Catalysts and methods for preparing renewable diesel and sustainable aviation fuels

Abstract

A process for preparing a renewable product from a biological feedstock wherein the biological feedstock is contacted with a hydroconversion catalyst under hydroconversion conditions, the biological feedstock comprising one or more biological components, and the hydroconversion catalyst comprising a hydrotreating catalyst and a hydroisomerization catalyst.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is related to and claims the benefit of priority of U.S. Provisional Patent Application Serial No. 63 / 357,626, filed on June 30, 2022, entitled “CATALYST AND PROCESS TO MAKERENEWABLE DIESEL AND SUSTAINABLE AVIATION FUEL,” the disclosure of which is incorporated herein in its entirety. Technical Field

[0003] Described herein are processes for the hydroconversion of biomass and biocomponent feedstocks to produce renewable products such as renewable diesel and / or sustainable aviation fuel. Background Art

[0004] In the process of developing alternatives to fossil fuels, the use of renewable resources has attracted great attention and efforts. The diversity, availability and versatility of various bio-based feedstocks, especially certain lipid sources and other carbohydrates, have received great attention, leading to the development and commercial application of many bio-based fuel technologies. Continuing economic interests and the desire to reduce fossil fuel use have provided incentives for the improvement of existing technologies and the development of new methods for using renewable bio-based feedstocks to produce renewable fuels and other renewable products.

[0005] Renewable fuel (biofuel) is regarded as an important means to reduce carbon and greenhouse gas emissions. Biofuel derived from food is a fuel made from food sources produced on arable land, and biofuel derived from non-food sources is generally produced by lignocellulosic biomass such as forestry residues or agricultural residues / waste. Typical biological raw materials in food source categories include multiple lipids (for example, vegetable oils, including used cooking oils, seed oils, animal fats, waste oils, algae oils, etc.). Typical non-food source raw materials include wood, grass, algae, crop byproducts, municipal solid waste, etc. Although renewable fuels derived from non-food sources are sometimes more preferred than biofuels derived from food sources, there is still a continuous need to improve the hydroconversion method for all raw material sources to produce renewable products such as sustainable aviation fuel and / or renewable diesel. Summary of the invention

[0006] The present invention relates to methods for preparing renewable products from biological feedstocks, such as feedstocks containing biocomponents of biological origin. Sustainable aviation fuel and renewable diesel or components thereof can be produced.

[0007] In one aspect, a method for preparing a sustainable jet fuel is provided, the method comprising contacting a hydrocarbon-containing feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a bio-feedstock or a biocomponent feedstock, and the hydroconversion catalyst comprises zeolite SSZ-91

[0008] In another aspect, a method for flexibly preparing sustainable jet fuel and / or renewable diesel from the same hydrocarbonaceous feedstock is provided, the method comprising contacting the hydrocarbonaceous feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a biofeedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

[0009] In another aspect, a method for upgrading a hydrocarbonaceous feedstock is provided, the method comprising contacting the hydrocarbonaceous feedstock and a hydroconversion catalyst under hydroconversion conditions to provide a diesel fuel that is both hydrotreated and hydroisomerized and has a reduced cloud point and / or a reduced pour point as compared to the cloud point and pour point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized, and / or to provide a jet fuel that is both hydrotreated and hydroisomerized and has a boiling point range and / or a reduced jet fuel freezing point as compared to the jet fuel boiling point range and / or jet fuel freezing point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized; wherein the hydrocarbonaceous feedstock comprises or is a biofeedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

[0010] In another aspect, a method for providing a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of a hydrotreated feedstock from which the diesel fuel is produced is provided, the method comprising contacting a diesel feedstock and a hydroconversion catalyst comprising zeolite SSZ 91 under hydroconversion conditions to provide a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of the hydrotreated feedstock from which the diesel fuel is produced, wherein the feedstock comprises or is a biomass feedstock or a biocomponent feedstock.

[0011] In another aspect, a method for providing a jet fuel that exhibits a reduced jet fuel freezing point and / or an improved jet fuel boiling point range as compared to the jet fuel freezing point and / or the jet fuel boiling point range of a hydrotreated feedstock from which the jet fuel is produced is provided, the method comprising contacting a jet fuel feedstock and a hydroconversion catalyst comprising zeolite SSZ-91 under hydroconversion conditions to provide a jet fuel that exhibits a reduced jet fuel freezing point and / or an improved jet fuel boiling point range as compared to the jet fuel freezing point and / or the jet fuel boiling point range of the hydrotreated feedstock from which the jet fuel is produced, wherein the feedstock comprises or is a biofeedstock or a biocomponent feed.

[0012] Those skilled in the art will appreciate that, unless mutually exclusive, the features described with respect to any aspect or embodiment described herein may be applied to any other aspect and / or embodiment through necessary changes. In addition, unless mutually exclusive, any feature described herein may be applied to any aspect / embodiment and / or combined with any other feature described herein. DETAILED DESCRIPTION

[0013] Although illustrative embodiments of one or more aspects are provided herein, the disclosed processes may be implemented using any number of techniques. The present disclosure is not limited to the exemplary or specific embodiments, any drawings, and any techniques (including any exemplary designs and embodiments illustrated and described herein) illustrated herein, and may be modified within the scope of the appended claims and the full scope of their equivalents.

[0014] The following description of the embodiment provides non-limiting representative examples, which refer to numbers to specifically describe the features and teachings of different aspects of the present invention. The described embodiments should be considered to be able to be implemented alone or in combination with other embodiments from the description of the embodiment. A person of ordinary skill in the art can learn and understand the different described aspects of the present invention when reading the description of the embodiment. The description of the embodiment should contribute to the understanding of the present invention, so that after reading the description of the embodiment, other implementation methods that are not specifically involved but within the scope of their ability will be understood as consistent with the application of the present invention.

[0015] Unless otherwise indicated, the following terms have the meanings as defined below.

[0016] The term "hydroconversion" refers to a process or step of hydrocracking, hydrogenation, hydrodeoxygenation, hydrodesulfurization, hydrodenitrogenation, hydrodemetallization, hydrodechlorination, hydrodecarboxylation, hydrodecarbonylation and / or hydrodearomatization of hydrocarbon or biomass feedstock (e.g., impurities) in the presence of hydrogen, and / or hydrogenation of unsaturated compounds in the feedstock. Depending on the type of hydrocracking and reaction conditions, the products of the hydrocracking process may have, for example, improved aromatic content, oxygen content, viscosity, viscosity index, saturate content, low temperature characteristics, volatility, and depolarization.

[0017] The term "hydroprocessing" refers to a process or step of hydrodesulfurizing, hydrodenitrogenating, hydrodeoxygenating, hydrodemetallizing and / or hydrodearomatizing components (e.g., impurities) of a feedstock in the presence of hydrogen, and / or hydrogenating unsaturated compounds in the feedstock.

[0018] As used herein, the term "biological raw material" refers to a biocomponent feedstock from or derived from a biological source. Exemplary biological raw materials include lipids, pyrolysis oils, biomass-derived feedstocks, etc. Triglycerides are components of some biological raw materials, such as lipids. Biological raw materials generally have a boiling range suitable for producing diesel, aviation or other fuels or distillates obtained therefrom. In the case of some biological raw materials containing triglycerides, such raw materials have an "apparent" boiling temperature range (based on the GC elution time of the triglyceride peak according to Simdist method ASTM D-2887) suitable for producing diesel, aviation or other fuels or distillates obtained therefrom. The biological raw material boiling range (or apparent boiling range) may also be suitable for producing base oils or components thereof. In some embodiments, the boiling point range of the biological raw material is about 250°F (121°C) to about 900°F (482°C), for example, about 300°F (149°C) to about 900°F (482°C) or about 250°F (121°C) to about 800°F (427°C). In some cases, for example, for typical lipids after hydroprocessing, a maximum boiling point of about 900°F (482°C) includes hydrocarbon molecules having a number of carbon atoms that makes them suitable for use in the applications described herein.

[0019] As used herein, the term "biocomponent feedstock" is used to refer to feedstock derived from a biocomponent-containing source, such as a plant-based oil or fat, an animal-based oil or fat, a fish-based oil or fat, or an algae-based oil or fat. In some embodiments, the biocomponent feedstock has a boiling point range of about 250°F (121°C) to about 900°F (482°C) at atmospheric pressure, such as about 300°F (149°C) to about 900°F (482°C), about 400°F to about 900°F (about 204°C to about 482°C), about 500°F to about 900°F (about 260°C to about 482°C), about 600°F (316°C) to about 900°F (482°C), or about 700°F (371°C) to about 900°F (482°C). In some embodiments, the 90% distillation temperature of the biocomponent feed is less than about 1000°F (538°C) or 900°F (482°C) or 800°F (427°C) or 700°F (371°C), or less than about 650°F (343°C). In some embodiments, the 90% distillation temperature of the biocomponent feed is in the range of about 550°F (288°C) to about 750°F (399°C), such as about 550°F (288°C) to about 700°F (371°C), about 600°F (316°C) to about 700°F (371°C). The 90% distillation temperature can be determined according to ASTM D-2887. In some embodiments, the 5% distillation temperature of the biocomponent feed is in the range of about 250°F (121°C) to about 600°F (316°C), such as about 300°F (149°C) to about 600°F (316°C) or about 400°F (204°C) to about 600°F (316°C). The 5% distillation temperature can be determined according to ASTM D 2887. In some embodiments, the biocomponent feed has a 90% distillation temperature in the range of about 550°F (about 288°C) to about 750°F (about 399°C) and a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C). In some embodiments, the biocomponent feed has a 90% distillation temperature in the range of about 550°F (288°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 300°F (149°C) to about 600°F (316°C). In some embodiments, the biocomponent feed has a 90% distillation temperature above about 600°F (316°C), such as about 605°F (about 318°C) to about 675°F (357°C) and a 5% distillation temperature below about 600°F (316°C), such as about 540°F (282°C) to about 580°F (304°C). In some embodiments, the biocomponent feed has a 90% distillation temperature in the range of about 600°F (316°C) or above to about 700°F (371°C) and a 5% distillation temperature in the range of about 400°F (204°C) to about 600°F (316°C) or below.In some cases, for example, for typical lipids after hydroprocessing, a maximum boiling point of about 900°F (482°C) includes hydrocarbon molecules having a number of carbon atoms that makes them suitable for use in the applications described herein.

