A feed injector and an ebullated bed reactor configuration and hydroconversion process using it

Abstract

A hydroconversion process operated in one or more ebullated bed reactor(s) is disclosed. The process comprises a) providing one or more top feed(s), a bottom feed, a hydrogen stream and a hydroconversion catalyst; b) subjecting a mixture of the one or more top feed(s), the bottom feed, and the hydrogen stream to hydroconversion in an ebullated catalyst bed arranged in an ebullated bed reactor and comprising the hydroconversion catalyst to provide a converted stream comprising gaseous compounds and liquid compounds; and c) removing a portion of the converted stream from the ebullated bed reactor as a conversion effluent. In the process the bottom feed and the hydrogen stream are fed to a plenum at the bottom of the ebullated bed reactor; the one or more top feed(s) is / are fed with a top feed injector into a recycle cup arranged above the ebullated catalyst bed and / or into a recycle downcomer connected to the recycle cup, and mixed therein into a portion of the liquid compounds of the converted stream to provide a mixed stream; a recycle pump connected to the recycle downcomer pumps the mixed stream into the plenum; and the content of the plenum is distributed to the ebullated catalyst bed. Also a reactor configuration for ebullated bed operation, an ebullated bed reactor system comprising two or more reactor configuration(s), and use of the reactor configuration or the ebullated bed reactor system are disclosed.

Description

[0001] A FEED INJECTOR AND AN EBULLATED BED REACTOR CONFIGURATION AND HYDROCONVERSION PROCESS USING IT

[0002] TECHNICAL FIELD

[0003] The present disclosure generally relates to a top feed injector arranged to an ebullated bed reactor. The disclosure relates particularly, though not exclusively, to a hydroconversion process operated in one or more ebullated bed reactor(s) using a top feed injector. The disclosure also relates to a reactor configuration for an ebullated bed operation comprising a top feed injector, an ebullated bed reactor system comprising two or more reactor configurations, and uses thereof.

[0004] BACKGROUND

[0005] This section illustrates useful background information without admission of any technique described herein representative of the state of the art.

[0006] There is an ongoing need to reduce greenhouse gas (GHG) emissions and / or carbon footprint in the transportation and petrochemical industry. Accordingly, interest towards sustainable materials usable in these fields is growing.

[0007] Fully biobased alternatives for drop-in replacements of fossil hydrocarbon products have been successfully created. For example, Neste MY Renewable Diesel is a Hydrotreated Vegetable Oil (HVO) developed by Neste Corporation. It is made by NEXBTL™ process, which is a proprietary HVO process of Neste Corporation, from 100% renewable raw materials such as waste and residues, and results in as much as 75-95% less greenhouse gas (GHG) emissions over the fuel’s life cycle when compared with fossil diesel. Renewable Neste RE™, on the other hand, is a 100% renewable feedstock of Neste Corporation showing a GHG emission reduction of more than 85% over the life cycle when used to replace conventional fossil feedstock in the chemical and polymers industry.

[0008] Co-processing of sustainable feed streams in reactor types well known from petroleum refineries for processing petroleum feeds has also been suggested. However, the sustainable feeds often have properties for which the conventional refinery units are not quite designed for, and may therefore require significant upgrading of the unit materials involving high investment costs, or additional process steps such as pre-treatment, preprocessing and / or dilution before introducing into the refinery unit. Additional process steps and units for them involve increased investment and operating costs, and add complexity of the process.

[0009] Also modifications to conventional refinery units have been suggested to allow processing of feed types for which the conventional refinery unit is not originally designed for.

[0010] LIS2011 / 0036752 discloses a method of hydroconverting in ebullated bed mode a petroleum feed containing a significant amount of light fractions. The hydroconversion method uses at least one ebullated-bed reactor for which injection of the feed is carried out at the top of said reactor, in the gas overhead. The method involves separating the feed within the reactor into a vaporized fraction and a liquid fraction. Also a reactor operating under ebullated bed conditions and usable in the method is disclosed.

[0011] In addition to the concepts dedicated for processing fully biogenic materials, for tackling global warming and vanishing crude oil reserves, further solutions for more sustainable industrial processes and products are urgently needed, particularly new approaches that could be implemented in existing petroleum refineries, making use of existing infrastructure such as reactors.

[0012] SUMMARY

[0013] It is an aim to solve or alleviate at least some of the problems related to prior art. An aim is to provide a new approach for producing materials, especially for use in the transportation and petrochemicals sectors, involving reduced GHG emissions and / or carbon footprint. A further aim is to provide a hydroconversion process operated in ebullated bed reactor(s), a reactor configuration for an ebullated bed operation and an ebullated bed reactor system, having improved flexibility regarding the feeds that can be utilised therein, for example feeds that are not compatible with each other and / or with the material design of the reactor. Yet a further aim is to provide an easy and cost-efficient way to retrofit existing ebullated bed reactors so as to enhance their flexibility regarding usable feeds.

[0014] The appended claims define the scope of protection. Any examples and technical descriptions of products, processes, and / or uses in the description and / or drawings not covered by the claims are presented as examples useful for understanding the invention.

[0015] According to a first example aspect there is provided a hydroconversion process operated in one or more ebullated bed reactor(s), the process comprising: a) providing one or more top feed(s), a bottom feed, a hydrogen stream and a hydroconversion catalyst; b) subjecting a mixture of the one or more top feed(s), the bottom feed, and the hydrogen stream to hydroconversion in an ebullated catalyst bed arranged in an ebullated bed reactor and comprising the hydroconversion catalyst to provide a converted stream comprising gaseous compounds and liquid compounds; and c) removing a portion of the converted stream from the ebullated bed reactor as a conversion effluent, wherein in the process: the bottom feed and the hydrogen stream provided in step a) are fed to a plenum at the bottom of the ebullated bed reactor, the one or more top feed(s) provided in step a) is / are fed with a top feed injector into a recycle cup arranged above the ebullated catalyst bed and / or into a recycle downcomer connected to the recycle cup, wherein the top feed injector has at least one top feed delivery channel opening into the recycle cup and / or at least one top feed delivery channel opening into the recycle downcomer, and mixed therein into a portion of the liquid compounds of the converted stream to provide a mixed stream, a recycle pump connected to the recycle downcomer pumps the mixed stream into the plenum, and the content of the plenum is distributed to the ebullated catalyst bed.

[0016] The inventors have found the present hydroconversion process operated in ebullated bed reactor(s), the reactor configuration for an ebullated bed operation and the ebullated bed reactor system and embodiments thereof to provide certain advantages compared to prior art processes using ebullated bed technology and reactors used therein. The advantages are related e.g to improved flexibility regarding the feeds that can be utilised in the hydroconversion process and the reactor configuration, for example feeds that are not compatible with each other and / or with the material design of the reactor, as well as to enhanced process control, cost reduction, and improved heat management. These advantages are based on a finding that one or more reactor feeds may be fed via a top feed injector into the recycle cup and / or into the recycle downcomer through at least one top feed delivery channel of the top feed injector, into a turbulent flow of a portion of the liquid compounds separated from the converted stream (so-called recycle stream), wherein the injected top feed(s) get instantly mixed and diluted. In this way the corrosive impact the top feed may have on the reactor metallurgy is substantially reduced, minimising upgrade requirements involving significant cost savings, and making processing of challenging feeds, particularly feeds having high total acid number (high TAN feeds), more economically viable with reduced downtime. The injection of challenging feeds via a separate feed injector having at least one top feed delivery channel opening into the recycle cup and / or into the recycle downcomer allows for precise control over the introduction of the feed into the internal recycle stream of the reactor. This enables operators to adjust feed rates and optimise dilution ratios e.g. according to specific process requirements, including feed quality, ensuring consistent and reliable operation of the ebullated bed reactor. The ability to fine-tune the feed injection enhances overall process flexibility for a variety of feedstocks and facilitates efficient operation, further improving the performance and reliability, especially when feeding challenging, e.g. high TAN feeds. The direct injection and dilution of the challenging feed within the internal recycle stream ensures thorough mixing, which promotes effective heat dispersion throughout the reactor. This optimised mixing capability enables better handling of exothermic reactions, minimising the risk of hotspots and enhancing temperature control within the ebullated catalyst bed. By efficiently managing heat release, the present process and reactor configuration contribute to enhanced safety and stability of the processing operation, reducing the likelihood of undesirable side reactions (runaways, fouling) and improving overall process reliability, for example by limiting the local gradients (acidity, temperature, water concentration) and their effects to the catalyst.

[0017] Hence, in certain preferred embodiments, the top feed(s) and the bottom feed meet one or more of the following conditions: the top feed has a higher total acid number (TAN) compared to the bottom feed, the top feed has a higher viscosity compared to the bottom feed, the top feed is not miscible with the bottom feed, and / or the top feed forms precipitates if mixed or heated with the bottom feed.

