Hydroconversion process for producing renewable products from biofeedstock

Abstract

A process for producing renewable products from a biofeedstock, the process comprising contacting the biofeedstock with a hydroconversion catalyst under hydroconversion conditions, the biofeedstock comprising one or more bio-components, and the hydroconversion catalyst comprising a hydrotreating catalyst and a hydroisomerization catalyst.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 357,633, filed on June 30, 2022, entitled "HYDROCONVERSION PROCESS TO MAKE RENEWABLE PRODUCTS FROM BIOFEEDSTOCK", the entire disclosure of which is incorporated herein by reference.

[0002] Described herein is a process for the hydroconversion of a biofeedstock to produce renewable products such as renewable diesel and / or sustainable aviation fuel.

Background Art

[0003] The use of renewable resources has gathered significant attention and effort in the development of alternatives to fossil fuels. The diversity, availability, and versatility of various biofeedstocks, particularly certain lipid sources and other carbohydrates, are of great interest and have led to the development and commercial use of multiple bio - based fuel technologies. The ongoing economic benefits and the desire to reduce the use of fossil fuels have motivated improvements in existing technologies and the development of new processes for producing renewable fuels and other renewable products using renewable biofeedstocks.

[0004] Renewable fuels (biofuels) are considered important for reducing carbon and greenhouse emissions. Biofuels derived from food are typically fuels made from food sources produced on arable land, while biofuels derived from non-food sources are typically produced from lignocellulosic biomass such as forestry residues or agricultural residues / wastes. Typical biofeedstocks in the food source category include a wide variety of lipids (e.g., vegetable oils including used cooking oil, seed oils, animal fats, waste oils, algal oils, etc.). Typical non-food source feedstocks include wood, grass, algae, crop by-products, municipal solid waste, etc. Renewable fuels derived from non-food sources may be preferred over biofuels derived from food sources, but continuous improvement of the hydroconversion process for all feedstock sources for producing renewable products is still needed.

Summary of the Invention

[0005] The present invention relates to a process for producing renewable products from a biofeedstock, such as a feed containing a bio-derived bio-component. Various renewable products can be produced, including diesel, aviation fuel and other fuels and distillates, as well as base oils or their components.

[0006] In one aspect, a process for making a renewable product from a biofeedstock is provided, the process comprising contacting the biofeedstock with a hydroconversion catalyst under hydroconversion conditions, the biofeedstock comprising one or more bio-components, and the hydroconversion catalyst comprising a hydrotreating catalyst and a hydrodewaxing catalyst.

[0007] In another aspect, the use of a zeolite SSZ-91-based catalyst for producing a renewable product is described, the SSZ-91 hydroconversion catalyst being contacted with a biofeedstock, or an intermediate product derived from the biofeedstock, under hydroconversion conditions to produce a renewable product, the hydroconversion including hydrotreating and hydrodewaxing.

[0008] Those skilled in the art will understand that, unless mutually exclusive, the features described in connection with any one of the aspects or embodiments described herein may be applied mutatis mutandis to any other aspect and / or embodiment. Furthermore, unless mutually exclusive, the features described herein can be applied to any aspect / embodiment and / or combined with any other feature described herein.

Brief Description of the Drawings

[0009]

Figure 1

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Modes for Carrying Out the Invention

[0010] Although exemplary embodiments of one or more aspects are shown herein, the disclosed process can be implemented using any number of methods. The present disclosure is not limited to the exemplary or specific embodiments illustrated herein, including any of the exemplary designs and embodiments illustrated and described herein, any of the drawings, and any of the techniques, but can be modified within the scope of the appended claims together with the full scope of equivalents.

[0011] The following description of the embodiments provides non-limiting representative examples while referring to numerical values for describing in detail the features and teachings of various aspects of the present invention. It should be recognized that the described embodiments can be practiced separately from or in combination with other embodiments from the description of the embodiments. A person skilled in the art can acquire and understand another described aspect of the present invention by reviewing the description of the embodiments. The description of the embodiments should facilitate the understanding of the present invention such that other practical forms, although not specifically covered, that are within the capabilities of a person skilled in the art who has read the description of the embodiments are understood to be consistent with the application of the present invention.

[0012] Unless otherwise indicated, the following terms have the meanings as defined in the following specification.

[0013] The term "hydroconversion" refers to a process or step carried out in the presence of hydrogen for the hydrocracking, hydrogenation, hydrodeoxygenation, hydrodesulfurization, hydrodenitrogenation, hydrodemetallization, hydrodechlorination, hydrodecarbonation, hydrodecarbonylation and / or hydrodearomatization (e.g., of impurities) of a hydrocarbon or biomass feedstock and / or for the hydrogenation of unsaturated compounds in the feedstock. Depending on the type of hydrocracking and the reaction conditions, the products of the hydrocracking process can have, for example, an improved aromatic content, oxygen content, viscosity, viscosity index, saturated fatty content, low temperature properties, volatility, and depolarization degree.

[0014] The term "hydrotreating" refers to a method or step carried out in the presence of hydrogen for the hydrodesulfurization, hydrodenitrogenation, hydrodeoxygenation, hydrodemetalation, and / or hydrodearomatization of components (e.g., impurities) of a feedstock and / or for the hydrogenation of unsaturated compounds in the feedstock.

[0015] As used herein, the term "biofeedstock" refers to a biocomponent feedstock derived from or obtained from a biological source. Exemplary biofeedstocks include lipids, pyrolysis oils, biomass-derived feedstocks, and the like. Triglycerides are components of some biofeedstocks such as lipids. Biofeedstocks typically have a boiling range suitable for producing diesel, aviation fuel, or other fuels, or distillates thereof. In the case of some biofeedstocks containing triglycerides, such feedstocks have an "apparent" boiling temperature range (based on the GC elution time of the triglyceride peak by the Simdist method ASTM D-2887) suitable for producing diesel, aviation fuel, or other fuels, or distillates thereof. The boiling range (or apparent boiling range) of a biofeedstock may also be suitable for producing a base oil or its components. In some embodiments, the biofeedstock has a boiling point in the range of about 250°F (121°C) to about 900°F (482°C), such as, 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, in the case of a typical lipid after hydrotreating, the upper boiling point of about 900°F (482°C) includes hydrocarbon molecules having a number of carbon atoms suitable for the uses described herein.

[0016] As used herein, the term "bio-component feedstock" is used to refer to feedstock derived from a bio-component-containing source, such as plant-based oils or fats, animal-based oils or fats, fish-based oils or fats, or algae-based oils or fats. In some embodiments, the bio-component feedstock has a boiling point in the range of about 250°F (121°C) to about 900°F (482°C) at atmospheric pressure, such as, for example, about 300°F (149°C) to about 900°F (about 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 bio-component feedstock has a 90% distillation temperature of less than about 1000°F (538°C), or less than 900°F (482°C), or less than 800°F (427°C), or less than 700°F (about 371°C), or less than about 650°F (343°C). In some embodiments, the bio-component feedstock has a 90% distillation temperature in the range of about 550°F (288°C) to about 750°F (399°C), such as, for example, 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 in accordance with ASTM D-2887. In some embodiments, the bio-component feedstock has a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C), such as, for example, 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 in accordance with ASTM D2887. In some embodiments, the bio-component feedstock 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 bio-component feedstock 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 bio-component feedstock has a 90% distillation temperature higher than about 600°F (316°C), for example, from about 605°F (about 318°C) to about 675°F (357°C), and a 5% distillation temperature less than about 600°F (316°C), for example, from about 540°F (282°C) to about 580°F (304°C). In some embodiments, the bio-component feedstock has a 90% distillation temperature in the range from about 600°F (316°C) to about 700°F (371°C), and a 5% distillation temperature in the range from about 400°F (204°C) to about 600°F (316°C). In some cases, for example, in the case of a typical lipid after hydrotreating, an upper boiling point of about 900°F (482°C) contains hydrocarbon molecules having a number of carbon atoms suitable for the uses described herein.