[0020] As used herein, the term "diesel fuel" refers to hydrocarbon products having a boiling point in the range of about 300°F to about 800°F (about 149°C to about 427°C) at atmospheric pressure.

[0021] The term "active source" means a reagent or precursor material that is capable of providing at least one element in a reactive form and that can be incorporated into the molecular sieve structure. The terms "source" and "active source" are used interchangeably herein.

[0022] The terms "molecular sieve" and "zeolite" are synonymous and include (a) intermediate and (b) final or target molecular sieves as well as molecular sieves produced by (1) direct synthesis or (2) post-crystallization treatment (secondary modification). Secondary synthesis techniques allow the synthesis of target materials from intermediate materials by heteroatom lattice substitution or other techniques. For example, aluminosilicates can be synthesized from intermediate borosilicates by post-crystallization heteroatom lattice substitution of Al for B. Such techniques are known, for example, as described in U.S. Pat. No. 6,790,433, issued Sept. 14, 2004 to CY Chen and Stacey Zones.

[0023] The terms "*MRE type molecular sieve", "EUO type molecular sieve" and "MTT type molecular sieve" include all molecular sieves specified in the International Zeolite Association framework and their isotypes, as described in Atlas of Zeolite Framework Types, edited by Ch. Baerlocher, LB McCusker and DH Olson, Elsevier, 6th revised edition, 2007 and in the Zeolite Structure Database on the International Zeolite Association website (http: / / www.iza-online.org).

[0024] SiO2 / Al2O3 Ratio (SAR): Determined by ICP elemental analysis. An infinite (∞) SAR indicates that there is no aluminum in the zeolite, i.e., the molar ratio of silica to alumina is infinite. In this case, the molecular sieve consists essentially of silica.

[0025] As used herein, the term "pour point" refers to the temperature at which an oil begins to flow under controlled conditions. The pour point can be determined by ASTM D5950.

[0026] As used herein, "cloud point" refers to the temperature at which a sample begins to appear cloudy as the oil cools under specified conditions. The cloud point can be determined by ASTM D5773.

[0027] "Group 2, 8, 9 and 10 metals" refers to elemental metals selected from Groups 2, 8, 9 and 10 of the Periodic Table of the Elements and / or metal compounds comprising such metals. "Group 6 metals" refers to elemental metals selected from Group 6 of the Periodic Table of the Elements and / or metal compounds comprising such metals.

[0028] The term "periodic table" refers to the version of the IUPAC periodic table as of December 1, 2018.

[0029] Unless otherwise indicated, the "feed rate" of a feedstock fed to a catalytic reaction zone is expressed herein as the volume of feed per volume of catalyst per hour, which may be referred to as the reciprocal hour (h -1 ) is the liquid hourly space velocity (LHSV).

[0030] For the purpose of this specification and the appended claims, unless otherwise stated, all the numbers representing quantity, percentage or ratio and other numerical values ​​used in the specification and claims should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters set forth in the following specification and the appended claims are approximate values ​​that can be changed according to the desired properties to be sought to obtain. It should be noted that, as used in this specification and the appended claims, unless clearly and explicitly limited to an indicator, the singular forms "a kind of / one (a)", "a kind of / one (an)" and "the" include multiple indicators. As used herein, the term "include" and its grammatical variants are intended to be non-restrictive, so that the narration of the items in the list does not exclude other similar items that can be replaced or added to the listed items. As used herein, the term "include" means to include the elements or steps identified after the term, but any such element or step is not exhaustive, and the embodiment may include other elements or steps.

[0031] Unless otherwise specified, the description of the type of element, material or other component (from which a single component or a mixture of components can be selected) is intended to include all possible sub-class combinations of the listed components and mixtures thereof. In addition, all numerical ranges proposed herein include their upper and lower limits.

[0032] If a standard test is referred to herein, the version of the test referred to is the most recent version at the time this patent application was filed, unless otherwise stated.

[0033] The patentable scope is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims. All citations mentioned herein are hereby incorporated by reference herein to the extent not inconsistent with this document.

[0034] The biological raw materials described herein include biocomponent feedstock or are biocomponent feedstock. In some embodiments, the biological raw materials include biocomponent feedstock, are essentially composed of biocomponent feedstock, or are composed of biocomponent feedstock. In some embodiments, the biocomponent feedstock constitutes at least about 5% by weight of the biological raw materials, such as at least about 10% by weight of the biological raw materials, at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, at least about 90% by weight, at least about 95% by weight, at least about 98% by weight, or at least about 99% by weight. In some embodiments, the biocomponent feedstock constitutes 5% to 100% by weight of the biological raw materials, such as 10% to 100% by weight of the biological raw materials, 50% to 100% by weight, 80% to 100% by weight, 95% to 100% by weight.

[0035] In some embodiments, the biological raw material comprises, consists essentially of, or consists of a biocomponent feedstock. In some embodiments, the biocomponent feedstock constitutes at least about 5% by weight of the biological raw material, such as at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, at least about 90% by weight, at least about 95% by weight, at least about 98% by weight, or at least about 99% by weight of the biological raw material. In some embodiments, the biocomponent feedstock constitutes 5% to 100% by weight of the biological raw material, such as 10% to 100% by weight, 50% to 100% by weight, 80% to 100% by weight, 95% to 100% by weight of the biological raw material.

[0036] In some embodiments, the biological feedstock is a blended feedstock comprising a biocomponent feedstock, or further comprising a hydrocarbon (e.g., petroleum) feedstock in combination with another feedstock such as a blended feedstock. For example, the blended feedstock may comprise a blended feedstock selected from gas oil, vacuum gas oil, long boiling residue, vacuum residue, atmospheric distillate, heavy fuel, oil, wax and paraffin, waste oil, deasphalted residue or crude oil, a charge produced by a thermal or catalytic conversion process, or a combination thereof. In some embodiments, the blended feed is selected from whole crude oil, atmospheric crude oil, vacuum tower residue, cycle oil, synthetic crude oil, gas oil, vacuum gas oil, bottoms oil, Fischer-Tropsch derived wax, lubricating oil stock, heating oil, heavy neutral feed, hydrotreated gas oil, hydrocracked gas oil, hydrotreated lubricating oil raffinate, bright stock, lubricating oil stock, synthetic oil, high pour point polyolefin (e.g., polyolefin with a pour point of about 0°C or higher); normal alpha olefin wax, slack wax, deoiled wax, microcrystalline wax, residual oil fraction from atmospheric distillation process, solvent deasphalted petroleum residue, shale oil, cycle oil, petroleum wax, slack wax and wax produced in chemical plant process. In some embodiments, the feedstock is a blended feedstock comprising biocomponent feed and non-biocomponent hydrocarbon feed. In some embodiments, the feedstock is a blended feedstock comprising biocomponent feed, hydrocarbon feed and blended feed (e.g., the same blended feed). The blended feedstock, blended feedstock and / or biofeedstock may also contain recycled products and / or intermediate process streams.

[0037] In some embodiments, the feedstock is a blended feedstock comprising a biocomponent feed and a blended feed, wherein the blended feedstock comprises at least about 5 wt % biocomponent feed and up to about 95 wt % blended feed, e.g., at least about 10 wt % biocomponent feed and up to about 90 wt % blended feed, at least about 50 wt % biocomponent feed and up to about 50 wt % blended feed, at least about 80 wt % biocomponent feed and up to about 20 wt % blended feed, or at least about 95 wt % biocomponent feed and up to about 5 wt % blended feed.

[0038] The paraffin content of the Fischer-Tropsch feed (if used) is typically at least about 90 wt %, such as at least about 95 wt % or at least about 97.5 wt %. The Fischer-Tropsch feed typically contains only very small amounts of olefins and cycloalkanes, such as less than about 1.0 wt % olefins or less than about 0.5 wt % olefins and / or less than about 1.0 wt % cycloalkanes, less than about 0.5 wt % cycloalkanes or less than about 0.1 wt % cycloalkanes. In some embodiments, the S content of the Fischer-Tropsch feed is less than about 50 ppm, such as less than about 20 ppm. In some embodiments, the N content of the Fischer-Tropsch feed is less than about 50 ppm, such as less than about 20 ppm. In some embodiments, the metal content of the Fischer-Tropsch feed is less than about 10 ppm, such as less than about 5 ppm. The paraffin content and cycloparaffin content of the Fischer-Tropsch feed can be determined by GC-FIMS analysis, as described in "Diesel Fuel Analysis by GC-FIMS: Normal Paraffins, Isoparaffins and Cycloparaffins", Briker, Y. et al., Energy Fuels 2001, Vol. 15 No. 4: pp. 996-1002. The nitrogen content of the Fischer-Tropsch feed can be determined according to ASTM D3228-20. The sulfur content of the Fischer-Tropsch feed can be determined according to ASTM D4629. The metal content of the Fischer-Tropsch feed can be measured by inductively coupled plasma atomic emission spectroscopy (ICPAES).