[0018] In certain preferred embodiments, the top feed(s) comprise(s) non-hydroprocessed feed(s) and / or selectively hydrogenated feed(s), of renewable or circular origin; and / or at least one or more of plant oil(s), animal fat(s), microbial oil(s), plant oleoresin(s), crude tall oil soap, crude tall oil (CTO), acid refined tall oil, depitched tall oil, crude fatty acids fraction (CFA), tall oil fatty acids fraction (TOFA), tall oil rosin fraction (TOR), distilled tall oil fraction (DTO), tall oil pitch (TOP), nutshell liquid(s), palm oil mill effluent (POME) bottom(s), lignin-derived biocrude(s), (ligno)cellulose-derived biocrude(s), algae biocrude(s), used lubricant(s), liquefied waste polymers, and / or liquefied municipal solid waste. In certain embodiments, both the top feed(s) and the bottom feed are of renewable and / or circular origin. Alternatively, both the top feed(s) and the bottom feed comprise components of renewable and / or circular origin.

[0019] While the solution provided by the present disclosure is especially well suited for challenging renewable and / or circular feed(s) as the top feed(s), it is usable and may be beneficial also for fossil feed(s) as top feed(s), especially fossil feed(s) of challenging nature. Hence, in certain embodiments, both the top feed(s) and the bottom feed are of fossil origin or comprise components of fossil origin.

[0020] According to a second example aspect there is provided a reactor configuration comprising: a reactor enclosure (1 ) encompassing a plenum (300) at the bottom of the reactor enclosure, a reaction space (100) arranged above the plenum, distribution means (2) arranged between the plenum and the reaction space, and a recycle cup (3) above the reaction space, wherein the recycle cup is connected to a recycle downcomer (4) providing a fluid communication between the recycle cup (3) and the plenum (300), a bottom feed inlet (10) opening into the plenum (300), a reaction product outlet (8) arranged at the top of the reactor enclosure, and a recycle pump (5) connected to the recycle downcomer (4) and configured to cause a flow from the recycle cup (3) to the plenum (300), wherein the reactor configuration is configured for ebullated bed operation, and characterised by: a top feed injector (9) arranged at the top of the reactor enclosure and having at least one top feed delivery channel opening into the recycle cup (9b) and / or at least one top feed delivery channel opening into the recycle downcomer (9a).

[0021] Further advantages of the reactor configuration relate to the possibility to retrofit existing ebullated bed reactors in an easy and cost-efficient way, to enhance their flexibility regarding usable feeds.

[0022] Hence, in certain preferred embodiments the reactor enclosure (1 ) has an opening at the top of the reactor enclosure originally configured to accommodate an instrument, particularly a pressure gauge or a thermometer, and retrofitted to accommodate the top feed injector (9). According to a third example aspect there is provided an ebullated bed reactor system comprising two or more reactor configuration(s) according to the second example aspect arranged in series, wherein the second and / or a further reactor configuration is configured to receive as a bottom feed at least a portion of the conversion effluent of the preceding reactor configuration; and preferably an interstage separation unit is arranged between any two reactor configurations and configured to remove a volatiles fraction from the conversion effluent of the preceding reactor configuration and to recover the non-volatiles fraction as the bottom feed for the subsequent reactor configuration.

[0023] According to a fourth example aspect use of the reactor configuration according to the second example aspect or the ebullated bed reactor system according to the third example aspect is provided for hydroconverting a top feed and a bottom feed in an ebullated catalyst bed comprising a hydroconversion catalyst, preferably in the hydroconversion process according to the first example aspect.

[0024] Different non-binding example aspects and embodiments have been illustrated in the foregoing. The embodiments in the foregoing are used merely to explain selected aspects or steps that may be utilised in different implementations. Some embodiments may be presented only with reference to certain example aspects. It should be appreciated that corresponding embodiments may apply to other example aspects as well.

[0025] BRIEF DESCRIPTION OF THE FIGURES

[0026] To further clarify the above and other advantages and features of the present hydroconversion process, the reactor configuration as well as the ebullated bed reactor system, a more particular description thereof will be rendered by reference to example embodiments of the reactor configuration and the top feed injector which are illustrated in the appended drawings. It is appreciated that these drawings may depict only typical embodiments and are therefore not considered limiting of their scope. The hydroconversion process, the reactor configuration as well as the ebullated bed reactor system will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0027] Figure 1 schematically illustrates an exemplary reactor configuration for ebullated bed operation comprising a top feed injector arranged at the reactor top;

[0028] Figure 2a schematically illustrates an exemplary top feed injector arranged at the reactor top and having a top feed delivery channel opening into a recycle downcomer; Figure 2b schematically illustrates an exemplary top feed injector arranged at the reactor top and having a top feed delivery channel opening into a recycle cup;

[0029] Figure 2c schematically illustrates an exemplary top feed injector arranged at the reactor top and having two top feed delivery channels, one opening into a recycle cup and one opening into a recycle downcomer. In this exemplary top feed injector the top feed delivery channel opening into the recycle downcomer is arranged concentrically inside the top feed delivery channel opening into the recycle cup.

[0030] DETAILED DESCRIPTION

[0031] In the present disclosure, like reference signs denote like elements or steps. All standards referred to herein are the latest revisions available at the filing date, unless otherwise mentioned.

[0032] As used herein, hydrocarbons refer to compounds consisting of carbon and hydrogen, including paraffins, n-paraffins, i-paraffins, olefins, naphthenes, and aromatics. Heteroatomcontaining hydrocarbons, such as oxygenated hydrocarbons, refer herein to hydrocarbons comprising covalently bound heteroatom such as oxygen.

[0033] As used herein, paraffins refer to non-cyclic alkanes, i.e. non-cyclic, open chain saturated hydrocarbons that are linear (normal paraffins, n-paraffins) or branched (isoparaffins, i- paraffins). In other words, paraffins refer herein to n-paraffins and / or i-paraffins.

[0034] In the context of the present disclosure, olefins refer to unsaturated, linear, branched, or cyclic hydrocarbons, excluding aromatic compounds. In other words, olefins refer to hydrocarbons having at least one unsaturated bond, excluding unsaturated bonds in aromatic rings.

[0035] As used herein, cyclic hydrocarbons refer to all hydrocarbons containing cyclic structure(s), including cyclic olefins, naphthenes, and aromatics. Naphthenes refer herein to cycloalkanes i.e. saturated hydrocarbons containing at least one cyclic structure, with or without side chains. As naphthenes are saturated compounds, they are compounds without aromatic ring structure(s) present. Aromatics refer herein to hydrocarbons containing at least one aromatic ring structure, i.e. cyclic structure having delocalized, alternating TT bonds all the way around said cyclic structure. Chemically, the renewable (i.e. biological) or non-renewable (such as fossil) origin of carbon-containing compounds, including hydrocarbons, can be determined by suitable method for analysing the content of carbon from renewable sources e.g. DIN 51637:2014- 02, ASTM D6866-2022, or EN 16640:2017. Said methods are based on the fact that carbon atoms of renewable or biological origin comprise a higher number of unstable radiocarbon (14C) atoms compared to carbon atoms of fossil origin. Therefore, it is possible to distinguish between carbon compounds derived from renewable or biological sources and carbon compounds derived from non-renewable (such as petroleum) sources by analysing the ratio of 12C and 14C isotopes. Thus, a particular ratio of said isotopes can be used as a “tag” to identify a renewable carbon compound and differentiate it from non-renewable carbon compounds. The isotope ratio does not change in the course of chemical reactions. Therefore, the isotope ratio can be used for identifying renewable carbon compounds and distinguishing them from non-renewable carbon compounds in feeds, co-feeds, fractions, or compositions, or various blends thereof. Numerically, the biogenic carbon content can be expressed as the amount of biogenic carbon in the material as a weight percent of the total carbon (TC) in the material (in accordance with ASTM D6866-2022 or EN 16640:2017).

[0036] As used herein, the term circular in connection with materials such as feeds, products or compositions refers to materials based on reused and / or recycled carbon from any source available. Typical exemplary sources for reused and / or recycled non-biogenic carbon, possibly also containing at least some biogenic carbon, include reclaimed organic commodities, especially waste plastics, end of life tires, used lubricants, and / or municipal solid waste.

[0037] As used herein, the term fossil refers to materials such as feeds, products or compositions that are obtainable, derivable, or originating from naturally occurring non-renewable compositions, such as crude oil, petroleum oil / gas, shale oil / gas, natural gas, or coal deposits, and the like, and combinations thereof, including any hydrocarbon-rich deposits that can be utilized from ground / underground sources.