[0017] As used herein, the term "Fisher-Tropsch feedstock" refers to a synthetic feedstock produced via the Fisher-Tropsch process and having a 90% distillation temperature generally less than about 1350°F (732°C), or less than about 1100°F (593°C), or less than about 1000°F (538°C), or less than about 900°F (482°C), or less than about 800°F (427°C), or less than about 750°F (399°C), or less than about 700°F (371°C). In some embodiments, the Fisher-Tropsch feedstock has a 90% distillation temperature in the range of about 550°F (288°C) to about 750°F (399°C), such as, for example, in the range of about 550°F (288°C) to about 700°F (371°C), or in the range of about 600°F (316°C) to about 700°F (371°C). The 90% distillation temperature can be determined in accordance with ASTM D2887. In some embodiments, the Fisher-Tropsch feedstock has a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C), such as, for example, in the range of about 300°F (149°C) to about 600°F (316°C), or in the range of about 340°F (171°C) to about 600°F (316°C), or in the range of about 340°F (171°C) to about 500°F (260°C), or in the range of about 340°F (171°C) to about 400°F (204°C). The 5% distillation temperature can be determined in accordance with ASTM D-2887. In some embodiments, the Fisher-Tropsch feedstock has a 90% distillation temperature in the range of about 550°F (288°C) to about 750°F (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 Fisher-Tropsch feedstock 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 Fisher-Tropsch feedstock has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 600°F (316°C).In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 500°F (260°C). In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 400°F (204°C). In some embodiments, a "Fischer-Tropsch feed" has a boiling point at atmospheric pressure in the range of about 250°F (121°C) to about 900°F (482°C), for example, in the range of about 250°F (121°C) to about 800°F (427°C).

[0018] The term "diesel fuel" is used herein to refer to hydrocarbon products having a boiling point at atmospheric pressure in the range of about 300°F to about 800°F (about 149°C to about 427°C).

[0019] The term "active source" means a reagent or precursor material that can react and supply at least one element in a form that can be incorporated into a molecular sieve structure. The terms "source" and "active source" may be used interchangeably herein.

[0020] The terms "molecular sieve" and "zeolite" are synonymous and include (a) intermediates, (b) final or target molecular sieves, and (1) molecular sieves produced by direct synthesis or (2) post-crystallization treatment (secondary modification). In secondary synthesis techniques, the target material can be synthesized 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 and are described, for example, in U.S. Patent No. 6,790,433 to C.Y. Chen and Stacey Zones, issued September 14, 2004.

[0021] The terms "MRE-type molecular sieve", "EUO-type molecular sieve", and "MTT-type molecular sieve" include all molecular sieves and their isotopes assigned to the framework of the International Zeolite Association as described in Atlas of Zeolite Framework Types, eds. Ch. Baerlocher, L.B. McCusker and D.H. Olson, Elsevier, 6th revised edition, 2007 and the Database of Zeolite Structures on the International Zeolite Association’s website (http: / / www.iza-online.org).

[0022] The SiO2 / Al2O3 ratio (SAR) is determined by ICP elemental analysis. An infinite (∞) SAR indicates that the zeolite does not contain aluminum, i.e., the molar ratio of silica to alumina is infinite. In that case, the molecular sieve is essentially composed of silica.

[0023] As used herein, the term "pour point" refers to the temperature at which oil begins to flow under controlled conditions. The pour point can be determined by ASTM D5950.

[0024] As used herein, the term "cloud point" refers to the temperature at which a sample begins to cloud when the oil is cooled under specific conditions. The cloud point can be measured by ASTM D5773.

[0025] "Group 2, 8, 9, and 10 metals" refers to elemental metal(s) selected from Groups 2, 8, 9, and 10 of the Periodic Table of the Elements, and / or metal compound(s) containing such metal(s). "Group 6 metals" refers to elemental metal(s) selected from Group 6 of the Periodic Table of the Elements, and / or metal compound(s) containing such metal(s).

[0026] The term "Periodic Table" refers to the IUPAC Periodic Table of the Elements, dated 1 December 2018.

[0027] Unless otherwise specified, the "feed rate" of the feedstock supplied to the catalytic reaction zone is, in this specification, expressed as the volume of the feed per unit volume of catalyst per hour, which may be referred to as the liquid hourly space velocity (LHSV) with units of reciprocal hours (h -1 ).

[0028] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, percentages, or ratios used in this specification and the claims, and other numerical values, are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations and may vary depending upon the desired properties sought to be obtained. It should be noted that, as used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless expressly and specifically limited to one referent. As used herein, the term "comprising" and its grammatical variations are intended to be non-limiting in that an enumeration of items in a list is not to be excluded from other similar items that may be substituted or added to the listed items. As used herein, the term "comprising" means including the element or step specified following the term, but such element or step is not exhaustive and one embodiment may include other elements or steps.

[0029] Unless otherwise specified, an enumeration of a genus of elements, materials, or other components from which an individual component or mixture of components can be selected is intended to include all possible sub-genus combinations of the listed components and their mixtures. Further, all numerical ranges set forth in this specification include their upper and lower limits.

[0030] When a standard test is referred to in this specification, unless otherwise indicated, the version of the test being referred to is the latest at the time of this patent application.

[0031] The patentable scope is defined by the claims and can include other examples that would be equivalent to those of a person of ordinary skill in the art. Such other examples are intended to be included in the claims if they have structural elements that do not differ from the language of the claims or if they include equivalent structural elements that do not substantially differ from the language of the claims. To the extent not inconsistent with this specification, all citations referred to in this specification are hereby incorporated by reference into this specification.

[0032] The biofeedstock described herein includes or is a biocomponent feedstock. In some embodiments, the biofeedstock includes, consists essentially of, or consists of a biocomponent feedstock. In some embodiments, the biocomponent feedstock constitutes at least about 5 wt% of the biofeedstock, such as at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, at least about 98 wt%, or at least about 99 wt% of the biofeedstock. In some embodiments, the biocomponent feedstock constitutes 5 wt% to 100 wt% of the biofeedstock, such as 10 wt% to 100 wt%, 50 wt% to 100 wt%, 80 wt% to 100 wt%, 95 wt% to 100 wt% of the biofeedstock.

[0033] In some embodiments, the biofeedstock comprises, consists essentially of, or consists of a biocomponent feed. In some embodiments, the biocomponent feed constitutes at least about 5 wt% of the biofeedstock, such as at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, at least about 98 wt%, or at least about 99 wt% of the biofeedstock. In some embodiments, the Fischer-Tropsch feed constitutes 5 wt% to 100 wt% of the biofeedstock, such as 10 wt% to 100 wt%, 50 wt% to 100 wt%, 80 wt% to 100 wt%, 95 wt% to 100 wt% of the biofeedstock.

[0034] In some embodiments, the biofeedstock is a mixed feedstock that includes a bio-component feedstock, or also includes a Fischer-Tropsch feedstock, in combination with another feedstock such as a mixed feed. For example, the mixed feedstock can include a mixed feedstock selected from light oil, vacuum gas oil, long residue, vacuum residue, atmospheric distillate, heavy fuel, oil, wax and paraffin, used oil, deasphalted residue or crude oil, a charge resulting from a thermal conversion process or a catalytic conversion process, or a combination thereof. In some embodiments, the mixed feed includes whole crude oil, reduced crude oil, vacuum tower residue, cycle oil, synthetic crude oil, light oil, vacuum gas oil, foots oil, Fischer-Tropsch derived wax, lubricating oil stock, heating oil, heavy neutral feedstock, hydrotreated light oil, hydrocracked light oil, hydrotreated lubricating oil raffinate, bright stock, lubricating oil stock, synthetic oil, high pour point polyolefin (e.g., a polyolefin having a pour point of about 0 °C or higher); normal alpha olefin wax, slack wax, dewaxed wax, microcrystalline wax, a residue fraction from an atmospheric distillation process, a solvent deasphalted petroleum residue, shale oil, cycle oil, petroleum wax, slack wax, and wax produced in a chemical plant process. In some embodiments, the feedstock is a mixed feedstock that includes a bio-component feedstock and a Fischer-Tropsch feedstock. In some embodiments, the feedstock is a mixed feedstock that includes a bio-component feedstock, a Fischer-Tropsch feedstock, and a mixed feed (e.g., the mixed feed described above). The mixed feedstock, the mixed feed, and / or the biofeedstock can also include recycle products and / or intermediate process streams.

