product mixture, and a target aromatic product mixture;
• and
• vi) blending the target paraffin product mixture, the target cycloparaffin product mixture, and the target aromatic product mixture to afford the diesel fuel.

A method of making a diesel fuel composition comprising:

• (i) contacting a first reduction gas and a first carbon source gas with a reduction catalyst to afford a hydrocarbon product mixture comprising olefins and paraffins;
• (ii) hydrogenating the hydrocarbon product mixture to yield a target paraffin product mixture;
• (iii) contacting a second reduction gas and a second carbon source gas with an aromatic catalyst to afford an aromatic product mixture comprising one or more aromatics and/or cyclic paraffins;
• (iv) hydrogenating a first portion of the aromatic product mixture to yield a target cycloparaffin product mixture;
• (v) hydrogenating a second portion of the aromatic product mixture to yield a target aromatic product mixture;
• and
• (vi) blending the target paraffin product mixture, the target cycloparaffin product mixture and the target aromatic product mixture to afford diesel fuel.

A method of making synthetic paraffinic diesel fuel comprising:

• (i) contacting a first reduction gas and a first carbon source gas with a reduction catalyst to afford a light hydrocarbon product mixture comprising one or more C2-4 paraffins and/or olefins;
• a medium hydrocarbon product mixture comprising one or more C5-8 paraffins and/or olefins, and a target hydrocarbon product mixture comprising one or more C9+ paraffins and/or olefins;
• (ii) removing oxygenates from the light hydrocarbon product mixture and the medium hydrocarbon product mixture to afford a converted light hydrocarbon product mixture and a converted medium hydrocarbon product mixture;
• (iii) contacting the converted light hydrocarbon product mixture and the converted medium hydrocarbon product mixture, optionally a second reduction gas, and optionally a second carbon source gas, with an oligomerization catalyst to afford a target oligomerization product mixture;
• (iv) hydrogenating the target oligomerization product mixture and the target hydrocarbon product mixture to yield a target paraffin product mixture and a target cycloparaffin product mixture;
• and
• (v) blending the target paraffin product mixture and the target cycloparaffin product mixture to make paraffinic diesel fuel.

A system for the production of diesel fuel comprising:

• a first reduction gas feed;
• a first carbon source gas feed;
• a reduction reactor comprising a reduction catalyst, said reduction reactor having a first reduction gas feed inlet, a first carbon source feed inlet, and a mixed hydrocarbon outlet;
• wherein the first reduction gas feed inlet is coupled to the first reduction gas feed, and the first carbon source gas feed inlet is coupled to the first carbon source gas feed;
• a first separator having a mixed hydrocarbon inlet, a light hydrocarbon outlet, a medium hydrocarbon outlet, and a target hydrocarbon outlet;
• and
• an oligomerization reactor comprising an oligomerization catalyst, said oligomerization reactor having a medium hydrocarbon inlet and a target oligomerization product outlet, wherein the medium hydrocarbon inlet is coupled to the medium hydrocarbon outlet on the first separator;
• a first hydrogenator having a target oligomerization product inlet and a target paraffin product outlet, wherein the target oligomerization product inlet is coupled to the target oligomerization product outlet;
• and
• a blender.