[0038] Renewable, circular, and fossil materials, feeds, products, or compositions are considered differing from one another based on their origin and impact on environmental issues. Therefore, they may be treated differently under legislation and regulatory framework. Typically, renewable, circular, and fossil materials etc. are differentiated based on their origin and information thereof provided by the producer. By hydroconversion in the presence of a hydroconversion catalyst is meant herein a process of treating organic material by means of molecular hydrogen at an elevated temperature and pressure. The reactions occurring in the hydroconversion may include thermal and catalytic reactions, such as thermal cracking, catalytic cracking, ring-opening, heteroatom cleavage, metal removal, etc, the catalytic reactions including particularly hydrotreatment and / or hydrocracking reactions. The hydrotreatment reactions may include removal of oxygen from oxygenated hydrocarbons as water i.e. hydrodeoxygenation (HDO), sulphur from organic sulphur compounds as dihydrogen sulphide (H2S), i.e. hydrodesulphurisation (HDS), nitrogen from organic nitrogen compounds as ammonia (NH3), i.e. hydrodenitrogenation (HDN), halogens, for example chlorine from organic chloride compounds as hydrochloric acid (HCI), i.e. hydrodechlorination (HDCI), and / or metals by hydrodemetallization; and / or hydrogenation of olefinic bonds to saturated bonds and / or of aromatics to naphthenes. Depending e.g. on the composition of the feed to the hydroconversion, different thermal and catalytic reactions may occur and / or prevail. Generally, the hydroconversion is capable of converting feeds of varying compositions to lower-boiling compounds e.g. by cracking, and to more pure materials, e.g. by reducing content of heteroatoms, metals, olefins, aromatics, or the like.

[0039] In the present disclosure, the term “effluent" as in “conversion effluent” refers to the effluent from the ebullated bed reactor or reactor configuration comprising gaseous and liquid hydroconversion products, excluding the ebullated bed catalyst withdrawn from the reactor as part of the catalyst renewing / withdrawal cycle.

[0040] In the present disclosure, the term challenging feeds is used when referring to renewable and / or circular feeds that are generally regarded challenging in catalytic processing in view of one or more aspect, particularly regarding presence and / or content of complex cyclic heteroatom-containing hydrocarbons, high total acid number (TAN), high content of high molecular weight compounds, high content of coke-forming compounds, high metals content, and / or high level of other impurities.

[0041] In the present disclosure, expressions “connected", “fluid communication”, and similar, are not limited to direct connection or communication between two or more elements but may encompass both indirect and direct linkages. Similarly, the two or more elements being connected or in communication do not need to be physically separate structures.

[0042] The present disclosure provides a hydroconversion process operated in one or more ebullated bed reactor(s), the process comprising: a) providing one or more top feed(s), a bottom feed, a hydrogen stream and a hydroconversion catalyst; b) subjecting a mixture of the one or more top feed(s), the bottom feed, and the hydrogen stream to hydroconversion in an ebullated catalyst bed arranged in an ebullated bed reactor and comprising the hydroconversion catalyst to provide a converted stream comprising gaseous compounds and liquid compounds; and c) removing a portion of the converted stream from the ebullated bed reactor as a conversion effluent, wherein in the process: the bottom feed and the hydrogen stream provided in step a) are fed to a plenum at the bottom of the ebullated bed reactor, the one or more top feed(s) provided in step a) is / are fed with a top feed injector into a recycle cup arranged above the ebullated catalyst bed and / or into a recycle downcomer connected to the recycle cup, wherein the top feed injector has at least one top feed delivery channel opening into the recycle cup and / or at least one top feed delivery channel opening into the recycle downcomer, and mixed therein into a portion of the liquid compounds of the converted stream to provide a mixed stream, a recycle pump connected to the recycle downcomer pumps the mixed stream into the plenum, and the content of the plenum is distributed to the ebullated catalyst bed.

[0043] Some of the benefits provided by the present hydroconversion process and reactor configuration were discussed in the Summary. In brief, the top feed injector arranged at the reactor top allows instant mixing and dilution of the injected top feed, bringing the benefits of lower reactor material costs, and minimised material upgrading requirements and downtime e.g. when retrofitting existing reactors, which involves significant cost savings. Use of the reactor configuration provides cost savings via the possibility to use feeds of lower quality and / or feeds without pretreatment, and via better control over the introduction of the feed, allowing consistent and reliable operation. Also enhanced heat dispersion throughout the reactor is attained, minimising the risk of hotspots within the ebullated catalyst bed and contributing to enhanced safety and stability of the processing operation as well as overall process reliability, reduced risk of runaways and fouling, and negative effects on the catalyst. One of the main benefits of the present hydroconversion process and reactor configuration is the possibility to utilise top feeds that are challenging in one way or another, for example because of incompatibility with the bottom feed and / or corrosiveness to materials typically used in the reactors.

[0044] Hence, in certain embodiments, the top feed(s) and the bottom feed meet one or more of the following conditions: the top feed has a higher total acid number (TAN) compared to the bottom feed, the top feed has a higher viscosity compared to the bottom feed, the top feed is not miscible with the bottom feed, and / or the top feed forms precipitates if mixed or heated with the bottom feed. In this context, the precipitate formation is not particularly limited but may encompass formation of e.g. solid or colloidal reaction and / or decomposition products that are suspended or deposited on surfaces, including fouling.

[0045] In certain embodiments, the top feed(s) comprise(s) non-hydroprocessed feed(s) and / or selectively hydrogenated feed(s), of renewable or circular origin. In the context of the present disclosure, “non-hydroprocessed” refers to feeds that have not been exposed to more than 1 bar (abs) of hydrogen in the presence of a catalyst comprising metal(s) of Group VIII of the Periodic Table, metal(s) of Group VIB of the Periodic Table and / or zeolites or zeolite-type materials. Similarly, “selectively hydrogenated” refers to feeds subjected to selective catalytic hydrogenation of certain heteroatoms, such as phosphorous, leaving e.g. significant content of other heteroatoms in the feed, or to selective catalytic hydrogenation of diolefins and optionally higher olefins leaving e.g. significant monoolefins content in the feed, just to name a few examples. Such selective hydrogenation methods are well known in the art. Selective hydrogenation of diolefins may for example be conducted as disclosed in WO2022144490. Such non-hydroprocessed and / or selectively hydrogenated feeds encompass feeds that may be essentially in their native form or as extracted from natural materials, and feeds that may have undergone even severe processing, such as pyrolysis or cracking, causing reduction in molecular weight but still leaving significant heteroatom content and / or elevated olefinicity in the feed.

[0046] In certain further embodiments, the top feed(s) may comprise partially hydroprocessed feed materials having residual content of heteroatoms and / or olefins to be reduced in the hydroconversion of the present process, and / or even fully hydroprocessed feed materials, for example when the hydroconversion catalyst(s) and conditions of the hydroconversion of the present process are optimised for hydrocracking rather than for hydrotreatment. In certain particular embodiments, the top feed(s) comprise(s) at least one or more of plant oil(s), animal fat(s), microbial oil(s), plant oleoresin(s), crude tall oil soap, crude tall oil (CTO), acid refined tall oil, depitched tall oil, crude fatty acids fraction (CFA), tall oil fatty acids fraction (TOFA), tall oil rosin fraction (TOR), distilled tall oil fraction (DTO), tall oil pitch (TOP), nutshell liquid(s), palm oil mill effluent (POME) bottom(s), lignin-derived biocrude(s), (ligno)cellulose-derived biocrude(s), algae biocrude(s), used lubricant(s), liquefied waste polymers, and / or liquefied municipal solid waste. These embodiments are beneficial for reducing GHG emissions and / or carbon footprint of the hydroconversion products, and typically contain or may even consist of biogenic materials.

[0047] In the context of the present disclosure, plant oil(s), animal fat(s), and / or microbial oil(s) refer to fatty materials typically of glyceridic origin. In certain preferred embodiments, plant oil(s) include rapeseed oil, canola oil, soybean oil, coconut oil, sunflower oil, macauba oil, palm oil, palm kernel oil, peanut oil, linseed oil, sesame oil, maize oil, poppy seed oil, cottonseed oil, soy oil, corn oil, castor oil, jatropha oil, pongamia oil, jojoba oil, olive oil, flaxseed oil, camelina oil, safflower oil, babassu oil, seed oil of any of Brassica species or subspecies, such as Brassica carinata seed oil, Brassica juncea seed oil, Brassica oleracea seed oil, Brassica nigra seed oil, Brassica napus seed oil, Brassica campestris oil, Brassica hirta seed oil and / or Brassica alba seed oil, rice bran oil, palm olein, palm stearin, palm fatty acid distillate (PFAD), and / or used cooking oils of vegetable origin; animal fat(s) include tallow, lard, yellow grease, brown grease, fish fat, poultry fat, and / or used cooking oil of animal origin; and microbial oil(s) include algal lipids, fungal lipids, and / or bacterial lipids.