[0035] In some embodiments, the feedstock is a mixed feedstock comprising a biocomponent feed and a mixed feed, the mixed feedstock comprising at least about 5 wt% biocomponent feed and up to about 95 wt% mixed feed, for example, at least about 10 wt% biocomponent feed and up to about 90 wt% mixed feed, at least about 50 wt% biocomponent feed and up to about 50 wt% mixed feed, at least about 80 wt% biocomponent feed and up to about 20 wt% mixed feed, or at least about 95 wt% biocomponent feed and up to about 5 wt% mixed feed.

[0036] A Fischer-Tropsch feedstock, when used, typically has a paraffin content of at least about 90 wt%, such as at least about 95 wt%, or at least about 97.5 wt%. A Fischer-Tropsch feedstock typically contains only very small amounts of olefins and cycloparaffins, 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% cycloparaffins, or less than about 0.5 wt% cycloparaffins, or less than about 0.1 wt% cycloparaffins. In some embodiments, the Fischer-Tropsch feedstock has an S content of less than about 50 ppm, such as less than about 20 ppm. In some embodiments, the Fischer-Tropsch feedstock has an N content of less than about 50 ppm, such as less than about 20 ppm. In some embodiments, the Fischer-Tropsch feedstock has a metal content of less than about 10 ppm, such as less than about 5 ppm. The paraffin content and cycloparaffin content of the Fischer-Tropsch feedstock 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 2001,15,4,996-1002. The nitrogen content of the Fischer-Tropsch feedstock can be determined in accordance with ASTM D3228-20. The sulfur content of the Fischer-Tropsch feedstock can be determined in accordance with ASTM D4629. The metal content of the Fischer-Tropsch feedstock can be measured by inductively coupled plasma atomic emission spectrometry (ICP-AES).

[0037] In some embodiments, the feedstock is a mixed feedstock comprising a combination of a Fischer-Tropsch feed and a mixed feed, the mixed feedstock comprising at least about 5 wt% Fischer-Tropsch feed and up to about 95 wt% mixed feed, for example, at least about 10 wt% Fischer-Tropsch feed and up to about 90 wt% mixed feed, at least about 50 wt% Fischer-Tropsch feed and up to about 50 wt% mixed feed, at least about 80 wt% Fischer-Tropsch feed and up to about 20 wt% mixed feed, or at least about 95 wt% Fischer-Tropsch feed and up to about 5 wt% mixed feed.

[0038] In some embodiments, the biofeedstock comprises, consists essentially of, or consists of a bio-component feed. Vegetable oils and fats include vegetable fats such as canola oil, soybean oil, coconut oil, sunflower oil, palm oil, palm kernel oil, peanut oil, linseed oil, colza oil, tall oil, corn oil, castor oil, jatropha oil, jojoba oil, olive oil, flaxseed oil, hempseed oil, cottonseed oil, camelina oil, safflower oil, mustard oil, kufeira oil, curcas oil, cranberry oil, babassu oil, taro oil, rice bran oil, etc. Animal oils and fats, and other sources include beef fat (tallow), pig fat (lard), turkey fat, fish fat / oil, and chicken fat), yellow and brown fats including algae and fish fat / oil, milk fat, sewage sludge, etc.

[0039] In some embodiments, the bio-component feed is selected from vegetable oils and animal fats comprising or consisting essentially of triglycerides and free fatty acids (FFAs). In some embodiments, the biofeedstock comprises or is a bio-component feed selected from lipids, vegetable oils, and animal fats comprising triglycerides and free fatty acids, for example, the bio-component feed is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

[0040] In some embodiments, the triglycerides and FFA contain aliphatic hydrocarbon chains having 6 to 24 carbon atoms (e.g., 8 to 24, 8 to 20, or 10 to 16 carbon atoms) in their structures. In some embodiments, the biocomponent feedstock contains triglycerides having the general formula (1): [Chemical Formula] wherein R, R 1 and R 2 are independently aliphatic hydrocarbon chains having 6 to 24 carbon atoms (e.g., 8 to 24, 8 to 20, 10 to 20, 10 to 18, or 10 to 16 carbon atoms). In some embodiments, R, R 1 , and R 2 are independently branched or unbranched, substituted or unsubstituted, fully saturated, or contain one or more (e.g., 1 to 4, 1 to 3, or 1 or 2) unsaturated carbon-carbon bonds. In some embodiments, R, R 1 and R 2 are unsubstituted. In some embodiments, R, R 1 , and R 2 are independently fully saturated or contain one or more (e.g., 1 to 4, 1 to 3, or 1 or 2) unsaturated carbon-carbon bonds. In some embodiments, R, R 1 and R 2 are unbranched.

[0041] In some embodiments, the biocomponent feedstock contains free fatty acids (FFA) having aliphatic hydrocarbon tails of 6 to 24 carbon atoms, such as 8 to 24 carbon atoms, 8 to 20 carbon atoms, 10 to 20 carbon atoms, 10 to 18 carbon atoms, or 10 to 16 carbon atoms. In some embodiments, the FFA contains unsaturated or saturated aliphatic hydrocarbon tails. In some embodiments, the FFA contains unbranched or branched aliphatic hydrocarbon tails.

[0042] In some embodiments, the bio-component feedstock is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

[0043] In some embodiments, the bio-component feedstock has an oxygen content of at least about 0.5 wt%, such as at least about 1.0 wt%, at least about 2.0 wt%, at least about 3.0 wt%, at least about 4.0 wt%, or at least about 5.0 wt% based on the total weight of the bio-component feedstock. In some embodiments, the bio-component feedstock has an oxygen content of up to about 15 wt%, such as up to about 10 wt%, or up to about 5 wt% based on the total weight of the bio-component feedstock. In some embodiments, the bio-component feedstock has an oxygen content in the range of about 1 - 15 wt%, such as in the range of about 5 - 15 wt%, or about 10 - 15 wt% based on the total weight of the bio-component feedstock. The oxygen content of the bio-component feedstock can be measured, for example, by neutron activation analysis according to ASTM E385-90(2002).

[0044] In some embodiments, the bio-component feedstock is hydrotreated, for example, with a hydroisomerization / hydrodewaxing catalyst before contacting with a hydroconversion catalyst for further hydrogenation. In some embodiments, the bio-component feedstock has a sulfur (S) content of 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 bio-component feedstock has a nitrogen (N) content of less than about 50 ppm, such as less than about 20 ppm, or less than about 10 ppm. In some embodiments, the hydrotreated bio-component feedstock typically has an oxygen content of about 0 wt%, or less than about 2 wt%, or less than 5 wt%. The nitrogen content of the bio-component feedstock can be determined according to ASTM D4629. The sulfur content of the bio-component feedstock can be determined according to ASTM D2622.

[0045] The hydroconversion catalyst includes a hydrotreating catalyst and a hydroisomerization catalyst, and may include a noble metal catalyst as the hydroconversion catalyst. In other cases, the hydroconversion catalyst may include a base metal catalyst and a noble metal catalyst. Without being limited thereto, the base metal catalyst typically includes a base metal selected from Mo, Ni, W, Co, and combinations thereof, or Mo, or a combination of Mo and Ni. Similarly, without being limited thereto, the noble metal catalyst typically includes a noble metal selected from Pt, Pd, or combinations thereof.

[0046] As used herein, the term "hydroisomerization catalyst" refers to a catalyst that promotes skeletal isomerization of hydrocarbon molecules. In some embodiments, suitable hydroisomerization catalysts include catalysts containing zeolite SSZ-91. For example, other hydroisomerization catalysts including zeolite SSZ-32 and / or zeolite SSZ-32x-based catalysts may also be suitable. Combinations of suitable hydroisomerization catalysts based on the same or different zeolite carriers may also be used.