[0039] In some embodiments, the feedstock may include a blended feedstock comprising a combination of a Fischer-Tropsch feedstock and a blended feedstock, wherein the blended feedstock comprises at least about 5 wt% of the Fischer-Tropsch feedstock and up to about 95 wt% of the blended feedstock, e.g., at least about 10 wt% of the Fischer-Tropsch feedstock and up to about 90 wt% of the blended feedstock, at least about 50 wt% of the Fischer-Tropsch feedstock and up to about 50 wt% of the blended feedstock, at least about 80 wt% of the Fischer-Tropsch feedstock and up to about 20 wt% of the blended feedstock, or at least about 95 wt% of the Fischer-Tropsch feedstock and up to about 5 wt% of the blended feedstock.

[0040] In some embodiments, biological raw materials comprise biocomponent feed, are substantially composed of biocomponent feed or are composed of biocomponent feed.Oil and fat based on plants include vegetable oil and fat, such as rapeseed (canola) oil, soybean oil, coconut oil, sunflower oil, palm oil, palm kernel oil, peanut oil, linseed oil, rapeseed oil, tall oil, corn oil, castor oil, jatropha oil, jojoba oil, olive oil, linseed oil, hempseed oil, cottonseed oil, camelina oil, safflower oil, mustard oil, calyx is apart from flower oil, jatropha oil, sea kale seed oil, babassu oil, tallow and rice bran oil.Animal oil and fat and other sources include beef fat (tallow), pig fat (lard), turkey fat, fish fat / fish oil and chicken fat, yellow and brown grease (including algae and fish fat / oil), fat in milk, sewage sludge etc.

[0041] In some embodiments, the biocomponent feedstock is selected from plant oils and animal fats comprising or consisting essentially of triglycerides and free fatty acids (FFA). In some embodiments, the biological raw material comprises or is a biocomponent feedstock selected from lipids, plant oils, and animal fats comprising triglycerides and free fatty acids, for example, wherein the biocomponent feedstock is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

[0042] In some embodiments, triglycerides and FFAs contain aliphatic hydrocarbon chains having 6-24 carbon atoms (e.g., 8 to 24, 8 to 20, or 10-16 carbon atoms) in their structures. In some embodiments, the biocomponent feed comprises triglycerides having the general formula (1):

[0043]

[0044] Among them, R 1 and R 2 is independently an aliphatic hydrocarbon chain having 6-24 carbon atoms (e.g., 8 to 24, 8 to 20, 10-20, 10-18, or 10-16 carbon atoms). 1 and R 2 are independently branched or unbranched, substituted or unsubstituted, fully saturated, or contain one or more (e.g., 1-4, 1-3, or 1 or 2) unsaturated carbon-carbon bonds. 1 and R 2 is unsubstituted. In some embodiments, R, R 1 and R 2 are independently fully saturated, or contain one or more (e.g., 1-4, 1-3, or 1 or 2) unsaturated carbon-carbon bonds. 1 and R 2 It is non-branched.

[0045] In some embodiments, the biocomponent feed comprises free fatty acids (FFAs) having aliphatic hydrocarbon tails of 6 to 24 carbon atoms, e.g., 8 to 24 carbon atoms, 8 to 20 carbon atoms, 10 to 20 carbon atoms, 10 to 18 carbon atoms, or 10-16 carbon atoms. In some embodiments, the FFAs comprise unsaturated or saturated aliphatic hydrocarbon tails. In some embodiments, the FFAs comprise unbranched or branched aliphatic hydrocarbon tails.

[0046] In some embodiments, the biocomponent feed is selected from the group consisting of canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

[0047] In some embodiments, the oxygenate content of the biocomponent feed is at least about 0.5% by weight, for example, at least about 1.0% by weight, at least about 2.0% by weight, at least about 3.0% by weight, at least about 4.0% by weight, or at least about 5.0% by weight, based on the total weight of the biocomponent feed. In some embodiments, the oxygenate content of the biocomponent feed is up to about 15% by weight, for example, up to about 10% by weight, or up to about 5% by weight, based on the total weight of the biocomponent feed. In some embodiments, the oxygenate content of the biocomponent feed is in the range of about 1-15% by weight, for example, in the range of about 5-15% by weight or about 10-15% by weight, based on the total weight of the biocomponent feed. The oxygenate content of the biocomponent feed can be measured by neutron activation analysis, for example, according to ASTM E385-90 (2002).

[0048] In some embodiments, the biocomponent feed is hydrotreated and then contacted with a hydroconversion catalyst, such as a hydroisomerization / hydrodewaxing catalyst, for further hydroprocessing. In some embodiments, the sulfur (S) content of the biocomponent feed is less than about 200 ppm, such as less than about 100 ppm, less than about 50 ppm, or less than about 20 ppm. In some embodiments, the nitrogen (N) content of the biocomponent feed is less than about 50 ppm, such as less than about 20 ppm or less than about 10 ppm. In some embodiments, the oxygenate content of the hydrotreated biocomponent feed is generally about 0 wt %, or alternatively less than about 2 wt % or 5 wt %. The nitrogen content of the biocomponent feed can be determined according to ASTM D4629. The sulfur content of the biocomponent feed can be determined according to ASTM D2622.

[0049] The hydroconversion catalyst may include a hydrotreating catalyst and / or a hydroisomerization catalyst, and may include a noble metal catalyst as a hydroconversion catalyst. In other cases, the hydroconversion catalyst may include a base metal catalyst and a noble metal catalyst. Although not limited thereto, the base metal catalyst generally includes a base metal selected from the following: Mo, Ni, W, Co and a combination thereof, or a combination of Mo or Mo and Ni. Similarly, although not limited thereto, the noble metal catalyst generally includes a noble metal selected from Pt, Pd or a combination thereof.

[0050] As used herein, the term "hydroisomerization catalyst" refers to a catalyst that facilitates the skeletal isomerization of hydrocarbon molecules. In some embodiments, suitable hydroisomerization catalysts include catalysts comprising zeolite SSZ-91. Other hydroisomerization catalysts may also be suitable, including, for example, catalysts based on zeolite SSZ-32 and / or zeolite SSZ-32x. Combinations of suitable hydroisomerization catalysts based on the same or different zeolite supports may also be used.

[0051] In some embodiments, the hydroisomerization catalyst comprises zeolite SSZ-91, or about 5 to about 95 weight percent zeolite SSZ-91, based on the total weight of the hydroisomerization catalyst, or about 10 to about 95 weight percent zeolite SSZ-91, or about 20 to about 90 weight percent zeolite SSZ-91, or about 25 to about 85 weight percent zeolite SSZ-91, or about 30 to about 80 weight percent zeolite SSZ-91, or about 35 to about 75 weight percent zeolite SSZ-91, or about 35 to about 65 weight percent zeolite SSZ-91, or about 35 to about 55 weight percent zeolite SSZ-91, or about 45 to about 75 weight percent zeolite SSZ-91, or about 55 to about 75 weight percent zeolite SSZ-91, based on the total weight of the hydroisomerization catalyst.

[0052] The hydroisomerization catalyst also comprises a metal modifier, such as a metal modifier selected from the 2nd, 8th, 9th and 10th group metals or a combination thereof. In some embodiments, the metal modifier is selected from the 8th, 9th or 10th group metals and combinations thereof, such as the metal modifier can be selected from Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt and combinations thereof. In some embodiments, the metal modifier is selected from the 10th group metals and combinations thereof. In some embodiments, the hydroisomerization catalyst comprises platinum, palladium or a combination thereof. Base metals may be included in the catalyst.

[0053] In some embodiments, the hydroisomerization catalyst comprises about 0.05 to about 10 wt%, or 5 wt% or 2.0 wt% of a metal modifier (e.g., selected from Groups 2, 8, 9, and 10 metals, or Groups 8, 9, or 10 metals, e.g., Group 10 metals such as platinum), based on the total weight of the hydroisomerization catalyst, for example, about 0.1 to about 1.5 wt%, or about 0.2 to about 1.5 wt%, or about 0.1 to about 1 wt%, based on the total weight of the hydroisomerization catalyst. In some cases, such as when base metals are included, the metal content can be higher, such as at least about 5 wt%, or 10 wt%, or 15 wt% or 20 wt%, or 25 wt%, or at least about 30 wt%, or in the range of about 2 wt% or 5 wt% to about 25 wt% or 30 wt%.

[0054] In some embodiments, the hydroisomerization catalyst comprises an oxide binder. In some embodiments, the oxide binder is an inorganic oxide, for example, the oxide binder can be selected from alumina, silica, ceria, titania, tungsten oxide, zirconium oxide, and combinations thereof. In some embodiments, the hydroisomerization catalyst comprises an oxide binder, which oxide binder includes alumina. Suitable aluminas are commercially available, including, for example, from of Alumina and Alumina or from of Alumina. Generally, the alumina can be any alumina known for use as a matrix material in a catalyst matrix. For example, the alumina can be boehmite, bayerite, g-alumina, h-alumina, q-alumina, d-alumina, c-alumina, or a mixture thereof. In some embodiments, the hydroisomerization catalyst comprises about 5 to about 95 weight percent of an oxide binder, such as about 5 to about 80 weight percent of an oxide binder, about 10 to about 70 weight percent of an oxide binder, about 20 to about 70 weight percent of an oxide binder, such as about 25 to about 65 weight percent of an oxide binder, based on the total weight of the hydroisomerization catalyst.

