Method and system for hydroprocessing renewable feedstock within a reactor

Abstract

A method and system for hydroprocessing a renewable feedstock in a reactor is provided. The system comprises the reactor with a catalyst bed and at least one feed line. The at least one feed line is structured for injecting the renewable feedstock directly into the catalyst bed of the reactor, to inhibit degradation of the wall of the reactor by the feedstock. The catalyst bed comprises a catalyst, and the injection of the feedstock directly into the catalyst bed causes the feedstock to contact the catalyst and initiate hydroprocessing of the feedstock. By injecting the renewable feedstock directly into the catalyst bed, at a distance from the wall of the reactor, the renewable feedstock will be diluted by the contents of the catalyst bed and the acidity of the renewable feedstock at the wall of the reactor will be lowered.

Description

METHOD AND SYSTEM FOR HYDROPROCESSING RENEWABLE FEEDSTOCK WITHIN A REACTORFIELD OF THE INVENTION

[0001] The present disclosure relates generally to hydroconversion systems for processing feedstock. In particular, the disclosure relates to a method and system for hydroprocessing a renewable feedstock within a reactor.BACKGROUND

[0002] Liquefied renewable feedstocks refer to liquid products from liquefaction process of solid biomass e.g., wood, algae, grass, as well as liquefaction processes of waste plastics, e.g., polyethylene, polystyrene etc. It is often difficult to feed solid versions of these renewable feedstocks directly into existing ebullated bed reactors. Liquefaction processes make these feedstocks fluid and pumpable with typical refinery equipment. Typical liquefaction technology includes pyrolysis (slow, fast, and flash), hydrothermal liquefaction, solvent liquefaction etc. The liquefied renewable feedstocks may also come from the byproduct of other commercial process, e.g., tall oil pitch from distillation of Kraft CTO (crude tall oil). Although the liquefied renewable feedstocks are now pumpable, these liquefied feedstocks pose several challenges in typical refinery service.

[0003] First, many of these feeds are acidic, leading to corrosion issues in the feed and reactor sections. Upgrading metallurgy is often required to handle the high acidity of such feeds.

[0004] Similarly, many of these feeds also contain olefin and di-olefin, which tend to polymerize under elevated temperature. The polymerization of the feedstock at these elevated temperatures can lead to plugging issue in feed line, heaters and other equipment before the feedstock enters the reactor.

[0005] Lastly, many of these liquified, renewable feedstocks are not as stable as typical refinery feed and may decompose at typical operating temperature in feed heater. This leads to vaporization and fouling in feed lines of the reactor. Similarly, some of the feed, e.g., fast pyrolysis bio-oil, may not be homogeneous. Phase separation may happen as a result of this non-homogeneity.

[0006] Therefore, new routes for introducing these feedstocks into ebullated bed reactors (and other similar types of fluidized reactors) without having to upgrade the reactor are needed.

[0007] The background herein is included solely to explain the context of the disclosure. This is not to be taken as an admission that any of the material referred to was published, known, or part of the common general knowledge as of the priority date.SUMMARY OF THE INVENTION

[0008] According to an aspect, there is provided: a method for hydroprocessing an at least partially renewable feedstock within a reactor, the method comprising: injecting the renewable feedstock directly into a catalyst bed of the reactor to inhibit degradation of the wall of thereactor by the renewable feedstock; wherein the catalyst bed comprises a catalyst; and wherein the renewable feedstock contacts the catalyst to initiate hydroprocessing of the renewable feedstock.

[0009] According to another aspect, there is provided a system for hydroprocessing a feedstock, the system comprising: a reactor that comprises a catalyst bed and at least one feed line; wherein the at least one feed line is structured for injecting the feedstock directly into the catalyst bed of the reactor, to inhibit degradation of the wall of the reactor by the feedstock; wherein the catalyst bed comprises a catalyst; and wherein the feedstock contacts the catalyst to initiate hydroprocessing of the feedstock.

[0010] Except where mutually exclusive, a feature described in relation to any aspect or embodiment described herein may be applied mutatis mutandis to any other aspect and / or embodiment. Furthermore, except where mutually exclusive, any feature described herein may be applied to any aspect / embodiment and / or combined with any other feature described herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments will now be described, by way of example only, with reference to the attached Figures, wherein:

[0012] Figure 1 shows a cross-sectional view of an embodiment of the system of the present disclosure, where the system includes an ebullated bed reactor;

[0013] Figure 2A shows a cross-sectional, close-up view of the embodiment of the system in Figure 1 ;

[0014] Figure 2B shows a cross-sectional, close-up view of the embodiment of the system in Figure 1 , where the feed in line includes an injection nozzle;