[0047] In some embodiments, the hydroisomerization catalyst includes zeolite SSZ-91, or from about 5 to about 95 wt% zeolite SSZ-91 based on the total weight of the hydroisomerization catalyst, or from about 10 to about 95 wt% zeolite SSZ-91, from about 20 to about 90 wt% zeolite SSZ-91, or from about 25 to about 85 wt% zeolite SSZ-91, or from about 30 to about 80 wt% zeolite SSZ-91, or from about 35 to about 75 wt% zeolite SSZ-91, or from about 35 to about 65 wt% zeolite SSZ-91, or from about 35 to about 55 wt% zeolite SSZ-91, or from about 45 to about 75 wt% zeolite SSZ-91, or from about 55 to about 75 wt% zeolite SSZ-91 based on the total weight of the hydroisomerization catalyst.

[0048] The hydroisomerization catalyst further comprises a metal modifier selected from metal modifiers such as Group 2, Group 8, Group 9, and Group 10 metals or combinations thereof. In some embodiments, the metal modifier is selected from Group 8, 9, or 10 metals and combinations thereof. For example, 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 Group 10 metals and combinations thereof. In some embodiments, the hydroisomerization catalyst comprises platinum, palladium, or a combination thereof. Base metals can be included in the catalyst.

[0049] In some embodiments, the hydroisomerization catalyst comprises from about 0.05 to about 10 wt%, 5 wt%, or 2.0 wt%, of a metal modifier (e.g., selected from Group 2, 8, 9, and 10 metals, or Group 8, 9, or 10 metals, e.g., Group 10 metals, e.g., platinum) based on the total weight of the hydroisomerization catalyst. For example, it can comprise from about 0.1 to about 1.5 wt%, or from about 0.2 to about 1.5 wt%, or from about 0.1 to about 1 wt% based on the total weight of the hydroisomerization catalyst. In some cases, for example, when base metals are included, the metal content is higher, e.g., at least about 5 wt%, or 10 wt%, or 15 wt%, or 20 wt%, or 25 wt%, or at least about 30 wt%, or can range from about 2 wt% or 5 wt% to about 25 wt% or 30 wt%.

[0050] 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, zirconia, and combinations thereof. In some embodiments, the hydroisomerization catalyst comprises an oxide binder comprising alumina. Suitable aluminas are commercially available, for example, Sasol's Catapal alumina and Pural alumina, or UOP's Versal alumina. Generally, the alumina can be any alumina known to be used as a catalyst-based matrix material. For example, the alumina can be boehmite, bayrilite, g-alumina, h-alumina, q-alumina, d-alumina, c-alumina or mixtures thereof. In some embodiments, the hydroisomerization catalyst comprises from about 5 to about 95 wt% of an oxide binder, based on the total weight of the hydroisomerization catalyst, for example, from about 5 to about 80 wt% of an oxide binder, from about 10 to about 70 wt% of an oxide binder, from about 20 to about 70 wt% of an oxide binder, for example, from about 25 to about 65 wt% of an oxide binder.

[0051] In some embodiments, the hydroisomerization catalyst comprises from about 5 to about 95 wt% of zeolite SSZ-91, from about 0.05 to about 2.0 wt% of a Group 8-10 metal, and from about 5 to about 95 wt% of an oxide binder based on the total weight of the hydroisomerization catalyst. In some embodiments, the hydroisomerization catalyst comprises from about 30 to about 80 wt% of zeolite SSZ-91, from about 0.1 to about 1.5 wt% of a Group 8-10 metal, and from about 20 to about 70 wt% of an oxide binder based on the total weight of the hydroisomerization catalyst.

[0052] Zeolite SSZ-91 and a method for producing zeolite SSZ-91 are described in US-A-9920260, which is hereby incorporated by reference in its entirety. Zeolite SSZ-91 is also referred to as SSZ-91 molecular sieve.

[0053] In some embodiments, zeolite SSZ-91 has an SiO2 / Al2O3 molar ratio (SAR) of 40 to 200, such as 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. The SAR is determined by inductively coupled plasma (ICP) elemental analysis.

[0054] In zeolite SSZ-91, at least 70% of the total ZSM-48 type material present in the product is composed of polytype 6. The proportion of polytype 6 among the total ZSM-48 type material present in the product is determined by DIFFaX simulation and is described in J. Am. Chem. Soc. 2012, 124, 13222-13230, where the obstacles were adjusted by three different failure probabilities. Note that the expression "at least X%" includes the case where no other ZSM-48 polytypes are present within the structure, i.e., when the material is 100% polytype 6. The structure of polytype 6 is described by Lobo and Koningsveld (see J. Am. Chem. Soc. 2002, 124, 13222-13230). In some embodiments, the SSZ-91 material has at least 80% of the total ZSM-48 type material present in the product composed of polytype 6. In some embodiments, the SSZ-91 material has at least 90% of the total ZSM-48 type material present in the product composed of polytype 6. The polytype 6 structure has been given the framework code *MRE by the Structure Commission of the International Zeolite Association.

[0055] Zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate containing microcrystals having an average aspect ratio collectively in the range of 1 to 8. In some embodiments, zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate containing microcrystals having an average aspect ratio collectively in the range of 1 to 6, such as 1 to 5, 1 to 4, or 1 to 3.

[0056] In some embodiments, zeolite SSZ-91 has a morphology characterized as polycrystalline aggregates having a diameter of about 100 nm to 1.5 μm, and each aggregate comprises an aggregate of microcrystals having an average aspect ratio in the range of 1 to 8 collectively. In some embodiments, zeolite SSZ-91 has a morphology characterized as polycrystalline aggregates having a diameter of about 100 nm to 1.5 μm, and each aggregate comprises an aggregate of microcrystals having an average aspect ratio in the range of 1 to 6, such as 1 to 5, 1 to 4, or 1 to 3 collectively. As used herein, the term "diameter" refers to the shortest length of the short end of each microcrystal being examined.

[0057] Zeolite SSZ-91 is a substantially phase-pure material. As used herein, the term "substantially phase-pure material" means that the material does not completely contain a zeolite phase other than the zeolite phase belonging to the ZSM-48 family of zeolites, or is present in an amount that does not measurably affect the selectivity of the material, or in an amount that gives a material disadvantage to the selectivity of the material. Two common phases that co-crystallize with SSZ-91 are the EUO type molecular sieves, such as EU-1, and magadiite and kenyaite. These additional phases can exist as separate phases or can intergrow with the SSZ-91 phase.

[0058] In some embodiments, zeolite SSZ-91 contains an EUO-type molecular sieve phase in an amount in the range of 0 to 7 weight percent of the total zeolite SSZ-91 product. In some embodiments, zeolite SSZ-91 contains an EUO-type molecular sieve phase in an amount in the range of 0 to 5.0 weight percent, such as 0 to 4.0 weight percent, or 0 to 3.5 weight percent. In some embodiments, zeolite SSZ-91 contains an EUO-type molecular sieve phase in an amount in the range of 0.1 to 7.0 weight percent, such as 0.1 to 5.0 weight percent, 0.1 to 4.0 weight percent, or 0.1 to 3.5 weight percent. In some embodiments, zeolite SSZ-91 contains 0 to 7 weight percent of EU-1, such as 0 to 5.0 weight percent of EU-1, 0 to 4.0 weight percent of EU-1, 0 to 3.5 weight percent of EU-1, 0.1 to 7.0 weight percent of EU-1, 0.1 to 5.0 weight percent of EU-1, 0.1 to 4.0 weight percent of EU-1, 0.1 to 3.5 weight percent of EU-1, 0.1 to 2 weight percent of EU-1, or 0.1 to 1 weight percent of EU-1.

[0059] The ratio of powder XRD peak intensities is known to vary linearly as a function of the weight fractions of any two phases in a mixture: (Iα / Iβ)=(RIRα / RIRβ)*(xα / xβ). Here, the RIR (reference intensity ratio) parameter can be found in The International Centre for Diffraction Data’s Powder Diffraction File (PDF) database (http: / / www.icdd.com / products / ). Thus, the weight percent 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.