[0048] In the context of the present disclosure, tall oil(s) refer to well-known tall oil materials including for example crude tall oil soaps (e.g. materials identified by CAS number 65997- 01-5); crude tall oils (CTO), typically derived from acidulation of crude tall oil soap (e.g. materials identified by CAS number 8002-26-4); and / or acid refined tall oil, typically obtained by treating CTO in solvent solution with sulfuric acid to remove dark colour bodies and odoriferous materials. Tall oil distillate(s) refer herein to vaporizable fractions of tall oil, particularly obtained by distillation of crude tall oil, including e.g. depitched tall oil, crude fatty acids fraction (CFA) comprising tall oil fatty acids with significant content of residual resin acids and unsaponifiables; tall oil fatty acids fraction (TOFA) having limited content of residual resin acids and unsaponifiables (e.g. materials identified by CAS number 61790- 12-3); tall oil rosin fraction (TOR) mainly containing resin acids with reduced content of tall oil fatty acids, typically at most 5 wt.-% (e.g. materials identified by CAS number 8052-10- 6); distilled tall oil fraction (DTO) covering class of crude tall oil distillates typically containing less than 90 wt.-% of tall oil fatty acids and having lower content of lightest fatty acids compared to CTO; and / or tall oil heads. Tall oil distillation residue(s) on the other hand refer herein to a residue from distillation of crude tall oils (e.g. materials identified by CAS number 8016-81-7), often referred to as tall oil pitch (TOP). Typical plant oleoresins include for example gum turpentine and crude sulfate turpentine (CST). Nutshell liquid(s) refer herein to liquid extracts from nut by-products, typically rich in unsaturated natural phenolic compounds, including e.g. cashew nutshell liquid(s) (CNSL; e.g. as identified by CAS number 8007-24-7), and / or to main components thereof such as anacardic acid, cardanol, cardol, and / or 2-methylcardoL Palm oil mill effluent (POME) bottom(s) refer herein to distillation residue of a crude or purified POME, which is a high solids, oily waste water stream of palm oil mills, the residue typically having a cut point of max. 260 °C. As used herein biocrude(s) refer to complex mixtures. For example typical lignin-derived biocrude(s) include e.g. biocrude(s) containing lignin mixed with solvent(s) and / or carrier oil(s), wherein the lignin may be in a partially depolymerised and / or derivatised form, and include e.g. Kraft lignin, lignosulfonates, organosolv lignin, and / or acetosolv lignin. Lignin-derived biocrudes are typically rich in heteroatom-containing cyclic (esp. aromatic) hydrocarbons. Exemplary materials include e.g. those disclosed in US4420644 (preferably modified by slurrying the lignin, such as Kraft lignin, with a fossil feed and / or the other renewable feeds), or those disclosed in WO16204682 where the lignin (e.g. Kraft or organosolv lignin) is mixed with a solvent and / or a carrier liquid such as a hydrocarbon oil and / or fatty acid esters. Typical (ligno)cellulose-derived biocrude(s) include herein e.g. biocrude(s) containing partially depolymerised and deoxygenated lignocellulose and / or cellulose, such as biocrude(s) obtained by subjecting (ligno)cellulose to any of the liquefactions reviewed by Lange, J.-P. in ChemSusChem, 11 (2018), pp. 997-1014, for example to thermal liquefaction in refinery stream(s) e.g. in vacuum gas oil or light cycle oil, or in biocrude(s), to thermal liquefaction in heavy hydrocarbon oil, to hydrothermal liquefaction, to low-temperature acidic liquefaction, and / or to hydroliquefaction, and biocrude(s) obtained by subjecting (ligno)cellulose to pyrolysis e.g. to catalytic or non-catalytic fast pyrolysis as studied by lisa et al in Fuel, 207 (2017), pp. 413-422. Typical algae biocrude(s) include e.g. hydrothermally liquefied (HTL) algae biomass, distillation residue of extracted algae oils, and the like. The composition of algae biocrude depends on the utilized algae species and oil production process. Algae biocrude(s) may have a significant content of fatty acids that may be present as free, bound in glycerides and / or in complex lipids such as phospho- and glycolipids. Algae biocrude(s) may also contain lipid oligomers, unsaponifiables, such as sterols and waxes, and / or pigments such as chlorophylls and carotenoids. Used lubricants may comprise oils collected from vehicle engines, industrial gearboxes, pumps, compressors, hydraulic unit, etc. The liquefied waste polymers may comprise thermally such as hydrothermally or by pyrolysis, or catalytically such as thermo-catalytically liquefied waste polymers, wherein the waste polymers may comprise waste plastics and / or end of life tires (ELT). The liquefied municipal solid waste (MSW) may comprise thermally such as hydrothermally or by pyrolysis, or catalytically such as thermo-catalytically liquefied MSW. Due to the mixed waste nature, these materials may have both non-biogenic and biogenic carbon content. For example used lubricants may vary from essentially fully fossil to essentially fully biogenic. The biogenic carbon content of MSW may also vary greatly, but is typically significant, such as from 40 to 70 wt.-%, based on the total weight of carbon (TC) in the MSW, due to biomass-waste present in MSW. Also the biogenic carbon content of ELT may vary, but is typically significant, such as from 15 to 40 wt.-%, based on the total weight of carbon (TC) in the ELT, due to e.g. natural rubber present in ELT. Also the biogenic carbon content of liquefied waste plastics may vary, but is currently foreseen much lower than the share of non-biogenic carbon content, due to the low share of bio-based plastics in the waste plastics, however this may change over time when the production of bio-based plastics increases.

[0049] One of the further advantages of the present process and reactor configuration is enhanced flexibility regarding the product slate adjustment, since the top feed injector allows e.g. to increase yields and paraffins and / or naphthenes content of certain fractions, particularly of middle distillates and sometimes also of naphtha fraction, and to reduce the bottom fraction yield, by selecting and varying the top feeds suitably.

[0050] Generally, plant oil(s), animal fat(s) and microbial oil(s) exhibit similarities e.g. in terms of fatty acid composition and oxygen content, and in that upon hydrotreatment they tend to form mainly paraffins, typically in the middle distillates boiling range, and sometimes also in naphtha range e.g. due to cracking reactions. In multi-reactor embodiments these top feeds are preferably fed to the second or subsequent reactor(s). The other embodied top feeds listed above may have more variance regarding hydrocarbon types formed upon hydrotreatment and their boiling range, but similarities in terms of having properties known to be difficult especially in catalytic processing, namely high content of cyclic heteroatomcontaining hydrocarbons, high content of high molecular weight compounds, high content of coke-forming compounds, high total acid number (TAN), high metals content, high level of other impurities, and / or high total load of two or more of these species. In some of these, e.g. in tall oil based materials, cyclic components may be more abundant, and anticipated to form naphthenes typically in middle distillates range. In multi-reactor embodiments these top feeds are preferably fed to the first reactor(s).

[0051] In certain embodiments, the top feed(s) is / are of fossil origin, or comprise components of fossil origin. Any fossil feeds in the need of the hydroconversion may be utilised as the top feed. However, the present solution is particularly beneficial for fossil feed(s) of challenging nature. Examples of such challenging top feed(s) or components of fossil origin include fossil feed(s) having high TAN, e.g. high TAN heavy vacuum gas oils or high TAN vacuum residues. Such high TAN fossil feeds may be obtained for example from high acid or high TAN crude oils, such as Boscan crude from Venezuela or Captain crude from the North Sea.

[0052] High total acid number (TAN) of the feed may be particularly demanding regarding material selection of the feed inlet and reactor in the proximity of the feed injection. However, by feeding the top feed with the top feed injector through at least one top feed delivery channel into the recycle cup and / or into the recycle downcomer connected to the recycle cup, the top feed(s) get mixed into and diluted with a portion of the liquid compounds separated from the converted stream, so-called recycle stream, accommodated by the recycle cup and the recycle downcomer. The flow of the converted stream and of the gaseous and liquid compounds separated therefrom in a gas-liquid separation zone is highly turbulent, particularly the recycle stream flow in the recycle cup and the upper part of the recycle downcomer. This ensures instant dilution and mixing of the top feed(s), so that top feed(s) of high TAN (typically more than 1 .5 mg KOH / g) may be utilised, even in existing ebullated bed reactors designed for fossil feeds, when retrofitted with the top injector feed. Hence, in certain particular embodiments, the top feed(s) have a total acid number (TAN) of at least 3 mg KOH / g, preferably at least 5 mg KOH / g, more preferably at least 10 mg KOH / g, even more preferably at least 20 mg KOH / g, further preferably at least 40 mg KOH / g or at least 50 mg KOH / g. Typically the top feed(s) provided in step a) have a total acid number (TAN) at most 250 mg KOH / g, such as at most 210 mg KOH / g, or at most 180 mg KOH / g. In certain further particular embodiments, the top feed(s) have a total acid number (TAN) within a range from more than 1 .5 mg KOH / g to at most 250 mg KOH / g, preferably from 3 mg KOH / g to at most 210 mg KOH / g, more preferably from 5 mg KOH / g to at most 180 mg KOH / g. The total acid number (TAN) values given in the present disclosure are as determined by ISO 660-2020 for fatty feeds or as determined by ISO 6619-1988 for hydrocarbon feeds. For use in the present process, pretreatment of the embodied top feed(s) such as e.g. esterification of free acids is not needed, nor extensive purifications to minimise impurities. Nevertheless, if the embodied top feed(s) would contain particularly high amounts of or difficult impurity species that are not foreseen to be tolerated or preferred in the hydroconversion or that may slip through downstream to the detriment of the recovered distillate(s) and / or bottom fraction in view of their intended uses, the content of said impurities may be reduced to acceptable limits using pretreatment methods known in the art. Exemplary pretreatment methods include treating with mineral acids, degumming, treating with hydrogen, heat treating, deodorizing, washing with water, treating with base, demetallation, distillation, removal of solids, bleaching, and / or any combinations thereof. For the same reasons, also the bottom feeds, e.g. as embodied in the following, may be pretreated, for example heavy crude oil feeds solvent deasphalted. In the context of the present process, the top feed(s) and the bottom feed provided in step a) encompass said feeds as is or in their pretreated forms, as the case may be.