[0055] In some embodiments, the hydroisomerization catalyst comprises from about 5 to about 95 weight percent zeolite SSZ-91, based on the total weight of the hydroisomerization catalyst; from about 0.05 to about 2.0 weight percent Group 8-10 metal; and from about 5 weight percent to about 95 weight percent oxide binder. In some embodiments, the hydroisomerization catalyst comprises from about 30 to about 80 weight percent zeolite SSZ-91, based on the total weight of the hydroisomerization catalyst; from about 0.1 to about 1.5 weight percent Group 8-10 metal; and from about 20 weight percent to about 70 weight percent oxide binder.

[0056] Zeolite SSZ-91 and a process for preparing zeolite SSZ-91 are described in US-A-9920260, which is incorporated herein by reference in its entirety.Zeolite SSZ-91 may also be referred to as SSZ-91 molecular sieve.

[0057] Zeolite SSZ-91 has a SiO2 / Al2O3 molar ratio (SAR) of 40 to 220. In some embodiments, zeolite SSZ-91 has a SiO2 / Al2O3 molar ratio (SAR) of 40 to 220, e.g., 70 to 200, 80 to 200, 70 to 180, 80 to 180, 70 to 160, 80 to 160, 70 to 140, 80 to 140, 100 to 160, 100 to 140, or 120 to 140. SAR is determined by inductively coupled plasma (ICP) elemental analysis.

[0058] Zeolite SSZ-91 is composed of at least 70% polytype 6 of the total ZSM-48-type material present in the product. The proportion of polytype 6 in the total ZSM-48-type material present in the product was determined by DIFFaX simulations and as described by Lobo and Koningsveld in J. Am. Chem. Soc. 2012, 124, 13222-13230, where disorder is adjusted by three different failure probabilities. It should be noted that the phrase "at least X%" includes the case where no other ZSM-48 polytypes are present in the structure, i.e. the material is 100% polytype 6. The structure of polytype 6 is as described by Lobo and Koningsveld ( See also , J. Am. Chem. Soc. 2002, 124, 13222-13230). In some embodiments, the SSZ-91 material consists of at least 80% polytype 6 of the total ZSM-48-type material present in the product. In some embodiments, the SSZ-91 material consists of at least 90% polytype 6 of the total ZSM-48-type material present in the product. The polytype 6 structure has been given the framework code *MRE by the Structure Committee of the International Zeolite Association.

[0059] Zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio in the range of 1 to 8. In some embodiments, zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio in the range of 1 to 6, e.g., 1 to 5, 1 to 4, or 1 to 3.

[0060] In some embodiments, zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates with diameters between about 100 nm and 1.5 μm, each of which comprises a series of crystallites with an overall average aspect ratio ranging from 1 to 8. In some embodiments, zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates with diameters between about 100 nm and 1.5 μm, each of which comprises a series of crystallites with an overall average aspect ratio ranging from 1 to 6, such as 1 to 5, 1 to 4, or 1 to 3. As used herein, the term diameter refers to the shortest length on the short end of each crystallite examined.

[0061] Zeolite SSZ-91 is a substantially pure phase material. As used herein, the term "substantially pure phase material" means that the material is completely free of zeolite phases other than those belonging to the ZSM-48 zeolite family, or the amount of its presence has an insufficiently measurable effect on the selectivity of the material, or is insufficient to cause a material disadvantage in the selectivity of the material. Two common phases co-crystallized with SSZ-91 are EUO-type molecular sieves, such as EU-1, and Magadiite and Kenyaite. These additional phases may exist as separate phases, or may coexist with the SSZ-91 phase.

[0062] In some embodiments, zeolite SSZ-91 comprises an EUO-type molecular sieve phase in an amount ranging from 0 to 7 wt % based on the weight of the total zeolite SSZ-91 product. In some embodiments, zeolite SSZ-91 comprises an EUO-type molecular sieve phase in an amount ranging from 0 to 5.0 wt %, such as 0 to 4.0 wt % or 0 to 3.5 wt %. In some embodiments, zeolite SSZ-91 comprises an EUO-type molecular sieve phase in an amount ranging from 0.1 to 7.0 wt %, such as 0.1 to 5.0 wt %, 0.1 to 4.0 wt % or 0.1 to 3.5 wt %. In some embodiments, zeolite SSZ-91 comprises 0 to 7 wt% EU-1, e.g., 0 to 5.0 wt% EU-1, 0 to 4.0 wt% EU-1, 0 to 3.5 wt% EU-1, 0.1 to 7.0 wt% EU-1, 0.1 to 5.0 wt% EU-1, 0.1 to 4.0 wt% EU-1, 0.1 to 3.5 wt% EU-1, 0.1 to 2 wt% EU-1, or 0.1 to 1 wt% EU-1.

[0063] It is known that the ratio of the powder XRD peak intensity varies linearly as a function of the weight fraction of any two phases in a mixture: (Iα / Iβ)=(RIRα / RIRβ)*(xα / xβ), where the RIR (reference intensity ratio) parameter can be found in the Powder Diffraction File (PDF) database of the International Diffraction Data Center (http: / / www.icdd.com / products / ). Therefore, the weight percentage of the EUO phase in zeolite SSZ-91 can be calculated by measuring the ratio between the peak intensity of the EUO phase and the peak intensity of the SSZ-91 phase.

[0064] In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 40 to 220; at least 70% polytype 6 of the total ZSM-48-type material; 0 to 7.0 wt% of the EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 8. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 40 to 220; at least 70% polytype 6 of the total ZSM-48-type material; 0 to 4.0 wt% of the EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 8. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 40 to 220; at least 70% polytype 6 of the total ZSM-48-type material; 0 to 3.5 wt% of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 8. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 40 to 200; at least 70% polytype 6 of the total ZSM-48-type material; 0 to 4.0 wt% of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 8. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 70 to 200; at least 70% polytype 6 of the total ZSM-48-type material; 0 to 4.0 wt% of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 80 to 200; at least 70% polytype 6 of the total ZSM-48-type material; 0.1 to 7.0 wt% of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 80 to 200; at least 70% polytype 6 of the total ZSM-48 type material; 0.1 to 4.0 weight percent EUO type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by comprising polycrystalline aggregates of crystallites having an overall average aspect ratio between 1 and 6.In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 80 to 200; at least 70% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent EU-1; ​​wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 80 to 200; at least 70% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 80 to 160; at least 70% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 70 to 160; at least 70% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 70 to 200; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 80 to 200; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 6. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 80 to 200; at least 80% polytype 6 of the total ZSM-48 type material; 0.1 to 7.0 weight percent of an EUO type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by comprising polycrystalline aggregates of crystallites having an overall average aspect ratio between 1 and 4.In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 80 to 200; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 4. In some embodiments, zeolite SSZ-91 comprises a silica (SiO2) to alumina (Al2O3) molar ratio (SAR) of 80 to 160; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of an EUO-type molecular sieve phase; wherein the zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 4. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 100 to 140; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of EUO-type molecular sieve phase; wherein zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 4. In some embodiments, zeolite SSZ-91 comprises a silicon oxide (SiO2) to aluminum oxide (Al2O3) molar ratio (SAR) of 100 to 140; at least 80% polytype 6 of the total ZSM-48-type material; 0.1 to 4.0 weight percent of EU-1; ​​wherein zeolite SSZ-91 has a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of between 1 and 4.

[0065] The zeolite SSZ-91 synthesized as described herein can be characterized by their XRD patterns. The powder XRD lines in Table 1 represent the original synthesized zeolite SSZ-91. Minor changes in the diffraction pattern may be due to changes in the lattice constant caused by changes in the molar ratio of the framework material of the sample. In addition, sufficiently small crystals will affect the shape and intensity of the peaks, resulting in significant broadening of the peaks. Minor changes in the diffraction pattern may also be caused by changes in the organic compounds used in the preparation and changes in the Si / Al molar ratio between samples. Calcination may also cause minor changes in the XRD pattern. Despite these minor perturbations, the basic lattice structure remains unchanged.

[0066] Table 1

[0067] Characteristic peaks of the original synthesized SSZ-91

[0068] 2-θ (a) d-spacing (nm) Relative Strength (b)

[0069] 7.55 1.170 W

[0070]

[0071] (a) ±0.20

[0072] (b) The powder XRD patterns provided are based on a relative intensity scale, where

[0073] The strongest line in the X-ray pattern was assigned a value of 100: W = weak (>0 to ≤20);

[0074] M = moderate (>20 to ≤40); S = strong (>40 to ≤60); VS = very strong (>60 to ≤100).

[0075] The X-ray diffraction patterns in Table 2 represent calcined SSZ-91.

[0076] Table 2 Characteristic peaks of calcined SSZ-91

[0077]

[0078] (a) ±0.20

[0079] (b) The powder XRD patterns provided are based on a relative intensity scale, where the most intense line in the X-ray pattern is assigned a value of 100: W = weak (>0 to ≤20);

[0080] M = moderate (>20 to ≤40); S = strong (>40 to ≤60); VS = very strong (>60 to ≤100).