[0060] In some embodiments, zeolite SSZ-91 comprises a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 40 to 220; at least 70% of polytype 6 of the total ZSM-48 type material; 0 to 7.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 8. In some embodiments, zeolite SSZ-91 comprises a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 40 to 220; at least 70% of polytype 6 of the total ZSM-48 type material; 0 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 8. In some embodiments, zeolite SSZ-91 comprises a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 40 to 220; at least 70% of polytype 6 of the total ZSM-48 type material; 0 to 3.5 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 8. In some embodiments, zeolite SSZ-91 comprises a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 40 to 200; at least 70% of polytype 6 of the total ZSM-48 type material; 0 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 8. In some embodiments, zeolite SSZ-91 comprises a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 70 to 200; at least 70% of polytype 6 of the total ZSM-48 type material; 0 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6.In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 7.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of EU-1, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 160; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of an EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively comprising microcrystals having an average aspect ratio of 1 to 6.In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 70 to 160; at least 70% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 70 to 200; at least 80% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 80% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 6. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 80% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 7.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 4. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 200; at least 80% of the total ZSM-48 type material is polytype 6; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a morphology characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 4.In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 80 to 160; at least 80% polytype 6 of the total ZSM-48 type material; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a form characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 4. In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 100 to 140; at least 80% polytype 6 of the total ZSM-48 type material; and contains 0.1 to 4.0 wt% of EU-1, where zeolite SSZ-91 has a form characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 4.

[0061] In some embodiments, zeolite SSZ-91 has a molar ratio of silicon oxide (SiO2) to aluminum oxide (Al2O3) (SAR) of 100 to 140; at least 80% polytype 6 of the total ZSM-48 type material; and contains 0.1 to 4.0 wt% of the EUO type molecular sieve phase, where zeolite SSZ-91 has a form characterized as a polycrystalline aggregate collectively containing microcrystals having an average aspect ratio of 1 to 4.

[0062] Zeolite SSZ-91 synthesized as described herein can be characterized by their XRD patterns. The powder XRD lines in Table 1 are representative of as-synthesized zeolite SSZ-91. Minor variations in the diffraction pattern may be due to variations in the molar ratio of the framework species of a particular sample due to changes in the lattice constant. Furthermore, sufficiently small crystals affect the shape and intensity of the peaks, leading to a significant broadening of the peaks. Minor changes in the diffraction pattern may also be due to variations in the organic compounds used in the preparation or variations in the Si / Al molar ratio for each sample. Calcination may also cause a minor shift in the XRD pattern. Despite these small perturbations, the basic crystal lattice structure does not change.

Table 1

[0063] The X-ray diffraction pattern lines in Table 2 represent the calcined SSZ-91.

Table 2

[0064] The powder X-ray diffraction patterns shown in this specification were collected by standard techniques. The radiation was CuK α radiation. The peak heights and positions were read as a function of 2θ (where θ is the Bragg angle), adjusted for the background from the relative peak intensities, and the interplanar spacing d corresponding to the recorded lines could be calculated.

[0065] Zeolite SSZ-91 can be used as-synthesized, but is usually heat-treated (calcined). The term "as-synthesized" refers to zeolite SSZ-91 in the form after crystallization and before removal of the SDA cations. The SDA can be removed, for example, by heat treatment (e.g., calcination) at a temperature that can be readily determined by one of ordinary skill in the art to be sufficient to remove the SDA from the molecular sieve in an oxidative atmosphere (e.g., air, a gas with an oxygen partial pressure greater than 0 kPa). The SDA can also be removed by ozonation and photolysis techniques (e.g., exposing the SDA-containing molecular sieve product to light or electromagnetic radiation having a wavelength shorter than visible light under conditions sufficient to selectively remove organic compounds from the molecular sieve), as described in U.S. Patent No. 6,960,327.

[0066] Subsequently, zeolite SSZ-91 can be calcined in steam, air, or an inert gas at a temperature in the range of 200 °C to 800 °C for a time in the range of 1 hour to several days, e.g., 1 to 48 hours. It is usually desirable to remove extra-framework cations (e.g., Na + ) by ion exchange and replace them with hydrogen, ammonium, or any desired metal ion.

[0067] When the formed molecular sieve 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 achieved by removing heteroatoms from the lattice by known techniques such as acid leaching.

[0068] Zeolite SSZ-91 produced from the processes disclosed herein can be formed into a wide variety of physical shapes. Zeolite SSZ-91 can be in the form of a powder, granules, or a shaped 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). When the catalyst is shaped, such as by extrusion with an organic binder, zeolite SSZ-91 may be extruded before drying, after drying, or partially dried and then extruded.

[0069] Zeolite SSZ-91 can be compounded with other materials that are resistant to the temperatures and other conditions used in organic conversion processes. Such matrix materials include active and inert materials, synthetic or natural molecular sieves, and inorganic materials such as clays, silica, and metal oxides. Examples of such materials and methods of using them are disclosed in U.S. Patent Nos. 4,910,006 and 5,316,753.

[0070] Hydroisomerization catalysts such as zeolite SSZ-91 can be in the as-synthesized form or the calcined form. In some embodiments, the hydroisomerization catalyst is formed from the calcined form of zeolite SSZ-91. In some embodiments, the hydroisomerization catalyst comprises a molecular sieve selected from zeolite SSZ-91 and a metal of Group 2, 8, 9, or 10 (e.g., a metal of Group 8-10 such as Pt).

[0071] In some embodiments, the hydroisomerization catalyst is formed by compositing molecular sieve zeolite SSZ-91 (as-synthesized or calcined form) with an oxide binder such as alumina. In some embodiments, compositing molecular sieve zeolite SSZ-91 (as-synthesized or calcined form) with an oxide binder involves mixing a molecular sieve selected from zeolite SSZ-91 (as-synthesized or calcined state) with the oxide binder and extruding the product. The mixture of the molecular sieve and the oxide binder can be formed into particles or extrudates having a wide range of physical shapes and dimensions. In some embodiments, the extrudates or particles may be dried and calcined before filling with metal. In some embodiments, the extrudates or particles are impregnated with a metal, such as a Group 2, 8, 9, or 10 metal (e.g., Group 8-10 metals such as Pt), and then dried and calcined. In some embodiments, the extrudates or particles are dried and calcined before filling with metal.

[0072] In some embodiments, the hydroisomerization catalyst is prepared by compositing 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, such as a Group 2, 8, 9, or 10 metal (e.g., Group 8-10 metals such as Pt), to form a metal-supported extrudate; drying the metal-supported extrudate; and calcining the dried metal-supported extrudate.

[0073] In some embodiments, the hydroisomerization catalyst is formed by impregnating a molecular sieve (such as zeolite SSZ-91) into a solution containing a metal, such as a Group 2, 8, 9, or 10 metal (such as a Group 8-10 metal like Pt). In some embodiments, the hydroisomerization catalyst is formed by impregnating a calcined molecular sieve into a solution containing a Group 2, 8, 9, or 10 metal (such as a Group 8-10 metal like Pt). In some embodiments, the hydroisomerization catalyst is formed by impregnating an extrudate base containing a molecular sieve and an oxide binder. In some embodiments, the extrudate base is exposed (e.g., immersed) in an impregnating solution containing a metal (such as a Group 2, 8, 9, or 10 metal (such as a Group 8-10 metal like Pt)) for 0.1 to 10 hours.

[0074] 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.

[0075] In some embodiments, an extrudate base formed by compositing a molecular sieve (such as zeolite SSZ-91) and an oxide binder is dried and calcined prior to impregnation. In some embodiments, the dried and calcined extrudate base is impregnated with an impregnating solution to form a metal-supported extrudate, which is then dried and calcined again to form the hydroisomerization catalyst.

[0076] In some embodiments, the impregnated extrudate base containing 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-supported 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.

[0077] The process of hydroconverting a biofeedstock involves contacting the biofeedstock with a hydroconversion catalyst under hydroconversion conditions. The hydroconversion occurs in the presence of hydrogen and may include hydrotreating and hydroisomerization processes.

[0078] In some embodiments according to the present invention, the 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 biofeedstock comprises only renewable bio-components. The biofeedstock may be utilized by itself, i.e., fossil fuel components or other non-biofeedstock components are not added together with the biofeedstock.