[0053] In certain embodiments, the bottom feed comprises at least one or more of hydroconverted hydrocarbon feed(s), fossil crude oil distillate(s), fossil crude oil distillation residue(s), distillate(s) of cracked fossil feed(s), and / or distillation residue(s) of cracked fossil feed(s). The hydroconverted hydrocarbon feeds may include for example at least a portion of a conversion effluent from a hydroconversion unit arranged upstream of the hydroconversion of step b), such as from a conventional ebullated bed reactor or similar as used in step b), and / or a recycled portion of the conversion effluent of step b), wherein the recycled portion of the conversion effluent of step b) is preferably a portion of the non-volatiles fraction recovered from the conversion effluent of step b), obtained e.g. as discussed in the following in connection with an interstage separation unit. Exemplary fossil crude oil distillate(s) include atmospheric distillate(s) and / or vacuum distillate(s) of fossil crude oil, and exemplary fossil crude oil distillation residue(s) include atmospheric distillation bottom(s) and / or vacuum distillation bottom(s) of fossil crude oil. Exemplary distillate(s) of cracked fossil feed(s) include atmospheric and / or vacuum distillate(s) of cracked fossil feed(s) such as of thermally and / or catalytically cracked vacuum distillate(s), atmospheric distillation residue(s) and / or vacuum distillation residue(s) of fossil crude oil, and exemplary distillation residue(s) of cracked fossil feed(s) include atmospheric and / or vacuum distillation residue(s) of cracked fossil feed(s) such as of thermally and / or catalytically cracked vacuum distillate(s), atmospheric distillation residue(s) and / or vacuum distillation residue(s) of fossil crude oil. Further top feed injection point(s) may be arranged into the internal recycle further downstream before the pump, to the pump, and / or even after the pump but before the mixed stream enters the plenum. Depending on the specific reactor configuration, some of these parts may be accessible for top feed injection, accommodate sufficiently turbulent flow to allow quick enough mixing and dilution of the top feed, and can be made of materials having adequate corrosion resistance.

[0054] The weight ratio of the total top feed(s) to the bottom feed fed to the ebullated bed reactor may be varied within broad ranges, and adjusted flexibly e.g. depending on the top feed quality. In certain typical embodiments the top feed(s) and the bottom feed are fed to the ebullated bed reactor in a weight ratio of the total top feed(s) to the bottom feed within a range from 5:95 to 95:5, preferably from 10:90 to 80:20.

[0055] The hydroconversion is conducted in the presence of added molecular hydrogen, for example co-feeding a hydrogen stream comprising e.g. recycle hydrogen recovered from the same ebullated bed reactor and / or from other hydroconversion units at the site, and / or make-up hydrogen. The hydrogen stream may be introduced into the ebullated bed reactor via its own inlet into the plenum, or via the bottom feed inlet, preferably as mixed with the bottom feed. Part of the hydrogen stream may also be introduced as mixed or carried over with the top feed(s).

[0056] In certain embodiments, the process comprises in step b) two or more ebullated bed reactor(s) arranged in series, and the bottom feed fed to the second and / or to a further ebullated bed reactor comprises at least a portion of the conversion effluent of the preceding ebullated bed reactor, and preferably the top feed(s) fed to the first, to the second and / or to a further ebullated bed reactor are selected independently from each other from the top feeds specified in the foregoing. These multi-reactor embodiments provide the benefit that even when using a fossil bottom feed in the first ebullated bed reactor, by selecting a biogenic and / or circular top feed for each subsequent ebullated bed reactor it is possible to gradually increase the biogenic and / or circular carbon content in the reactor series so that the conversion effluent of the last reactor may even consist essentially of biogenic and / or circular hydrocarbons. Further, by sharing the impurity-removal load between the ebullated bed reactors arranged in series, distillate(s) and a bottom fraction of higher purity and quality may be obtained due to the reduced slip-through risk of impurities. Additionally these embodiments allow feeding top feeds and / or bottom feeds of different qualities into different reactors, e.g. feeding top feeds and / or bottom feeds having highest content of heavy molecules and / or impurities into the first reactor and less heavy and / or less impure to the subsequent reactors.

[0057] The operating conditions, feed rates, catalyst renewal rates, catalysts, and the like, may be similar to those used in conventional ebullated bed operation, see e.g. Handbook of Petroleum Refining, CRC Press 2017, edited by James G. Speight, Chapter 11.4.8 H-Oil Process and 11.4.13 LC-Fining Process p. 492-495 and 499-501 , preferably as adapted to the used feeds and targeted conversion products. For example feeds having higher carbon number and / or more complex molecules may benefit from operating at higher temperature and / or higher pressure, especially when targeting middle distillate range products.

[0058] For example, in certain embodiments, the ebullated bed reactor(s) is / are operated at a temperature (as determined at the reactor inlet) within a range from 270 °C to 500 °C, preferably from 300 °C to 450 °C. Within these temperature ranges thermal cracking may be abundant, and catalytic heteroatom removal and hydrogenation of any present or formed olefins enhanced. In certain embodiments, the ebullated bed reactor(s) is / are operated at a pressure (as determined at the reactor outlet) within a range from 3 MPa to 50 MPa, preferably from 8 MPa to 20 MPa. Within the specified elevated pressure ranges, sufficient hydrogen partial pressure may be ensured and residual olefins and heteroatoms minimised in the hydroconversion products despite the significant hydrogen consumption, and the H2 partial pressure reducing effect caused by the formed gaseous conversion products towards the end of the reactor. In certain embodiments, the ebullated bed reactor(s) is / are operated using a space velocity within a range from 0.05 to 5, preferably from 0.2 to 1 m3 feed entering the reactor per m3 reactor volume per hour, and / or a ratio of H2 to the total fresh feed (top and bottom feed) entering the reactor within a range from 50 to 2000, preferably from 100 to 1500 normal liters H2 per liter feed. The rate of replacement of used catalyst by fresh catalyst can be, for example, about 0.05 kg to about 10 kg per m3 of feed. Preferably, the catalyst loading and fresh catalyst addition rate in the ebullated catalyst bed shall be selected so that the catalyst activity is maintained essentially constant.

[0059] The present process may utilise any conventional hydroconversion catalyst aimed for ebullated bed operation. In certain preferred embodiments, the hydroconversion catalyst includes one or more hydrotreatment catalysts and / or one or more hydrocracking catalysts. In certain embodiments the hydroconversion catalyst(s) is / are selected from sulfided hydroconversion catalysts comprising at least one or more metals from Group VIII of the Periodic Table and / or from Group VI B of the Periodic Table, preferably at least one or more of Ni, Mo, W, and / or Co, even more preferably at least one or more of Ni and / or Co and Mo and / or W, such as NiMo, CoMo, NiCoMo, NiW, and / or NiMoW, preferably on a support such as alumina, silica, amorphous silica-alumina, zeolites and / or zeolite-type materials. These kinds of solid heterogeneous hydroconversion catalysts are commercially available for use in ebullated bed systems, including catalysts designed primarily for certain hydrotreatment reactions such as hydrodemetallization, and / or even for hydrocracking. In addition to these hydroconversion catalyst(s), also co-catalysts may be utilised to achieve additional reactions and / or to boost any of the hydrotreatment and / or hydrocracking reactions, as known in the art. The solid heterogeneous hydroconversion catalyst typically comprises a support structure having a large surface area and interconnected channels or pores and the active metal(s), such as sulfides of cobalt, nickel, tungsten, and / or molybdenum, e.g. dispersed within the channels or pores. The pores of the support may be of limited size to maintain mechanical integrity of the heterogeneous catalyst and prevent breakdown and formation of excessive fines in the reactor. Heterogeneous catalysts usable in the present process may have a shape of cylindrical pellets, cylindrical extrudates, trilobes, rings, saddles, spherical solids, or the like. Also dispersed metal sulfide catalysts e.g. as disclosed in LIS20210371762 may be used in the present process. These catalysts have typically a submicron particle size (below 1 pm), such as less than about 500 nm, or even less than about 50 nm, and may also include molecular or molecularly-dispersed catalyst compounds. These catalysts or their precursors may be dispersed in the bottom feed. The catalyst precursors form dispersed catalysts in situ e.g. by decomposition upon heating. The present process and reactor configuration are advantageous for using dispersed catalysts as there are more options regarding which feed to incorporate in, and it is even possible to introduce different dispersed catalysts or their precursors into different feeds.

[0060] Hence, in certain embodiments, the process further comprises dispersing a co-catalyst and / or a co-catalyst precursor into the bottom feed before subjecting to the hydroconversion in step b).