[0081] The powder X-ray diffraction patterns presented herein were collected by standard techniques. The radiation is CuK α The peak height and position (as a function of 2θ, where θ is the Bragg angle) are read from the relative intensity of the peak (adjusted for the background), and the interplanar spacing d corresponding to the recorded line can be calculated.

[0082] Zeolite SSZ-91 can be used in the as-synthesized state, but is typically heat treated (calcined). The term "as-synthesized" refers to zeolite SSZ-91 in the form after crystallization and before removal of SDA cations. SDA can be removed by heat treatment (e.g., calcination), such as calcination in an oxidizing atmosphere (e.g., air, a gas with an oxygen partial pressure greater than 0 kPa) at a temperature that can be easily determined by one skilled in the art to be sufficient to remove SDA from the molecular sieve. SDA can also be removed by ozonation and photolysis techniques as described in U.S. Pat. No. 6,960,327 (e.g., exposing a molecular sieve product containing SDA to light or electromagnetic radiation with a wavelength shorter than visible light under conditions sufficient to selectively remove organic compounds from the molecular sieve).

[0083] The zeolite SSZ-91 may then be calcined in steam, air or an inert gas at a temperature in the range of 200°C to 800°C for a period of time ranging from 1 hour to several days, such as in the range of 1 to 48 hours. Typically, it is desirable to remove extra-framework cations (e.g., Na + ) and replace it with hydrogen, ammonium or any desired metal ion.

[0084] When the molecular sieve formed is an intermediate molecular sieve, the target molecular sieve (e.g., zeolite SSZ-91) can be achieved using post-synthesis techniques (such as heteroatom lattice substitution techniques). The target molecular sieve (e.g., zeolite SSZ-91) can also be obtained by removing heteroatoms from the lattice by known techniques (such as acid leaching).

[0085] Zeolite SSZ-91 made by the methods disclosed herein can be formed into a variety of physical shapes. Zeolite SSZ-91 can be in the form of a powder, granules, or a molded product, such as an extrudate having a particle size sufficient to pass through a 2-mesh (Tyler) screen and be retained on a 400-mesh (Tyler) screen. In the case where the catalyst is molded (such as by extrusion with an organic binder), the zeolite SSZ-91 can be extruded before drying, or dried or partially dried and then extruded.

[0086] Zeolite SSZ-91 can be compounded with other materials that are tolerant to the temperatures and other conditions employed in organic conversion processes. Such matrix materials include active and inactive materials and synthetic or naturally occurring molecular sieves and inorganic materials such as clays, silica, and metal oxides. Examples of such materials and the manner in which they can be used are disclosed in U.S. Pat. Nos. 4,910,006 and 5,316,753.

[0087] The hydroisomerization catalyst, such as zeolite SSZ-91, may be in as-synthesized or calcined form. In some embodiments, the hydroisomerization catalyst is formed from a calcined form of zeolite SSZ-91. In some embodiments, the hydroisomerization catalyst comprises a molecular sieve selected from zeolite SSZ-91 and a Group 2, 8, 9, or 10 metal (e.g., a Group 8-10 metal such as Pt).

[0088] In some embodiments, the hydroisomerization catalyst is formed by compounding molecular sieve zeolite SSZ-91 (in original synthetic or calcined form) with an oxide binder such as alumina. In some embodiments, compounding molecular sieve zeolite SSZ-91 (in original synthetic or calcined form) with an oxide binder includes mixing a molecular sieve selected from zeolite SSZ-91 (in original synthetic or calcined form) with an oxide binder and extruding the product. The mixture of molecular sieve and oxide binder can be formed into particles or extrudates with a wide range of physical shapes and sizes. In some embodiments, the extrudate or particles can be dried and calcined before loading metal. In some embodiments, the extrudate or particles are impregnated with metal, such as the 2nd, 8th, 9th or 10th group metals (e.g., 8th-10th group metals such as Pt), then dried and calcined. In some embodiments, the extrudate or particles are dried and calcined before loading metal.

[0089] In some embodiments, the hydroisomerization catalyst is prepared by compounding a molecular sieve (such as zeolite SSZ-91) with an oxide binder to form an extrudate base; impregnating the extrudate base with an impregnation solution containing a metal, e.g., a Group 2, 8, 9, or 10 metal (e.g., a Group 8-10 metal such as Pt), to form a metal-loaded extrudate; drying the metal-loaded extrudate; and calcining the dried metal-loaded extrudate.

[0090] In some embodiments, the hydroisomerization catalyst is formed by impregnating a molecular sieve (such as zeolite SSZ-91) with a solution containing a metal, e.g., a Group 2, 8, 9, or 10 metal (e.g., a Group 8-10 metal such as Pt). In some embodiments, the hydroisomerization catalyst is formed by impregnating a calcined form of a molecular sieve with a solution containing a Group 2, 8, 9, or 10 metal (e.g., a Group 8-10 metal such as Pt). In some embodiments, the hydroisomerization catalyst is formed by impregnating an extrudate base comprising a molecular sieve and an oxide binder. In some embodiments, the extrudate base is exposed to an impregnation solution (e.g., soaked in an impregnation solution) containing a metal (e.g., a Group 2, 8, 9, or 10 metal (e.g., a Group 8-10 metal such as Pt)) for 0.1 to 10 hours.

[0091] In some embodiments, the extrudate base is dried (e.g., at a temperature in the range of about 100°F (38°C) to about 300°F (149°C) for about 0.1 to about 10 hours) and calcined (at a temperature in the range of about 390°F (199°C) to about 1200°F (649°C) or about 600°F (316°C) to about 1200°F (649°C) for about 0.1 to about 10 hours) prior to impregnation.

[0092] In some embodiments, the extrudate base formed by the composite molecular sieve (e.g., from zeolite SSZ-91) and the oxide binder is dried and calcined prior to impregnation. In some embodiments, the dried and calcined extrudate base is impregnated with an impregnation solution to form a metal-loaded extrudate before being dried and calcined again to form a hydroisomerization catalyst.

[0093] In some embodiments, the impregnated extrudate base comprising zeolite SSZ-91 is dried at a temperature in the range of about 100°F (38°C) to about 300°F (149°C) for about 0.1 to about 10 hours. In some embodiments, the dried metal-loaded extrudate is calcined at a temperature in the range of about 600°F (316°C) to about 1200°F (649°C) for about 0.1 to about 10 hours. In some embodiments, the calcination is carried out in air.

[0094] The method of hydroconverting a biological feedstock comprises contacting the biological feedstock with a hydroconversion catalyst under hydroconversion conditions. The hydroconversion is carried out in the presence of hydrogen and may include hydrotreating and hydroisomerization processes.

[0095] In some embodiments according to the present invention, hydroconversion is carried out in the presence of a hydroconversion catalyst comprising SSZ-91. In some embodiments, the hydroisomerization catalyst comprises SSZ-91. In some embodiments, the biomass feedstock comprises only renewable biocomponents. The biomass feedstock may also be used alone, i.e., wherein no fossil fuel component or other non-biological feedstock component is added with the biomass feedstock.

[0096] The method can also be a single-stage method, for example, wherein intermediate products and / or final products are not removed between each stage or catalyst bed. In some embodiments, the method can be advantageously carried out in a single reactor. In some embodiments, the method can be carried out in two or more reactors connected in series, wherein the first reactor or catalyst section includes a hydrotreating section, and the reactor or catalyst section downstream of the first reactor or catalyst section includes a hydroisomerization section. In some embodiments, all products from the hydrotreating section are directly sent to the hydroisomerization section, i.e., intermediate products are not removed between each section. In some embodiments, a separate hydrocracking catalyst is not used in the method to produce renewable products. It will be appreciated by those skilled in the art that various reactor configurations and catalyst loading arrangements are possible according to the present invention.

[0097] Hydroconversion conditions generally include temperatures in the range of about 300°F to about 800°F (149°C to 427°C); pressures in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); and a temperature in the range of about 0.1 to about 20 h. -1A feed rate of biomass feedstock within the LHSV range; and about 1000 or 1500 or 2000 to about 10,000 standard cubic feet of H2 / barrel of biomass feedstock (about 180 to about 1800 m 3 H2 / m 3 The ratio of the hydrogen feed (into the biomass feed) to the biomass feed rate.

[0098] In some embodiments, the hydroisomerization conditions (e.g., the hydroisomerization conditions in reactor 14) include a temperature in the range of about 300°F to about 800°F (149°C to 427°C), such as about 550°F to about 700°F (288°C to 371°C). In some embodiments, the hydroisomerization conditions include a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), such as about 100 to about 2500 psig (0.69 to 17.24 MPa). In some embodiments, the hydroisomerization conditions include heating the biomass feedstock at a temperature of about 0.1 to about 20 h. -1 LHSV, e.g., from about 0.1 to about 5 h -1 The feed rate is within the LHSV range to a reactor containing a hydroisomerization catalyst.

[0099] In some embodiments, the hydroisomerization conditions include hydrogen and biomass feedstock at a rate of about 1000 or 1500 or 2000 to about 10,000 standard cubic feet of H2 / barrel of feedstock (about 180 to about 1800 m 3 H2 / m 3 Feed, for example, about 2500 to about 5000 scf H2 / bbl feed (about 440 to about 890 m 3 H2 / m 3 The ratio of feed) is fed to the reactor.