[0079] The process may also be a single-stage process, e.g., intermediate products and / or final products are not removed between stages or between catalyst beds. The process may advantageously be carried out in a single reactor in some embodiments. In some embodiments, the process may be carried out in two or more reactors connected in series, where the first reactor or catalyst section comprises a hydrotreating section and reactor, or catalyst section, and downstream of the first reactor or catalyst section, a hydroisomerization section is included. In some embodiments, all of the products from the hydrotreating section are sent directly to the hydroisomerization section, i.e., intermediate products are not removed between sections. In some embodiments, a separate hydrocracking catalyst is not used within the process to produce renewable products. Those skilled in the art will understand that various reactor configurations and catalyst filling arrangements are possible according to the present invention.

[0080] The hydroconversion conditions typically include a temperature in the range of about 300°F to about 800°F (149°C to 427°C); a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); about 0.1 to about 20 h -1The supply rate of the bio-feedstock within the range of LHSV; and the supply rates of hydrogen and the bio-feedstock in a ratio of about 1000 or 1500, or 2000 to about 10,000 standard cubic feet of H2 per barrel of the bio-feedstock (per 1 m of the feed 3 per about 180 to about 1800 m 3 of H2).

[0081] Figures 1 - 3 show specific embodiments according to the present invention and provide a comparison with prior art processes (Figure 1). Figure 1 shows a prior art process in which feedstock 10 is supplied to a hydrotreating reactor 20 which is the first stage of a two-stage reactor system. Intermediate by-products (including, for example, H2S, H2O, CO, and CO2) are withdrawn 40 prior to the second dewaxing stage. The hydrotreated product is supplied to a dewaxing reactor 50 (30, producing a dewaxed product 60. Figure 2 shows an embodiment according to the present invention in which bio-feedstock 12 is supplied to a single-stage, single-reactor 21 including catalyst sections for hydrotreating 22 and hydroisomerization 52. Intermediate by-products are not withdrawn prior to passing the effluent directly from the hydrotreating section to the hydroisomerization section. The hydrotreated and hydroisomerized renewable product 62 is produced from a single-stage, single-reactor system. Figure 3 shows an embodiment according to the present invention in which bio-feedstock 13 is supplied to a two-stage reactor system including reactor catalyst sections for hydrotreating 23 and hydroisomerization 53. Intermediate product 33 is passed directly from the hydrotreating reactor to the hydroisomerization reactor. Intermediate by-products are not withdrawn prior to passing the effluent directly from the hydrotreating reactor section to the hydroisomerization reactor section. The hydrotreated and hydroisomerized renewable product 63 is produced from a two-stage reactor system. In some cases, more than one reactor may be used in either or both of the hydrotreating catalyst section and / or the hydroisomerization catalyst section.

[0082] 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 a temperature of 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 a pressure of about 100 to about 2500 psig (0.69 to 17.24 MPa). In some embodiments, the hydroisomerization conditions include a rate in the range of about 0.1 to about 20 h -1 LHSV, such as a rate of about 0.1 to about 5 h -1 including the feed rate of the biofeedstock to the reactor containing the hydroisomerization catalyst at LHSV.

[0083] In some embodiments, the hydroisomerization conditions include hydrogen and biofeedstock fed to the reactor at a ratio of about 1000, or 1500, or 2000 to about 10,000 standard cubic feet of H2 per barrel of feedstock (about 180 to about 1800 m 3 per m of feedstock 3 H2, such as about 2500 to about 5000 scf H2 per barrel of diesel feedstock (about 440 to about 890 m 3 per m of feedstock 3 H2).

[0084] 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), such as 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), such as a pressure of about 100 to about 2500 psig (0.69 to 17.24 MPa); a rate of about 0.1 to about 20 h - 1 LHSV, such as a rate of about 0.1 to about 5 h -The feed rate of the feedstock to the reactor containing the hydroisomerization catalyst within the range of LHSV; about 1000, or 1500, or 2000 to about 10,000 standard cubic feet of H2 per barrel of feedstock (about 180 to about 1800 m 3 per m of feedstock 3 H2, for example, about 2500 to about 5000 scf H2 per barrel of feedstock (about 440 to about 890 m 3 per m of feedstock 3 H2) of hydrogen and the biofeedstock supplied to the reactor.

[0085] In some embodiments, the process of contacting the biofeedstock with the hydroisomerization catalyst provides a diesel fuel having an increased ratio of isoparaffins to normal paraffins compared to the feedstock. In some embodiments, contacting the biofeedstock with the hydroisomerization catalyst provides a diesel fuel having a lower cloud point and a lower pour point compared to the cloud point and pour point of the diesel feedstock.

[0086] In some embodiments, contacting the biofeedstock with the hydroisomerization catalyst provides a diesel fuel having a lower cloud point and a lower pour point compared to the cloud point and pour point of the hydrotreated biofeedstock, where the diesel fuel has 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.

[0087] The biofeedstock is generally contacted with a hydrotreating catalyst under hydrotreating conditions before contacting the feedstock with a hydroisomerization catalyst. In some embodiments, the hydrotreating conditions are 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), for example, about 500°F (260°C) or 550°F (288°C) to about 750°F (399°C), or 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), for example, about 100 to about 2500 psig (0.69 to 17.24 MPa); about 0.1 to about 20 h - 1 LHSV, for example, about 0.1 to about 5 h - The feed rate of the feedstock to a reactor containing a hydroisomerization catalyst in the range of 1 LHSV; about 1000, or 1500, or 2000 to about 10,000 standard cubic feet of H2 per barrel of feedstock (about 180 to about 1800 m 3 per m of feedstock 3 H2, for example, about 2500 to about 5000 scf H2 per barrel of feedstock (about 440 to about 890 m 3 per m of feedstock 3 H2) of hydrogen and biofeedstock fed to the reactor.

[0088] The hydrotreating catalyst can generally include a refractory inorganic oxide support and a Group 6 metal modifier and / or a Group 8-10 metal modifier. In some embodiments, the hydrotreating catalyst includes a refractory inorganic oxide support, a Group 6 metal modifier, and a Group 8-10 metal modifier. The oxide support is also referred to herein as a binder. The support of the hydrotreating catalyst can be prepared from, or include, alumina, silica, silica / alumina, titania, magnesia, zirconia, etc., or combinations thereof. The hydrotreating catalyst support can include amorphous materials, crystalline materials, or combinations thereof. Examples of amorphous materials include, but are not limited to, amorphous alumina, amorphous silica, amorphous silica-alumina, etc.

[0089] In some embodiments, the hydrogenation carrier may include amorphous alumina. When using a combination of silica and alumina, the distribution of silica and alumina in the carrier may be uniform or non-uniform. In some embodiments, the carrier may be composed of an alumina gel in which silica, silica / alumina, or an alumina-based material is dispersed. The carrier may also include 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 cause harmful decomposition of the raw materials.

[0090] In some embodiments, silica and / or alumina constitutes at least about 90% by weight of the carrier of the hydrogenation catalyst, and in some embodiments, the carrier may be at least substantially all silica or all alumina.

[0091] In some embodiments, the Group 8-10 metal modifier of the hydrotreating catalyst comprises Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt, or a combination thereof. In some embodiments, the Group 8-10 metal modifier of the hydrotreating catalyst comprises a Group 9 metal, a Group 10 metal, or a combination thereof. In some embodiments, the Group 8-10 metal modifier of the hydrotreating catalyst comprises Co and / or Ni, or is Co and / or Ni. In some embodiments, the Group 8-10 metal modifier of the hydrotreating catalyst comprises Ni, or is Ni. In some embodiments, the Group 8-10 metal modifier of the hydrotreating catalyst comprises Co and Ni. In some embodiments, the Group 8-10 metal modifier is an oxide, a hydroxide, or a salt. In some embodiments, the Group 8-10 metal modifier is a salt. The amount of the Group 8-10 metal modifier in the hydrotreating catalyst, calculated as the metal oxide, is generally 0.1 to 20 wt% (e.g., 1.0 or 2 to 10 wt%) based on the bulk dry weight of the catalyst. In some embodiments, the Group 6 metal modifier of the hydrotreating catalyst is selected from Cr, Mo, W, and combinations thereof. In some embodiments, the Group 6 metal modifier of the hydrotreating catalyst comprises Mo, or is Mo. In some embodiments, the Group 6 metal modifier is an oxide, an oxo acid, or an ammonium salt of an oxo or polyoxo anion. The amount of the Group 6 metal modifier in the hydrotreating catalyst, calculated as the metal oxide, is generally 5 to 50 wt% (e.g., 10 to 40 wt%, or 15 to 30 wt%) based on the bulk dry weight of the catalyst. In some embodiments, the hydrotreating catalyst comprises Ni and Mo.