[0061] In certain embodiments, the process further comprises d) recovering from the conversion effluent at least one or more distillate(s) and a bottom fraction. This can be done using any conventional separation and / or fractionation technology. For example, at least part of the gaseous compounds in the conversion effluent may first be separated in a gas-liquid separator, and the liquid effluent may be fractionated e.g. using one or more distillation columns and / or evaporators operated under atmospheric pressure and / or vacuum. The recovered distillates may include e.g. a naphtha fraction, an aviation fuel range fraction, a gas oil fraction, and / or a vacuum gas oil fraction. The recovered bottom fraction is what remains after recovering the distillate(s). In certain embodiments, the process further comprises subjecting at least a portion of the conversion effluent, such as one or more of the distillate(s) or the bottom fraction, to one or more further conversion(s), preferably to one or more further catalytic conversion(s), more preferably to one or more further catalytic hydroconversion(s) and / or catalytic hydroprocessing(s). These embodiments may include for example subjecting at least a portion of the conversion effluent to a catalytic hydroconversion in an ebullated bed reactor not having the top feed injector. In certain embodiments, at least a portion of the one or more distillate(s) recovered in step d) is subjected to one or more catalytic hydroprocessing(s) in fixed bed reactor(s), wherein the catalytic hydroprocessing(s) include at least one or more of hydrotreatment, hydrocracking, hydroisomerisation, and / or hydrodearomatisation. The hydroconversion according to the present disclosure provides effective heteroatom removal, metals removal, hydrogenation of unsaturations and cracking of heavier molecules, so that the recovered distillate(s) are suitable for catalytic hydroprocessing in fixed bed reactors even when using heavy and / or highly impure top and / or bottom feed(s). Hence, an easier downstream catalytic upgrading is anticipated e.g. in terms of less severe process conditions, slower catalyst deactivation, reduced coking and plugging. Hydroprocessing, such as hydrotreatment, hydrocracking, hydroisomerisation, and / or hydrodearomatisation, is especially advantageous as the further conversion, as high quality aviation fuel components, diesel components, steam cracking feeds and / or solvents are attainable with good cold properties and / or low aromatics contents.

[0062] The present disclosure also provides a reactor configuration comprising: a reactor enclosure (1 ) encompassing a plenum (300) at the bottom of the reactor enclosure, a reaction space (100) arranged above the plenum, distribution means (2) arranged between the plenum and the reaction space, and a recycle cup (3) above the reaction space, wherein the recycle cup is connected to a recycle downcomer (4) providing a fluid communication between the recycle cup (3) and the plenum (300), a bottom feed inlet (10) opening into the plenum (300), a reaction product outlet (8) arranged at the top of the reactor enclosure, and a recycle pump (5) connected to the recycle downcomer (4) and configured to cause a flow from the recycle cup (3) to the plenum (300), wherein the reactor configuration is configured for ebullated bed operation, and characterised by: a top feed injector (9) arranged at the top of the reactor enclosure and having at least one top feed delivery channel opening into the recycle cup (9b) and / or at least one top feed delivery channel opening into the recycle downcomer (9a).

[0063] The recycle cup and the recycle downcomer accommodate a turbulent flow of a so-called recycle stream comprising liquid compounds separated in a gas-liquid separation zone from the converted stream, wherein the injected top feed gets instantly mixed and diluted. This may be further enhanced by fine-tuning the shape and / or positioning of the top feed delivery channel(s). The top feed delivery channel may have more than one opening into the recycle cup and / or the recycle downcomer, for example with perforations along the channel head, or two or more top feed delivery channels could be arranged, so as to better spread and / or direct the top feed injection. The quick mixing and dilution in the recycle cup and / or in the recycle downcomer helps to ensure that even when feeding challenging top feed(s) such as high TAN feeds to an existing refinery unit designed for typical fossil feeds, major corrosion issues may be avoided as the reactor shell is protected from exposure to the corrosive top feed.

[0064] The recycle pump connected to the recycle downcomer in the reactor configuration allows the hydroconversion catalyst to be maintained in the reaction space under ebullated bed conditions by continuously recycling a portion of the liquid compounds separated from the converted stream. The recycle pump allows a sufficient recycle stream flow rate to maintain an optimal fluidization rate in the reaction space. In general, the recycle flow corresponds to about 2 to 10 times the flow rate of total fresh feed (top and bottom feeds), preferably 5 to 7 times. The recycle flow can be adjusted by adjusting the rotational speed (rpm) of the pump. The recycle pump may be any submersible or non-submersible pump suitable for recirculating fluid throughout the ebullated bed reactor, for example a centrifugal pump or any other type of dynamic pump, or e.g. a positive displacement pump.

[0065] In certain embodiments, the top feed injector (9) has at least two top feed delivery channels, at least one opening into the recycle cup (9b) and at least one opening into the recycle downcomer (9a), and optionally at least one top feed delivery channel opening into the recycle downcomer is arranged concentrically inside at least one top feed delivery channel opening into the recycle cup (9ac, 9bc). These embodiments allow simultaneous feeding of different top feeds or the same feed to different locations to further enhance dilution and mixing. As a precautionary measure, particularly in view of high speed feed injection, high TAN and / or particles in the injected feed, a wear element and / or a wear coating may be arranged in the recycle cup and / or in the recycle downcomer in the trajectory of the injected top feed. Exemplary materials for such wear element and / or wear coating may include e.g. SS 317, Alloy 625, 254SMO, 914L or certain commercially available ceramic coatings, just to name a few.

[0066] Hence, in certain embodiments, the top feed injector (9) is configured to inject one or more top feed(s) (40,45) via the top feed delivery channel(s) into the recycle cup (3) and / or into the recycle downcomer (4), and a wear element and / or a wear coating (60) is arranged in the recycle cup (3) and / or in the recycle downcomer (4) in the trajectory of the top feed.

[0067] In certain embodiments, the top feed delivery channel(s) (9a, 9b) of the top feed injector (9) is / are of metallurgy or coated with a coating having higher total acid number (TAN) corrosion resistance compared to the plenum (300).

[0068] In certain embodiments, the reactor enclosure (1 ) further encompasses a gas overhead space (400) at the top of the reactor enclosure, a gas-liquid separation zone (500) between the gas overhead space (400) and the reaction space (100), and one or more gas-liquid separation means (6) arranged in the gas-liquid separation zone (500).

[0069] In certain embodiments, at least one or more, preferably all of the following is / are met in the reactor configuration: the bottom feed inlet (10) is configured to feed a bottom feed (15) and a hydrogen stream (20) into the plenum (300), the distribution means (2) is / are configured to distribute the content of the plenum to the reaction space (100), the reaction space (100) is configured to accommodate an ebullated catalyst bed (200) for converting the distributed content of the plenum to provide a converted stream comprising gaseous compounds and liquid compounds, the gas / liquid separation means (6) is / are arranged in the gas-liquid separation zone (500) and configured to subject the converted stream to gas-liquid separation, the recycle cup (3) is arranged in the gas-liquid separation zone (500) and configured to receive a first portion of the liquid compounds separated from the converted stream as a recycle stream, the reaction product outlet (8) has openings (8a) at least into the gas-liquid separation zone (500) and is configured to receive through the opening(s) a second portion of the liquid compounds and at least a portion of the gaseous compounds separated from the converted stream as a conversion effluent (30) and to remove the conversion effluent from the reactor enclosure (1 ), the top feed injector (9) is configured to inject one or more top feed(s) (40,45) via the top feed delivery channel(s) (9a, 9b, 9c) into the recycle cup (3) and / or into the recycle downcomer (4) to mix the tops feed(s) into the recycle stream to provide a mixed stream (50), and / or the recycle pump (5) is configured to cause the mixed stream (50) to flow to the plenum (300) and to mix therein with the bottom feed (15) and the hydrogen stream (20).

[0070] The possibility to introduce via the top feed injector feeds for which the unit was not originally designed, and that are challenging in one way or another, for example because of incompatibility with the bottom feed and / or corrosiveness to materials typically used in the reactors, is a major benefit. It allows significant broadening of the feed pool for producing sustainable hydrocarbons particularly in existing refinery units, with minimal material upgrading needs and without reducing lifetime thereof.

[0071] In certain embodiments, the reactor enclosure (1 ) has an opening at the top of the reactor enclosure (1 ) originally configured to accommodate an instrument, particularly a pressure gauge or a thermometer, and retrofitted to accommodate the top feed injector (9).

[0072] In certain embodiments, the reactor configuration further comprises means for withdrawing spent ebullated catalyst bed material from the reactor enclosure, preferably spent catalyst particles, and means for adding fresh ebullated catalyst bed material to the reactor enclosure, preferably fresh catalyst particles. The withdrawing and addition may be conducted e.g. continuously, or periodically, preferably using a rate of replacement of used catalyst by fresh catalyst as discussed in the foregoing.

[0073] The present disclosure also provides an ebullated bed reactor system comprising two or more reactor configuration(s) according to the second example aspect arranged in series, wherein the second and / or a further reactor configuration is configured to receive as a bottom feed at least a portion of the conversion effluent of the preceding reactor configuration.