[0100] In some embodiments, the hydroisomerization conditions are as follows: a temperature in the range of about 300°F (149°C) or 325°F (163°C) or 350°F (177°C) or 375°F (191°C) or 390°F (199°C) to about 800°F (427°C), for example, about 550°F to about 750°F (288°C to 399°C) or 570°F to about 675°F (299°C to 357°C); a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), for example, about 100 to about 2500 psig (0.69 to 17.24 MPa); the feedstock is heated at about 0.1 to about 20 h -1 LHSV, e.g., from about 0.1 to about 5 h -1A feed rate of about 1000 or 1500 or 2000 to about 10,000 standard cubic feet of H2 / barrel of feed (about 180 to about 1800 m 3 H2 / m 3 Feed, for example, about 2500 to about 5000 scf H2 / barrel feed (about 440 to about 890 m 3 H2 / m 3 The ratio of hydrogen (feed) to feedstock fed to the reactor.

[0101] In some embodiments, by contacting a biomass feedstock with a hydroisomerization catalyst, the method provides an aviation (e.g., jet) fuel that is both hydrotreated and hydroisomerized and comprises an increased ratio of iso-paraffins to normal-paraffins as compared to the feedstock. In some embodiments, contacting a biomass feedstock with a hydroisomerization catalyst provides a jet fuel that exhibits a boiling point range and / or a reduced jet fuel freezing point as compared to the jet fuel boiling point range and / or jet fuel freezing point of a hydrotreated feedstock that has not been hydroisomerized.

[0102] In some embodiments, contacting the biofeedstock and the hydroisomerization catalyst provides a diesel fuel that exhibits a lower cloud point and a lower pour point compared to the cloud point and pour point of the hydrotreated biofeedstock, wherein the diesel fuel exhibits a cloud point at least 10°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 10°C lower than the pour point of the hydrotreated biofeedstock, or a cloud point at least 20°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 20°C lower than the pour point of the hydrotreated biofeedstock, or a cloud point at least 30°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 30°C lower than the pour point of the hydrotreated biofeedstock.

[0103] In some embodiments, by contacting a biomass feedstock with a hydroisomerization catalyst, the method provides a diesel fuel comprising an increased ratio of iso-paraffins to normal-paraffins compared to the feedstock. In some embodiments, contacting a biomass feedstock with a hydroisomerization catalyst provides a diesel fuel that exhibits a lower cloud point and a lower pour point compared to the cloud point and pour point of the diesel feedstock.

[0104] In some embodiments, contacting the biofeedstock and the hydroisomerization catalyst provides a diesel fuel that exhibits a lower cloud point and a lower pour point compared to the cloud point and pour point of the hydrotreated biofeedstock, wherein the diesel fuel exhibits a cloud point at least 10°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 10°C lower than the pour point of the hydrotreated biofeedstock, or a cloud point at least 20°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 20°C lower than the pour point of the hydrotreated biofeedstock, or a cloud point at least 30°C lower than the cloud point of the hydrotreated biofeedstock and a pour point at least 30°C lower than the pour point of the hydrotreated biofeedstock.

[0105] In some cases, both sustainable jet fuel and diesel fuel can be produced using the same feedstock by simply changing the process temperature.

[0106] The biomass feedstock and the hydroprocessing catalyst are typically contacted under hydroprocessing conditions, and then the feedstock and the hydroisomerization catalyst are contacted. In some embodiments, the hydroprocessing conditions include a temperature in the range of about 300°F (149°C) or 325°F (163°C) or 350°F (177°C) or 375°F (191°C) or 390°F to about 800°F (199°C to 427°C), such as about 500°F (260°C) or 550°F (288°C) to about 750°F (399°C), 590°F to about 675°F (310°C to 357°C); a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), such as about 100 to about 2500 psig (0.69 to 17.24 MPa); the feedstock is heated at about 0.1 to about 20 h -1 LHSV, e.g., from about 0.1 to about 5 h -1 LHSV range of rate is fed to the reactor containing the hydroisomerization catalyst; and hydrogen and feedstock at about 1000 or 1500 or 2000 to about 10,000 standard cubic feet H2 / barrel feedstock (about 180 to about 1800m 3 H2 / m 3 feed), such as about 2500 to about 5000 scf H2 / bbl feed (about 440 to about 890 m 3 H2 / m 3 The ratio of feed) is fed to the reactor.

[0107] The hydroprocessing catalyst may generally comprise a refractory inorganic oxide carrier and a Group 6 metal modifier and / or a Group 8-10 metal modifier. In some embodiments, the hydroprocessing catalyst comprises a refractory inorganic oxide carrier, a Group 6 metal modifier, and a Group 8-10 metal modifier. The oxide carrier may also be referred to as a binder herein. The carrier of the hydroprocessing catalyst may be prepared from or comprise alumina, silica, silica / alumina, titania, magnesia, zirconium oxide, etc., or a combination thereof. The hydroprocessing catalyst carrier may comprise an amorphous material, a crystalline material, or a combination thereof. Examples of amorphous materials include, but are not limited to, amorphous alumina, amorphous silica, amorphous silica-alumina, etc.

[0108] In some embodiments, the hydroprocessing support may include amorphous alumina. When a combination of silica and alumina is used, the distribution of silica and alumina in the support may be uniform or non-uniform. In some embodiments, the support may consist of an alumina gel in which silica, silica / alumina or an alumina base material is dispersed. The support may also contain refractory materials other than alumina or silica, such as other inorganic oxides or clay particles, provided that such materials do not adversely affect the hydrogenation activity of the final catalyst or do not cause harmful cracking of the feedstock.

[0109] In some embodiments, silica and / or alumina comprise at least about 90 weight percent of the support for the hydroprocessing catalyst, and in some embodiments, the support may be at least substantially all silica or all alumina.

[0110] In some embodiments, the 8-10 Group metal modifier of the hydroprocessing catalyst includes Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt, or a combination thereof. In some embodiments, the 8-10 Group metal modifier of the hydroprocessing catalyst includes a 9th Group metal, a 10th Group metal, or a combination thereof. In some embodiments, the 8-10 Group metal modifier of the hydroprocessing catalyst includes or is Co and / or Ni. In some embodiments, the 8-10 Group metal modifier of the hydroprocessing catalyst includes or is Ni. In some embodiments, the 8-10 Group metal modifier of the hydroprocessing catalyst includes Co and Ni. In some embodiments, the 8-10 Group metal modifier is an oxide, a hydroxide, or a salt. In some embodiments, the 8-10 Group metal modifier is a salt. The amount of the Group 8-10 metal modifier in the hydroprocessing catalyst is typically 0.1 to 20 wt % or 0.1 to 25 wt % (e.g., 1.0 or 2.0 to 10 wt %) calculated as metal oxide, based on the bulk dry weight of the catalyst. In some embodiments, the Group 6 metal modifier of the hydroprocessing catalyst is selected from Cr, Mo, W, and combinations thereof. In some embodiments, the Group 6 metal modifier of the hydroprocessing catalyst includes or is Mo. In some embodiments, the Group 6 metal modifier is an ammonium salt of an oxide, an oxyacid, or an oxyanion or polyoxyanions. Based on the bulk dry weight of the catalyst, the amount of the Group 6 metal modifier in the hydroprocessing catalyst is typically 5 to 50 wt % (e.g., 10 to 40 wt % or 15 to 30 wt %) calculated as metal oxide. In some embodiments, the hydroprocessing catalyst comprises Ni and Mo.

[0111] In some embodiments, the 8-10 group metal modifier and / or the 6 group metal modifier of the hydroprocessing catalyst can be dispersed on the inorganic oxide support. Many methods are known in the art to deposit the 8-10 group and / or the 6 group metal or compounds containing such metals onto the support; such methods include ion exchange, impregnation and coprecipitation. In some embodiments, the impregnation of the support with the 8-10 group and the 6 group metal modifier can be carried out at a controlled pH value. The 8-10 group and the 6 group metal modifier can be added to the impregnation solution as a metal salt such as a halide salt, and / or an amine complex, and / or a salt of an inorganic acid. Other examples of metal salts that can be used include nitrates, carbonates and bicarbonates, and carboxylates such as acetates, citrates and formates.

[0112] Optionally, the impregnated support can be allowed to stand with the impregnation solution for a time ranging from, for example, about 2 to about 24 hours. After the oxide support is impregnated with the Group 8-10 metal modifier and / or the Group 6 metal modifier, the impregnated support can be dried and / or calcined. After the hydroprocessing catalyst is dried and calcined, the prepared catalyst can be reduced with hydrogen or sulfided with a sulfur-containing compound, as is conventional in the art, and placed in, for example, a hydroprocessing reactor located upstream of a hydroisomerization reactor for use.