[0092] In some embodiments, the Group 8-10 metal modifier and / or the Group 6 metal modifier of the hydrogenation catalyst can be dispersed on an inorganic oxide support. Many methods for depositing Group 8-10 and / or Group 6 metals, or compounds containing such metals, on a support are well known in the art, and such methods include ion exchange, impregnation, and coprecipitation. In some embodiments, the impregnation of the support with the Group 8-10 and Group 6 metal modifiers can be carried out at a controlled pH value. The Group 8-10 and Group 6 metal modifiers can be added to the impregnation solution as metal salts such as halide salts and / or amine complexes and / or salts of mineral acids. Other examples of metal salts that can be used include nitrates, carbonates, and bicarbonates, as well as carboxylates such as acetates, citrates, and formates.

[0093] Optionally, the impregnated support can be left standing with the impregnation solution for a period, for example, in the range of about 2 to about 24 hours. After impregnating the oxide support 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 hydrotreating catalyst is dried and calcined, the prepared catalyst can be reduced with hydrogen or sulfided with a sulfur-containing compound, and can be used in a hydrotreating reactor, for example, located upstream of a hydroisomerization reactor.

[0094] To avoid misunderstanding, the present disclosure relates to the subject matter described in the following numbered clauses.

[0095] 1. A process for producing a renewable product from a biofeedstock, the process comprising contacting the biofeedstock with a hydroconversion catalyst under hydroconversion conditions, the biofeedstock comprising one or more bio-components, and the hydroconversion catalyst comprising a hydrotreating catalyst and a hydroisomerization catalyst.

[0096] 2. The process according to clause 1, wherein the hydroconversion catalyst comprises zeolite SSZ-91.

[0097] 3. The process according to clauses 1 to 2, wherein the hydroconversion catalyst comprises SSZ-91.

[0098] 4. The process according to clauses 1 to 3, wherein the biofeedstock contains only renewable bio-components.

[0099] 5. The process according to clauses 1 to 4, wherein fossil fuel components are not used together with the biofeedstock of the process.

[0100] 6. The process according to clauses 1 to 5, wherein the process is a single-stage process.

[0101] 7. The process according to clause 6, wherein the single-stage process is carried out in a single reactor.

[0102] 8. The process according to clause 6, wherein the single-stage process is carried out in two or more reactors connected in series, the first reactor comprises a hydrotreating section, and the reactor downstream of the first reactor comprises a hydroisomerization section.

[0103] 9. The process according to clauses 1 to 8, wherein the hydroconversion catalyst is a noble metal catalyst, or a combination of a base metal catalyst and a noble metal catalyst, or contains them.

[0104] 10. The process according to clauses 1 to 9, wherein the hydroconversion catalyst contains a base metal catalyst and a noble metal catalyst.

[0105] 11. The process according to clauses 9 to 10, wherein the base metal is selected from Mo, Ni, W, Co, and combinations thereof.

[0106] 12. The process according to clause 11, wherein the base metal is Mo, or a combination of Mo and Ni.

[0107] 13. The process according to clauses 9 to 12, wherein the noble metal is selected from Pt, Pd, and combinations thereof.

[0108] 14. The process according to clauses 1 to 13, wherein the process includes a hydrotreating section and a hydroisomerization section, and all of the products from the hydrotreating section are directly passed to the hydroisomerization section.

[0109] 15. The process according to clauses 1 to 14, wherein the renewable product includes an intermediate distillation product, a base oil product, or a combination thereof.

[0110] 16. The process according to clause 15, wherein the renewable product includes naphtha, kerosene, jet fuel, diesel fuel, base oil, or a combination thereof.

[0111] 17. The process according to any one of clauses 1 to 16, wherein a hydrocracking catalyst is not used to produce the renewable product.

[0112] 18. The hydroconversion conditions are a temperature in the range of about 300°F to about 800°F (149°C to 427°C), a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), about 0.1 to about 20 h -1 a feed rate of the biofeedstock in the range of LHSV, and a ratio of hydrogen to biofeedstock feed rate of about 1000 to about 10,000 standard cubic feet H2 per barrel of biofeedstock (about 180 to about 1800 m 3 H2 per m of feedstock), and the process according to clauses 1 to 17. 3

[0113] 19. The process according to clause 18, wherein the hydroconversion conditions are hydrotreating or hydroisomerization.

[0114] 20. The process according to clauses 1 to 19, wherein the hydroconversion catalyst includes zeolite SSZ-91 and Group 8 to 10 metals.

[0115] ​21. The process according to clauses 1 to 20, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91, in its calcined form, has an X-ray diffraction pattern substantially as shown in the following table:

Table 3

[0116] 22. The process according to clauses 1 to 21, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having a silicon dioxide to aluminum oxide ratio of 40 to 220, 70 to 160, or 80 to 160, or 80 to 140, or 100 to 160.

[0117] 23. The process according to clauses 1 to 22, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having at least about 80% polytype 6 of all ZSM-48 type materials present in the zeolite SSZ-91, or at least about 90% polytype 6 of all ZSM-48 type materials present in the zeolite SSZ-91.

[0118] 24. The process according to clauses 1 to 23, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91 contains 0.1 to 4.0 wt% EUO type molecular sieve phase.

[0119] 25. The process according to clauses 1 to 24, wherein the hydroconversion catalyst comprises zeolite SSZ-91 containing 0.1 to 4.0 wt% EU-1.

[0120] 26. The process according to clauses 1 to 25, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having a morphology characterized as a polycrystalline aggregate comprising microcrystals having an average aspect ratio of 1 to 4 collectively.

[0121] 27. The hydroconversion catalyst is a silicon dioxide to aluminum oxide ratio of 40 to 220 or 70 to 160, Characterized as a polycrystalline aggregate containing microcrystals having an average aspect ratio in the range of 1 to 4 collectively, The process according to clauses 1 to 26, comprising zeolite SSZ-91, having at least about 80% of the polytype 6 of all ZSM-48 type materials present in the zeolite SSZ-91 and an EUO type molecular sieve phase of 0.1 to 4.0% by weight.

[0122] 28. The process according to clauses 1 to 27, wherein the hydroconversion catalyst comprises about 5 to about 95% by weight of zeolite SSZ-91 and about 0.05 to about 2.0% by weight of a metal modifier.

[0123] 29. The biofeedstock comprises a bio-component feed selected from lipids, vegetable oils and animal fats containing triglycerides and free fatty acids, or is a bio-component feed selected from lipids, vegetable oils and animal fats containing triglycerides and free fatty acids. For example, the bio-component feed is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil and combinations thereof. The process according to clauses 1 to 28.

[0124] 30. The process according to clauses 1 to 29, wherein the bio-feedstock comprises a bio-component feedstock selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, colza 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, milk fat, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, cranberry oil, etc., or is a bio-component feedstock selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, colza 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, milk fat, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, cranberry oil, etc.

[0125] 31. The process according to clauses 1 to 30, wherein the process produces a diesel fuel having a cloud point lower than the cloud point of the hydrogenated bio-feedstock.

[0126] 32. The process according to clause 31, wherein the diesel fuel has a cloud point at least 10 °C lower than the cloud point of the hydrogenated bio-feedstock, or at least 20 °C lower than the cloud point of the bio-feedstock, or at least 30 °C lower than the cloud point of the hydrogenated bio-feedstock.

[0127] 33. The process according to clauses 31 to 32, wherein the diesel fuel has a pour point at least 10 °C lower than the pour point of the hydrogenated bio-feedstock, or at least 20 °C lower than the pour point of the hydrogenated bio-feedstock, or at least 30 °C lower than the pour point of the hydrogenated bio-feedstock.