[0074] In certain embodiments, the ebullated bed reactor system comprises an interstage separation unit arranged between any two reactor configurations and configured to remove a volatiles fraction from the conversion effluent of the preceding reactor configuration and to recover the non-volatiles fraction as the bottom feed for the subsequent reactor configuration. Removing compounds volatile at the separation conditions, for example a volatiles fraction comprising at least compounds boiling below 300 °C at atmospheric pressure, and feeding only the non-volatiles fraction, for example comprising at least compounds boiling above 300 °C at atmospheric pressure, to the subsequent reactor configuration may be particularly beneficial in view of the additional top feed fed to each reactor configuration. Generally, when the vapour load is reduced, a reactor smaller than without the interstage separation may suffice. Additionally, higher hydrogen partial pressure and longer residence time may be attained in the subsequent reactor, thereby intensifying the hydroconversion. Also, a higher (full) capacity may then be achieved in the subsequent reactor configuration for converting the heavier compounds.

[0075] Further benefits of the ebullated bed reactor system and embodiments thereof are apparent from the present disclosure, e.g. as discussed in connection with the present hydroconversion process and / or reactor configuration.

[0076] Furthermore, the present disclosure provides use of the reactor configuration according to the second example aspect or the ebullated bed reactor system according to the third example aspect for hydroconverting a top feed and a bottom feed in an ebullated catalyst bed comprising a hydroconversion catalyst, preferably in the hydroconversion process according to the first example aspect. Benefits of the uses of the reactor configuration and the ebullated bed reactor system, and embodiments thereof, are apparent from the present disclosure, e.g. as discussed in connection with the present hydroconversion process, reactor configuration and / or ebullated bed reactor system.

[0077] In embodiments of the hydroconversion process according to the first example aspect, any one or more of the hydroconversion process features, including the ebullated bed reactor(s) (as reactor configuration(s) for ebullated bed operation), the top feed(s), the bottom feed, the hydrogen stream, the hydroconversion catalyst, the ebullated catalyst bed, the converted stream, the conversion effluent, the plenum, the top feed injector, the recycle cup, the recycle downcomer, the mixed stream, and / or the recycle pump, may be as specified in the present disclosure in connection with the embodiments of the reactor configuration according to the second example aspect and / or in connection with the embodiments of the ebullated bed reactor system according to the third example aspect. Similarly, in embodiments of the reactor configuration according to the second example aspect, any one or more of the reactor configuration features, including the reactor enclosure, the plenum, the reaction space, the distribution means the recycle cup, the recycle downcomer, the bottom feed, the bottom feed inlet, the reaction product outlet, the recycle pump, the top feed, the top feed injector, the top feed delivery channel, the gas overhead space, the gas-liquid separation zone, and / or the gas-liquid separation means, may be as specified in the present disclosure in connection with the embodiments of the process according to the first example aspect and / or in connection with the embodiments of the ebullated bed reactor system according to the third example aspect.

[0078] Schematic presentation of the hydroconversion process and the reactor configuration

[0079] Fig. 1 schematically shows a reactor configuration according to an example embodiment. A hydroconversion process according to an example embodiment may be operated using the reactor configuration example embodiment shown in Figi , and is explained in the following with reference to Fig 1 .

[0080] In the reactor configuration shown in Fig 1 , there is a reactor enclosure 1 encompassing a plenum 300 at the bottom of the reactor enclosure, a reaction space 100 arranged above the plenum, distribution means 2 arranged between the plenum and the reaction space, and a recycle cup 3 above the reaction space, wherein the recycle cup is connected to a recycle downcomer 4 providing a fluid communication between the recycle cup 3 and the plenum 300. The reactor enclosure 1 of the reactor configuration shown in Fig 1 further encompasses a gas overhead space 400 at the top of the reactor enclosure, a gas-liquid separation zone 500 (indicated as patterned) between the gas overhead space 400 and the reaction space 100, and one or more gas-liquid separation means 6 arranged in the gasliquid separation zone 500. The reactor configuration shown in Fig 1 has also a bottom feed inlet 10 opening into the plenum 300, a reaction product outlet 8 arranged at the top of the reactor enclosure, a recycle pump 5 connected to the recycle downcomer 4, and a top feed injector 9 arranged at the top of the reactor enclosure and having at least one top feed delivery channel opening into the recycle cup and / or into the recycle downcomer. In the hydroconversion process using the reactor configuration according to the example embodiment shown in Fig 1 , a bottom feed 15, such as a heavy petroleum feed e.g. vacuum residue, is mixed with a hydrogen stream 20 and fed via a bottom feed inlet 10 into the plenum 300 of the reactor enclosure 1. The content of the plenum 300 is distributed with distribution means 2 to the reaction space 100 accommodating a hydroconversion catalyst in an ebullated catalyst bed 200. The catalyst bed 200 is ebullated by operation of the recycle pump 5, which maintains a flow from the recycle cup 3 via the recycle downcomer 4 and the plenum 300 to the recycle space 100 and further to the gas-liquid separation zone 500. The content of the plenum 300 is converted in the ebullated catalyst bed 200 to provide a converted stream comprising gaseous and liquid compounds, that flows upwards to the gas-liquid separation zone 500. In the gas-liquid separation zone 500, the converted stream is subjected to gas-liquid separation by separation means 6. The gas-liquid separation is further enhanced by the turbulent flow of the converted stream in the gas-liquid separation zone 500. The gas-liquid separation zone 500 accommodates fluid mostly in liquid state, for which a level 7 may be envisioned. A portion of the separated gaseous compounds flow to the gas overhead space 400 located above the level 7, while another portion thereof together with a portion of the liquid compounds separated from the converted stream enter the reaction product outlet 8 through its openings 8a and exit the reactor as a conversion effluent 30. Another portion of the liquid compounds separated from the converted stream are sucked into the recycle cup 3 and the recycle downcomer 4 as a recycle stream. The top feed 40 is fed with the top feed injector 9, via the top feed delivery channel(s) into the recycle cup 3, the recycle downcomer 4 or both, to mix and dilute the top feed(s) into the recycle stream to provide a mixed stream 50. Operation of the recycle pump 5 causes the mixed stream 50 to flow to the plenum 300 and to mix therein with the bottom feed 15 and the hydrogen stream 20.

[0081] Fig. 2a schematically shows a top feed injector 9 according to an example embodiment usable in the present hydroconversion process and reactor configuration. The top feed injector 9 is arranged at the top of the reactor enclosure 1 of a reactor configuration configured for ebullated bed operation (here in connection with Figs 2a-2c referred to as a reactor). The top feed injector 9 shown in Fig 2a has one top feed delivery channel opening into the recycle downcomer 9a of the reactor. The top feed injector shown in Fig 2a is configured to inject the top feed 40 via the top feed delivery channel 9a to the recycle downcomer 4, and to mix and dilute the injected top feed into the recycle stream therein, to provide a mixed stream 50. Fig. 2b schematically shows another top feed injector 9 according to an example embodiment usable in the present hydroconversion process and reactor configuration. The top feed injector 9 is arranged at the top of the reactor enclosure 1 of the ebullated bed reactor. The top feed injector 9 shown in Fig 2b has one top feed delivery channel opening into the recycle cup 9b of the reactor. The top feed injector shown in Fig 2b is configured to inject the top feed 40 via the top feed delivery channel 9b to the recycle cup 3, and to mix and dilute the injected top feed into the recycle stream therein, to provide a mixed stream 50.

[0082] Fig. 2c schematically shows yet another top feed injector 9 according to an example embodiment usable in the present hydroconversion process and reactor configuration. The top feed injector 9 is arranged at the top of the reactor enclosure 1 of the ebullated bed reactor. The top feed injector 9 shown in Fig 2c has one top feed delivery channel opening into the recycle downcomer 9acarranged concentrically inside the top feed delivery channel opening into the recycle cup 9bcof the reactor. The top feed injector shown in Fig 2c is configured to inject a top feed 40 via the top feed delivery channel 9acto the recycle downcomer 4, and a top feed 45, that may be the same of different feed as top feed 40, via the top feed delivery channel 9bcto the recycle cup 3, to mix and dilute the injected top feeds into the recycle stream therein, to provide a mixed stream 50.

[0083] Various embodiments have been presented. It should be appreciated that in this document, words comprise, include and contain are each used as open-ended expressions with no intended exclusivity.

[0084] The foregoing description has provided by way of non-limiting examples of particular implementations and embodiments of the invention a full and informative description of the best mode presently contemplated by the inventors for carrying out the invention. It is however clear to a person skilled in the art that the invention is not restricted to details of the embodiments presented in the foregoing, but that it can be implemented in other embodiments using equivalent means or in different combinations of embodiments without deviating from the characteristics of the invention.

[0085] Furthermore, some of the features of the afore-disclosed embodiments of this invention may be used to advantage without the corresponding use of other features. As such, the foregoing description shall be considered as merely illustrative of the principles of the present invention, and not in limitation thereof. Hence, the scope of the invention is only restricted by the appended patent claims.