[0113] For the avoidance of doubt, the present disclosure relates to the subject matter described in the following numbered paragraphs:

[0114] 1. A method for preparing a sustainable jet fuel, the method comprising contacting a hydrocarbon-containing feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a bio-feedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

[0115] 2. A method for flexibly preparing sustainable jet fuel and / or renewable diesel from the same hydrocarbon-containing feedstock, the method comprising contacting the hydrocarbon-containing feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a bio-feedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

[0116] 3. A method for upgrading a hydrocarbon-containing feedstock, the method comprising:

[0117] contacting the hydrocarbonaceous feedstock and the hydroconversion catalyst under hydroconversion conditions to provide a diesel fuel that is both hydrotreated and hydroisomerized and has a reduced cloud point and / or a reduced pour point as compared to the cloud point and pour point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized, and / or a jet fuel having an improved jet fuel that is both hydrotreated and hydroisomerized and has a boiling point range and / or a reduced jet fuel freezing point as compared to the jet fuel boiling point range and / or jet fuel freezing point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized;

[0118] wherein the hydrocarbonaceous feedstock comprises or is a biomass feedstock or a biocomponent feedstock, and the hydroconversion catalyst comprises zeolite SSZ-91.

[0119] 4. The process of paragraph 3, wherein the product produced comprises a diesel fuel that is both hydrotreated and hydroisomerized and has a reduced cloud point and / or a reduced pour point compared to the cloud point and pour point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized.

[0120] 5. The method of paragraph 3, wherein the product produced comprises a jet fuel that is both hydrotreated and hydroisomerized and has a boiling point range and / or a reduced jet fuel freezing point compared to the jet fuel boiling point range and / or jet fuel freezing point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized.

[0121] 6. The method of any of paragraphs 2-5, wherein the same hydrocarbonaceous feedstock is used to produce sustainable jet fuel and / or renewable diesel.

[0122] 7. The method of any of paragraphs 2-6, wherein the process temperature is adjusted to produce the jet fuel or diesel product.

[0123] 8. The process of any of paragraphs 2-6, wherein no hydrocracking catalyst is required or used to produce the jet fuel or the diesel product.

[0124] 9. The process of any of paragraphs 1-8, wherein the feedstock is contacted with a hydrotreating catalyst under hydrotreating conditions to provide a hydrotreated feedstock, and the hydrotreated feedstock is then contacted with the hydroconversion catalyst.

[0125] 10. The method of paragraph 9, wherein the hydroprocessing conditions include:

[0126] Temperatures in the range of about 300°F to about 800°F (149°C to 427°C) or 450°F to 750°F (232°C to 399°C);

[0127] Pressures in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge);

[0128] From about 0.1 to about 20h -1 a feed rate for feeding a diesel feedstock to a reactor containing the hydrotreating catalyst at a rate within the LHSV range; and

[0129] Based on about 1000 to about 10,000 standard cubic feet of H2 (about 180 to about 1800m3) per barrel of diesel feedstock 3 H2 / m 3 Hydrogen and feedstock are fed to the reactor in a ratio of 1:1 to 2:1.

[0130] 11. The process of any of paragraphs 1-10, wherein the feedstock and a hydroisomerization catalyst are contacted under hydroisomerization conditions to provide a hydroisomerized feedstock.

[0131] 12. The method of paragraph 11, wherein the hydroisomerization conditions include:

[0132] Temperatures in the range of about 300°F to about 800°F (149°C to 427°C) or 450°F to 750°F (232°C to 399°C);

[0133] Pressures in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge);

[0134] From about 0.1 to about 20h -1 a feed rate for feeding a diesel feedstock to a reactor containing the hydrotreating catalyst at a rate within the LHSV range; and

[0135] Based on about 1000 to about 10,000 standard cubic feet of H2 (about 180 to about 1800m3) per barrel of diesel feedstock 3 H2 / m 3 Hydrogen and feedstock are fed to the reactor in a ratio of 1:1 to 2:1.

[0136] 13. The process of any of paragraphs 1-12, wherein the hydroconversion catalyst comprises zeolite SSZ91 and a Group 8-10 metal.

[0137] 14. The process of any one of paragraphs 1-13, wherein the hydroconversion catalyst comprises zeolite SSZ-91, wherein the zeolite SSZ-91 in its calcined form has an X-ray diffraction pattern substantially as shown in the following table:

[0138]

[0139] (a) ±0.20

[0140] (b) The powder XRD patterns provided are based on a relative intensity scale, where the most intense line in the X-ray pattern is assigned a value of 100:

[0141] W = weak (>0 to ≤20); M = moderate (>20 to ≤40); S = strong (>40 to ≤60);

[0142] VS = Very Strong (>60 to ≤100).

[0143] 15. The process of any of paragraphs 1-14, wherein the hydroconversion catalyst comprises zeolite SSZ 91 having a silica to alumina ratio of 40 to 220, or 70 to 160, or 80 to 160, or 80 to 140, or 100 to 160.

[0144] 16. The process of any of paragraphs 1-15, wherein the hydroconversion catalyst comprises zeolite SSZ91 having at least about 80% polytype 6 of the total ZSM-48 type material present in the zeolite SSZ-91 or at least about 90% polytype 6 of the total ZSM-48 type material present in the zeolite SSZ-91.

[0145] 17. The process of any of paragraphs 1-16, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91 comprises 0.1 to 4.0 wt% EUO-type molecular sieve phase.

[0146] 18. The process of any of paragraphs 1-17, wherein the hydroconversion catalyst comprises zeolite SSZ91 comprising 0.1 to 4.0 wt% EU-1.

[0147] 19. The process of any of paragraphs 1-18, wherein the hydroconversion catalyst comprises zeolite SSZ91 having a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of 1 to 4.

[0148] 20. The process of any one of paragraphs 1-19, wherein the hydroconversion catalyst comprises zeolite SSZ91 having:

[0149] a silicon oxide to aluminum oxide ratio of 40 to 220 or 70 to 160;

[0150] A morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio ranging from 1 to 4;

[0151] At least about 80% polytype 6 of the total ZSM-48 type material present in the zeolite SSZ-91; and 0.1 to 4.0 wt. % EUO type molecular sieve phase.

[0152] 21. The process of any of paragraphs 1-20, wherein the hydroconversion catalyst comprises from about 5 to about 95 weight percent zeolite SSZ-91 and from about 0.05 to about 25.0 weight percent of a metal modifier.

[0153] 22. A method according to any one of paragraphs 1-21, wherein the raw material includes or is a biological raw material or biocomponent feed selected from the following: vegetable oils and animal fats including triglycerides and free fatty acids, for example, wherein the biocomponent feed is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil and combinations thereof.

[0154] 23. The method of paragraphs 1-21, wherein the feedstock comprises or is a biological feedstock or biocomponent feed selected from the group consisting of canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, rapeseed oil, tall oil, sunflower oil, hempseed oil, olive oil, linseed oil, coconut oil, castor oil, peanut oil, palm oil, mustard oil, cottonseed oil, tallow, yellow and brown greases, lard, whale oil, fat in milk, fish oil, algae oil, sewage sludge, calyx oil, camelina oil, jatropha oil, jatropha oil, babassu oil, palm kernel oil, crambe seed oil, etc.

[0155] 24. The process of any of paragraphs 2-23, wherein contacting the feedstock and the hydroconversion catalyst provides a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of the hydrotreated feedstock.

[0156] 25. The method of any of paragraphs 2-24, wherein the diesel fuel exhibits a cloud point at least 10°C lower than the cloud point of the hydrotreated feedstock and a pour point at least 10°C lower than the pour point of the hydrotreated feedstock, or a cloud point at least 20°C lower than the cloud point of the feedstock and a pour point at least 20°C lower than the pour point of the hydrotreated feedstock, or a cloud point at least 30°C lower than the cloud point of the hydrotreated feedstock and a pour point at least 30°C lower than the pour point of the hydrotreated feedstock.

[0157] 26. A method for providing a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of a hydrotreated feedstock from which the diesel fuel is produced, the method comprising contacting a diesel feedstock and a hydroconversion catalyst comprising zeolite SSZ 91 under hydroconversion conditions to provide a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of the hydrotreated feedstock from which the diesel fuel is produced, wherein the feedstock comprises or is a biomass feedstock or a biocomponent feedstock.

[0158] 27. A method for providing a jet fuel that exhibits a reduced jet fuel freezing point and / or improved jet fuel boiling point range as compared to the jet fuel freezing point and / or jet fuel boiling point range of a hydrotreated feedstock from which the jet fuel is produced, the method comprising contacting a jet fuel feedstock and a hydroconversion catalyst comprising zeolite SSZ-91 under hydroconversion conditions to provide a jet fuel that exhibits a reduced jet fuel freezing point and / or improved jet fuel boiling point range as compared to the jet fuel freezing point and / or jet fuel boiling point range of the hydrotreated feedstock from which the jet fuel is produced, wherein the feedstock comprises or is a biomass feedstock or a biocomponent feedstock.

[0159] The present disclosure is not limited to the specific embodiments described in this application, which are intended to illustrate various aspects. Obviously, many modifications and changes can be made without departing from its spirit and scope. In addition to those methods and systems listed here, functionally equivalent methods and systems within the scope of the present disclosure can be apparent from the above representative descriptions. These modifications and changes are intended to fall within the scope of the attached representative claims. The present disclosure is only subject to the terms of the attached representative claims and the full range of equivalents authorized by these representative claims. It will also be understood that the terms used herein are only used for the purpose of describing specific embodiments and are not intended to be limited.

[0160] The foregoing description and its associated embodiments are given for illustrative purposes only. It is not exhaustive and does not limit the invention to the exact form disclosed. Those skilled in the art will appreciate from the foregoing description that modifications and changes may be made according to the above teachings, or modifications and changes may be obtained by practicing the disclosed embodiments. For example, in some cases, the steps described do not need to be performed in the same order discussed or with the same degree of separation. Similarly, various steps may be omitted, repeated or combined as needed to achieve the same or similar purposes. Therefore, the present invention is not limited to the above embodiments, but is defined by the appended claims according to the full scope of their equivalents.