[0128] This disclosure is not to be limited by the specific embodiments described herein, which are intended as illustrations of various aspects. Although it may be apparent, many modifications and changes can be made without departing from the spirit and scope thereof. In addition to those listed herein, functionally equivalent methods and systems within the scope of this disclosure will be apparent from the foregoing representative description. Such modifications and changes are to be included within the scope of the appended representative claims. This disclosure should be limited only by the literal terms of the appended representative claims, together with the full scope of equivalents to which such representative claims are entitled. It should also be understood that the terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting.

[0129] The foregoing description, together with the associated embodiments, is presented only by way of illustration and for the purpose of example only. The description is not exhaustive and does not limit the invention to the precise form disclosed. Those skilled in the art will recognize from the above description that modifications and changes are possible in light of the above teachings, or can be made by practicing the disclosed embodiments. For example, in some cases, each step described need not be performed in the same order or at the same interval as described. Similarly, different steps can be omitted, repeated, or combined, as necessary, to achieve the same or similar objectives. Accordingly, the invention is not limited to the embodiments described above, but instead is defined by the appended claims in light of the full scope of equivalents.

[0130] In the foregoing specification, different preferred embodiments have been described with reference to the accompanying drawings. However, it may be apparent that various modifications and changes can be made thereto without departing from the broader scope of the invention as set forth in the claims that follow, and further embodiments can be practiced. Accordingly, the specification and drawings are to be regarded as illustrative rather than limiting.

[0131] Although it is the case when permitted, all publications, patents, and patent applications cited in this specification are hereby incorporated by reference in their entirety herein to the extent that such disclosure is not inconsistent with the present invention.

Claims

1. A process for producing renewable products from a biofeedstock, the process comprising contacting the biofeedstock with a hydroconversion catalyst under hydroconversion conditions, the biofeedstock comprising one or more bio-components, the hydroconversion catalyst comprising a hydrotreating catalyst and a hydroisomerization catalyst, said process.

2. The process according to claim 1, wherein the hydroconversion catalyst comprises zeolite SSZ-91.

3. The process according to any one of claims 1 to 2, wherein the hydroconversion catalyst comprises SSZ-91.

4. The process according to any one of claims 1 to 3, wherein the biofeedstock comprises only renewable bio-components.

5. The process according to any one of claims 1 to 4, wherein fossil fuel components are not used with the biofeedstock of the process.

6. The process according to any one of claims 1 to 5, wherein the process is a single-stage process.

7. The process according to claim 6, wherein the single-stage process is carried out in a single reactor.

8. The process according to claim 6, wherein the single-stage process is carried out in two or more reactors connected in series, the first reactor comprising a hydrotreating section, and the reactor downstream of the first reactor comprising a hydroisomerization section.

9. The process according to any one of claims 1 to 8, wherein the hydroconversion catalyst is a noble metal catalyst, or a combination of a base metal catalyst and a noble metal catalyst, or comprises a noble metal catalyst, or a combination of a base metal catalyst and a noble metal catalyst.

10. The process according to any one of claims 1 to 9, wherein the hydroconversion catalyst comprises a base metal catalyst and a noble metal catalyst.

11. The process according to any one of claims 9 to 10, wherein the base metal is selected from Mo, Ni, W, Co, and combinations thereof.

12. The process according to claim 11, wherein the base metal is Mo, or a combination of Mo and Ni.

13. The process according to any one of claims 9 to 12, wherein the noble metal is selected from Pt, Pd, and combinations thereof.

14. The process according to any one of claims 1 to 13, wherein the process comprises a hydrotreating section and a hydroisomerization section, and all of the products from the hydrotreating section are passed directly to the hydroisomerization section.

15. The process according to any one of claims 1 to 14, wherein the renewable product comprises an intermediate distillation product, a base oil product, or a combination thereof.

16. The process according to claim 15, wherein the renewable product comprises naphtha, kerosene, jet fuel, diesel fuel, base oil, or a combination thereof.

17. The process according to any one of claims 1 to 16, wherein no hydrocracking catalyst is used to produce the renewable product.

18. The hydroconversion conditions are a temperature in the range of about 300°F to about 800°F (149°C to 427°C), a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), About 0.1 to about 20 h －１ The supply rate of the bio-feedstock within the range of LHSV, and About 1000 to about 10,000 standard cubic feet of H per barrel of biofeedstock ２ (per 1 m of feed ３ about 180 to about 1800 m ３ H ２ ) The process according to any one of claims 1 to 17, comprising a hydrogen and biofeedstock feed rate in the ratio of

19. The process according to claim 18, wherein the hydroconversion conditions are hydrotreating or hydroisomerization.

20. The process according to any one of claims 1 to 19, wherein the hydroconversion catalyst comprises zeolite SSZ-91 and a Group 8 to 10 metal.

21. The process according to any one of claims 1 to 20, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91, in its calcined form, has an X-ray diffraction pattern substantially as shown in the following table: 【Table 1】

22. The process according to any one of claims 1 to 21, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having a silicon dioxide to aluminum oxide ratio of 40 to 220, 70 to 160, or 80 to 160, or 80 to 140, or 100 to 160.

23. The process according to any one of claims 1 to 22, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having at least about 80% of the total ZSM-48 type material present in the zeolite SSZ-91 in polytype 6, or at least about 90% of the total ZSM-48 type material present in the zeolite SSZ-91 in polytype 6.

24. The process according to any one of claims 1 to 23, wherein the hydroconversion catalyst comprises zeolite SSZ-91, and the zeolite SSZ-91 comprises a EUO-type molecular sieve phase of 0.1 to 4.0% by weight.

25. The process according to any one of claims 1 to 24, wherein the hydroconversion catalyst comprises zeolite SSZ-91 comprising 0.1 to 4.0% by weight of EU-1.

26. The process according to any one of claims 1 to 25, wherein the hydroconversion catalyst comprises zeolite SSZ-91 having a morphology characterized as a polycrystalline aggregate comprising microcrystals having an average aspect ratio collectively in the range of 1 to 4.

27. The hydroconversion catalyst is a ratio of silicon oxide to aluminum oxide of 40 to 220 or 70 to 160, a morphology characterized as a polycrystalline aggregate comprising microcrystals having an average aspect ratio collectively in the range of 1 to 4, zeolite SSZ-91 having at least about 80% polytype 6 of all ZSM-48 type materials present in the zeolite SSZ-91 and an EUO type molecular sieve phase of 0.1 to 4.0% by weight. The process according to any one of claims 1 to 26, comprising zeolite SSZ-91.

28. The process according to any one of claims 1 to 27, wherein the hydroconversion catalyst comprises about 5 to about 95% by weight of zeolite SSZ-91 and about 0.05 to about 2.0% by weight of a metal modifier.

29. The process according to any one of claims 1 to 28, wherein the biofeedstock comprises a lipid, vegetable oil and animal fat selected from a bio-component feedstock comprising triglycerides and free fatty acids, or is a bio-component feedstock selected from a lipid, vegetable oil and animal fat comprising triglycerides and free fatty acids. For example, the bio-component feedstock is selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, and combinations thereof.

30. The process according to claims 1 to 29, wherein the bio-feedstock comprises a bio-component feedstock selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, colza 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, milk fat, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, cranberry oil, etc., or is a bio-component feedstock selected from canola oil, corn oil, soybean oil, castor oil, camelina oil, palm oil, rapeseed oil, soybean oil, colza 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, milk fat, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, cranberry oil, etc.

31. The process according to claims 1 to 30, wherein the process produces a diesel fuel having a cloud point lower than the cloud point of the hydrogenated bio-feedstock.

32. The process according to claim 31, wherein the diesel fuel has a cloud point at least 10 °C lower than the cloud point of the hydrogenated bio-feedstock, or at least 20 °C lower than the cloud point of the bio-feedstock, or at least 30 °C lower than the cloud point of the hydrogenated bio-feedstock.

33. The process according to claims 31 to 32, wherein the diesel fuel has a pour point at least 10 °C lower than the pour point of the hydrogenated bio-feedstock, or at least 20 °C lower than the pour point of the hydrogenated bio-feedstock, or at least 30 °C lower than the pour point of the hydrogenated bio-feedstock.

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