Claims

CLAIMS1. A hydroconversion process operated in one or more ebullated bed reactor(s), the process comprising: a) providing one or more top feed(s), a bottom feed, a hydrogen stream and a hydroconversion catalyst; b) subjecting a mixture of the one or more top feed(s), the bottom feed, and the hydrogen stream to hydroconversion in an ebullated catalyst bed arranged in an ebullated bed reactor and comprising the hydroconversion catalyst to provide a converted stream comprising gaseous compounds and liquid compounds; and c) removing a portion of the converted stream from the ebullated bed reactor as a conversion effluent, wherein in the process: the bottom feed and the hydrogen stream provided in step a) are fed to a plenum at the bottom of the ebullated bed reactor, the one or more top feed(s) provided in step a) is / are fed with a top feed injector into a recycle cup arranged above the ebullated catalyst bed and / or into a recycle downcomer connected to the recycle cup, wherein the top feed injector has at least one top feed delivery channel opening into the recycle cup and / or at least one top feed delivery channel opening into the recycle downcomer, and mixed therein into a portion of the liquid compounds of the converted stream to provide a mixed stream, a recycle pump connected to the recycle downcomer pumps the mixed stream into the plenum, and the content of the plenum is distributed to the ebullated catalyst bed.

2. The hydroconversion process according to claim 1 , wherein the top feed(s) and the bottom feed meet one or more of the following conditions: the top feed has a higher total acid number (TAN) compared to the bottom feed, the top feed has a higher viscosity compared to the bottom feed, the top feed is not miscible with the bottom feed, and / or the top feed forms precipitates if mixed or heated with the bottom feed.

3. The hydroconversion process according to claim 1 or 2, wherein the top feed(s) comprise(s) non-hydroprocessed feed(s) of renewable or circular origin, and / or selectively hydrogenated feed(s) of renewable or circular origin; and / or at least one or more of plantoil(s), animal fat(s), microbial oil(s), plant oleoresin(s), crude tall oil soap, crude tall oil (CTO), acid refined tall oil, depitched tall oil, crude fatty acids fraction (CFA), tall oil fatty acids fraction (TOFA), tall oil rosin fraction (TOR), distilled tall oil fraction (DTO), tall oil pitch (TOP), nutshell liquid(s), palm oil mill effluent (POME) bottom(s), lignin-derived biocrude(s), (ligno)cellulose-derived biocrude(s), algae biocrude(s), used lubricant(s), liquefied waste polymers, and / or liquefied municipal solid waste.

4. The hydroconversion process according to any one of the preceding claims, wherein the top feed(s) have a total acid number (TAN) within a range from more than 1 .5 mg KOH / g to at most 250 mg KOH / g, preferably from 3 mg KOH / g to at most 210 mg KOH / g, more preferably from 5 mg KOH / g to at most 180 mg KOH / g.

5. The hydroconversion process according to any one of the preceding claims, wherein the bottom feed comprises at least one or more of hydroconverted hydrocarbon feed(s), fossil crude oil distillate(s), fossil crude oil distillation residue(s), distillate(s) of cracked fossil feed(s), and / or distillation residue(s) of cracked fossil feed(s).

6. The hydroconversion process according to any one of the preceding claims, wherein the process comprises in step b) two or more ebullated bed reactor(s) arranged in series, and the bottom feed fed to the second and / or to a further ebullated bed reactor comprises at least a portion of the conversion effluent of the preceding ebullated bed reactor, and preferably the top feed(s) fed to the first, to the second and / or to a further ebullated bed reactor are selected independently from each other from the top feeds specified in claim 3.

7. The hydroconversion process according to any one of the preceding claims, wherein the ebullated bed reactor(s) is / are operated at a temperature (as determined at the reactor inlet) within a range from 270 °C to 500 °C, preferably from 300 °C to 450 °C, and / or at a pressure (as determined at the reactor outlet) within a range from 3 MPa to 50 MPa, preferably from 8 MPa to 20 MPa.

8. The hydroconversion process according to any one of the preceding claims, wherein the process further comprises dispersing a co-catalyst and / or a co-catalyst precursor into the bottom feed before subjecting to the hydroconversion in step b).

9. The hydroconversion process according to any one of the preceding claims, wherein the process further comprises d) recovering from the conversion effluent at least one or more distillate(s) and a bottom fraction.

10. The hydroconversion process according to any one of the preceding claims, wherein the process further comprises subjecting at least a portion of the conversion effluent to one or more further conversion(s), preferably to one or more further catalytic conversion(s), more preferably to one or more further catalytic hydroconversion(s) and / or catalytic hydroprocessing(s).11 . A reactor configuration comprising: a reactor enclosure (1 ) encompassing a plenum (300) at the bottom of the reactor enclosure, a reaction space (100) arranged above the plenum, distribution means (2) arranged between the plenum and the reaction space, and a recycle cup (3) above the reaction space, wherein the recycle cup is connected to a recycle downcomer (4) providing a fluid communication between the recycle cup (3) and the plenum (300), a bottom feed inlet (10) opening into the plenum (300), a reaction product outlet (8) arranged at the top of the reactor enclosure, and a recycle pump (5) connected to the recycle downcomer (4) and configured to cause a flow from the recycle cup (3) to the plenum (300), wherein the reactor configuration is configured for ebullated bed operation, and characterised by: a top feed injector (9) arranged at the top of the reactor enclosure and having at least one top feed delivery channel opening into the recycle cup (9b) and / or at least one top feed delivery channel opening into the recycle downcomer (9a).

12. The reactor configuration according to claim 11 , wherein the top feed injector (9) has at least two top feed delivery channels, at least one opening into the recycle cup (9b) and at least one opening into the recycle downcomer (9a), and optionally at least one top feed delivery channel opening into the recycle downcomer is arranged concentrically inside at least one top feed delivery channel opening into the recycle cup (9ac, 9bc).

13. The reactor configuration according to claim 11 or 12, wherein the top feed injector (9) is configured to inject one or more top feed(s) (40,45) via the top feed delivery channel(s) into the recycle cup (3) and / or into the recycle downcomer (4), and a wear element and / or a wear coating (60) is arranged in the recycle cup (3) and / or in the recycle downcomer (4) in the trajectory of the top feed(s).

14. The reactor configuration according to any one of claims 11 to 13, wherein the top feed delivery channel(s) (9a, 9b) of the top feed injector (9) is / are of metallurgy or coated with a coating having higher total acid number (TAN) corrosion resistance compared to the plenum (300).

15. The reactor configuration according to any one of claims 11 to 14, wherein the reactor enclosure (1 ) further encompasses a gas overhead space (400) at the top of the reactor enclosure, a gas-liquid separation zone (500) between the gas overhead space (400) and the reaction space (100), and one or more gas-liquid separation means (6) arranged in the gas-liquid separation zone (500).

16. The reactor configuration according to any one of claims 11 to 15, wherein at least one or more, preferably all of the following is / are met in the reactor configuration: the bottom feed inlet (10) is configured to feed a bottom feed (15) and a hydrogen stream (20) into the plenum (300), the distribution means (2) is / are configured to distribute the content of the plenum to the reaction space (100), the reaction space (100) is configured to accommodate an ebullated catalyst bed (200) for converting the distributed content of the plenum to provide a converted stream comprising gaseous compounds and liquid compounds, the gas / liquid separation means (6) is / are arranged in the gas-liquid separation zone (500) and configured to subject the converted stream to gas-liquid separation, the recycle cup (3) is arranged in the gas-liquid separation zone (500) and configured to receive a first portion of the liquid compounds separated from the converted stream as a recycle stream, the reaction product outlet (8) has openings (8a) at least into the gas-liquid separation zone (500) and is configured to receive through the opening(s) a second portion of the liquid compounds and at least a portion of the gaseous compounds separated from the converted stream as a conversion effluent (30) and to remove the conversion effluent from the reactor enclosure (1 ), the top feed injector (9) is configured to inject one or more top feed(s) (40,45) via the top feed delivery channel(s) (9a, 9b, 9c) into the recycle cup (3) and / or into the recycle downcomer (4) to mix the tops feed(s) into the recycle stream to provide a mixed stream (50), and / orthe recycle pump (5) is configured to cause the mixed stream (50) to flow to the plenum (300) and to mix therein with the bottom feed (15) and the hydrogen stream (20).

17. The reactor configuration according to any one of claims 11 to 16, wherein the reactor enclosure (1 ) has an opening at the top of the reactor enclosure originally configured to accommodate an instrument, particularly a pressure gauge or a thermometer, and retrofitted to accommodate the top feed injector (9).

18. The reactor configuration according to any one of claims 11 to 17, further comprising means for withdrawing spent ebullated catalyst bed material from the reactor enclosure, preferably spent catalyst particles, and means for adding fresh ebullated catalyst bed material to the reactor enclosure, preferably fresh catalyst particles.

19. An ebullated bed reactor system comprising two or more reactor configuration(s) according to claims 11 to 18 arranged in series, wherein the second and / or a further reactor configuration is configured to receive as a bottom feed at least a portion of the conversion effluent of the preceding reactor configuration; and preferably an interstage separation unit is arranged between any two reactor configurations and configured to remove a volatiles fraction from the conversion effluent of the preceding reactor configuration and to recover the non-volatiles fraction as the bottom feed for the subsequent reactor configuration.

20. Use of the reactor configuration according to claims 11 to 18 or the ebullated bed reactor system according to claim 19 for hydroconverting a top feed and a bottom feed in an ebullated catalyst bed comprising a hydroconversion catalyst, preferably in the hydroconversion process according to claims 1 to 10.

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