[0161] In the foregoing description, various preferred embodiments have been described with reference to the accompanying drawings. However, it will be apparent that various modifications and variations may be made thereto, and that additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the appended claims. Therefore, the description and drawings should be regarded as illustrative rather than restrictive.

[0162] Where permitted, all publications, patents, and patent applications cited in this application are incorporated herein by reference in their entirety to the extent such disclosure is not inconsistent with the present invention.

Claims

1. A method for preparing a sustainable jet fuel, the method comprising contacting a hydrocarbon-containing feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a bio-feedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

2. A method for flexibly preparing sustainable jet fuel and / or renewable diesel from the same hydrocarbon-containing feedstock, the method comprising contacting the hydrocarbon-containing feedstock and a hydroconversion catalyst, wherein the feedstock comprises or is a bio-feedstock or a biocomponent feed, and the hydroconversion catalyst comprises zeolite SSZ-91.

3. A method for upgrading a hydrocarbon-containing feedstock, the method comprising: contacting the hydrocarbonaceous feedstock and the hydroconversion catalyst under hydroconversion conditions to provide a diesel fuel that is both hydrotreated and hydroisomerized and has a reduced cloud point and / or a reduced pour point as compared to the cloud point and pour point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized, and / or a jet fuel having an improved jet fuel that is both hydrotreated and hydroisomerized and has a boiling point range and / or a reduced jet fuel freezing point as compared to the jet fuel boiling point range and / or jet fuel freezing point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized; wherein the hydrocarbonaceous feedstock comprises or is a biomass feedstock or a biocomponent feedstock, and the hydroconversion catalyst comprises zeolite SSZ-91.

4. The process of claim 3, wherein the product produced comprises a diesel fuel that has been both hydrotreated and hydroisomerized and has a reduced cloud point and / or a reduced pour point compared to the cloud point and pour point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized.

5. The process of claim 3, wherein the product produced comprises a jet fuel that is both hydrotreated and hydroisomerized and has a boiling point range and / or a reduced jet fuel freezing point compared to the jet fuel boiling point range and / or jet fuel freezing point of the hydrotreated hydrocarbonaceous feedstock that has not been hydroisomerized.

6. The method of any one of claims 2-5, wherein the same hydrocarbonaceous feedstock is used to produce sustainable jet fuel and / or renewable diesel.

7. The method of any one of claims 2-6, wherein the process temperature is adjusted to produce the jet fuel or diesel product.

8. The method of any one of claims 2-6, wherein no hydrocracking catalyst is required or used to produce the jet fuel or the diesel product.

9. The process of any one of claims 1-8, wherein the feedstock and a hydrotreating catalyst are contacted under hydrotreating conditions to provide a hydrotreated feedstock, and the hydrotreated feedstock is then contacted with the hydroconversion catalyst.

10. The method of claim 9, wherein the hydroprocessing conditions include: Temperatures in the range of about 300°F to about 800°F (149°C to 427°C) or 450°F to 750°F (232°C to 399°C); Pressures in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); From about 0.1 to about 20h -1 a feed rate for feeding a diesel feedstock to a reactor containing the hydrotreating catalyst at a rate within the LHSV range; and Based on about 1000 to about 10,000 standard cubic feet of H2 (about 180 to about 1800 m3) per barrel of diesel feedstock 3 H2 / m 3 Hydrogen and feedstock are fed to the reactor in a ratio of 1:1 to 2:

1.

11. The process of any one of claims 1 to 10, wherein the feedstock and a hydroisomerization catalyst are contacted under hydroisomerization conditions to provide a hydroisomerized feedstock.

12. The method according to claim 11, wherein the hydroisomerization conditions include: Temperatures in the range of about 300°F to about 800°F (149°C to 427°C) or 450°F to 750°F (232°C to 399°C); Pressures in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); From about 0.1 to about 20h -1 a feed rate for feeding a diesel feedstock to a reactor containing the hydrotreating catalyst at a rate within the LHSV range; and Based on about 1000 to about 10,000 standard cubic feet of H2 (about 180 to about 1800m3) per barrel of diesel feedstock 3 H2 / m 3 Hydrogen and feedstock are fed to the reactor in a ratio of 1:1 to 2:

1.

13. The process of any one of claims 1 to 12, wherein the hydroconversion catalyst comprises zeolite SSZ91 and a Group 8-10 metal.

14. The process of any one of claims 1 to 13, wherein the hydroconversion catalyst comprises zeolite SSZ-91, wherein the zeolite SSZ-91 in its calcined form has an X-ray diffraction pattern substantially as shown in the following table: (a) ±0.20 (b) The powder XRD patterns provided are based on a relative intensity scale, where the most intense line in the X-ray pattern is assigned a value of 100: W = weak (>0 to ≤20); M = moderate (>20 to ≤40); S = strong (>40 to ≤60); VS = Very Strong (>60 to ≤100).

15. The process of any one of claims 1-14, wherein the hydroconversion catalyst comprises zeolite SSZ 91 having a silica to alumina ratio of from 40 to 220, or from 70 to 160, or from 80 to 160, or from 80 to 140, or from 100 to 160.

16. The process of any one of claims 1-15, wherein the hydroconversion catalyst comprises zeolite SSZ91 having at least about 80% polytype 6 of the total ZSM-48-type material present in the zeolite SSZ-91 or at least about 90% polytype 6 of the total ZSM-48-type material present in the zeolite SSZ-91.

17. The process according to any one of claims 1 to 16, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91 comprises 0.1 to 4.0 wt% of EUO type molecular sieve phase.

18. The process of any one of claims 1 to 17, wherein the hydroconversion catalyst comprises zeolite SSZ91 comprising 0.1 to 4.0 wt% EU-1.

19. The process of any one of claims 1-18, wherein the hydroconversion catalyst comprises zeolite SSZ91 having a morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio of 1 to 4.

20. The process of any one of claims 1 to 19, wherein the hydroconversion catalyst comprises zeolite SSZ91 having: a silicon oxide to aluminum oxide ratio of 40 to 220 or 70 to 160; A morphology characterized by polycrystalline aggregates comprising crystallites having an overall average aspect ratio ranging from 1 to 4; At least about 80% polytype 6 of the total ZSM-48 type material present in the zeolite SSZ-91; and 0.1 to 4.0 wt. % EUO type molecular sieve phase.

21. The process of any one of claims 1-20, wherein the hydroconversion catalyst comprises from about 5 to about 95 weight percent zeolite SSZ-91 and from about 0.05 to about 25.0 weight percent of a metal modifier.

22. The method of any one of claims 1-21, wherein the feedstock comprises or is a bio-raw material or biocomponent feedstock selected from the group consisting of vegetable oils and animal fats comprising triglycerides and free fatty acids, for example, wherein the biocomponent feedstock is selected from the group consisting of canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

23. The method of claims 1-21, wherein the feedstock comprises or is a bio-feedstock or bio-component feedstock selected from the group consisting of canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, rapeseed oil, tall oil, sunflower oil, hempseed oil, olive oil, linseed oil, coconut oil, castor oil, peanut oil, palm oil, mustard oil, cottonseed oil, tallow, yellow and brown greases, lard, whale oil, fat in milk, fish oil, algae oil, sewage sludge, calyx oil, camelina oil, jatropha oil, jatropha oil, babassu oil, palm kernel oil, crambe seed oil, and the like.

24. The process of any one of claims 2-23, wherein contacting the feedstock and the hydroconversion catalyst provides a diesel fuel exhibiting a lower cloud point and a lower pour point than the cloud point and pour point of the hydrotreated feedstock.

25. The method of any one of claims 2-24, wherein the diesel fuel exhibits a cloud point at least 10°C lower than the cloud point of the hydrotreated feedstock and a pour point at least 10°C lower than the pour point of the hydrotreated feedstock, or a cloud point at least 20°C lower than the cloud point of the feedstock and a pour point at least 20°C lower than the pour point of the hydrotreated feedstock, or a cloud point at least 30°C lower than the cloud point of the hydrotreated feedstock and a pour point at least 30°C lower than the pour point of the hydrotreated feedstock.

26. A method for providing a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of a hydrotreated feedstock from which the diesel fuel is produced, the method comprising contacting a diesel feedstock and a hydroconversion catalyst comprising zeolite SSZ 91 under hydroconversion conditions to provide a diesel fuel that exhibits a lower cloud point and a lower pour point than the cloud point and pour point of the hydrotreated feedstock from which the diesel fuel is produced, wherein the feedstock comprises or is a biomass feedstock or a biocomponent feedstock.

27. A method for providing a jet fuel that exhibits a reduced jet fuel freezing point and / or improved jet fuel boiling point range as compared to the jet fuel freezing point and / or jet fuel boiling point range of a hydrotreated feedstock from which the jet fuel is produced, the method comprising contacting a jet fuel feedstock and a hydroconversion catalyst comprising zeolite SSZ-91 under hydroconversion conditions to provide a jet fuel that exhibits a reduced jet fuel freezing point and / or improved jet fuel boiling point range as compared to the jet fuel freezing point and / or jet fuel boiling point range of the hydrotreated feedstock from which the jet fuel is produced, wherein the feedstock comprises or is a biomass feedstock or a biocomponent feedstock.

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