[0015] Figure 3 shows a schematic diagram of the reactor of Figure 1 implemented within a simulation environment in the ANSYS Computational Fluid Dynamics (CFD) simulation software (version 2023.1.0);

[0016] Figure 4 shows a graphical representation of the ACID level at the inner surface of the wall of the reactor for the first reaction simulation at 1000 BPSD (Barrel Per Stream Day) feed rate;

[0017] Figure 5A shows a graphical illustration of the reactor of Figure 3, where the results for the first reaction simulation at a first time point are shown;

[0018] Figure 5B shows a graphical illustration of the reactor of Figure 3, where the results for the first reaction simulation at a second time point are shown;

[0019] Figure 5C shows a graphical illustration of the reactor of Figure 3, where the results for the first reaction simulation at a third time point are shown;

[0020] Figure 6 shows a graphical representation of the ACID level at the inner surface of the wall of the reactor for the second reaction simulation at 2000 BPSD feed rate;

[0021] Figure 7A shows a graphical illustration of the reactor of Figure 3, where the results for the second reaction simulation at a first time point are shown;

[0022] Figure 7B shows a graphical illustration of the reactor of Figure 3, where the results for the second reaction simulation at a second time point are shown; and

[0023] Figure 7C shows a graphical illustration of the reactor of Figure 3, where the results for the second reaction simulation at a third time point are shown.DETAILED DESCRIPTION

[0024] Although illustrative embodiments of one or more aspects are provided herein, the disclosed processes may be implemented using any number of techniques. The disclosure is not limited to the illustrative or specific embodiments, any drawings, and any techniques illustrated herein, including any exemplary designs and embodiments illustrated and described herein, and may be modified within the scope of the appended claims along with their full scope of equivalents.

[0025] For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the Figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiment or embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the embodiments described herein. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

[0026] Various terms used throughout the present description may be read and understood as follows, unless the context indicates otherwise: “or” as used throughout is inclusive, as though written “and / or”; singular articles and pronouns as used throughout include their plural forms, and vice versa; similarly, gendered pronouns include their counterpart pronouns so that pronouns should not be understood as limiting anything described herein to use, implementation, performance, etc. by a single gender; “exemplary” should be understood as “illustrative” or “exemplifying” and not necessarily as “preferred” over other embodiments. Further definitions for terms may be set out herein; these may apply to prior and subsequent instances of those terms, as will be understood from a reading of the present description. It will also be noted that the use of the term “a” or “an” will be understood to denote “at least one” in all instances unless explicitly stated otherwise or unless it would be understood to be obvious that it must mean “one.”

[0027] As used herein, the "comprising" and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and / or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and / or steps. The foregoing also applies to words having similar meanings such as the terms, "including", "having" and their derivatives. It will be understood that any embodiments described as “comprising” certain components may also “consist of” or “consist essentially of,” these components, wherein “consisting of” has a closed- ended or restrictive meaning and “consisting essentially of” means including the components specified but excluding other components except for materials present as impurities, unavoidable materials present as a result of processes used to provide the components, and components added for a purpose other than achieving the technical effects described herein. For example, a composition defined using the phrase “consisting essentially of’ encompasses any known acceptable additive, excipient, diluent, carrier, and the like, suitable for the composition described herein. Typically, a composition consisting essentially of a set of components will comprise less than 5% by weight, typically less than 3% by weight, more typically less than 1% by weight of non-specified components.

[0028] As used herein, the terms “about” and “approximately” are meant to cover variations that may exist in the upper and lower limits of the ranges of values, such as variations in properties, parameters, and dimensions.

[0029] Unless otherwise explained, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice for testing of the present invention, the typical materials and methods are described herein.

[0030] In addition, in describing and claiming the present invention, the common terminology generally used is described herein below. If a term is used in this disclosure but is not specifically described herein, the definition from the IUPAC Compendium of Chemical Terminology can be applied, as long as that definition does not conflict with any other disclosure or description applied herein, or render indefinite or non-enabled any claim to which that definition is applied. All references herein to elements or metals belonging to a certain Group refer to the Periodic T able of the Elements and Hawley's Condensed Chemical Dictionary, 13th Edition. Also, any references to the Group or Groups shall be to the Group or Groups as reflected in the Periodic Table of Elements using the CAS system for numbering groups. To the extent that any definition, description or usage provided by any document incorporated herein by reference conflicts with the description or usage provided herein, the description or usage provided herein controls. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting.

[0031] Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components and the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, “each” refers to each member of a set or each member of a subset of a set.

[0032] Unless otherwise specified, the recitation 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-generic combinations of the listed components and mixtures thereof. In addition, all number ranges presented herein are inclusive of their upper and lower limit values.

[0033] If a standard test is mentioned herein, unless otherwise stated, the version of the test to be referred to is the most recent at the time of filing this patent application.

[0034] The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. To an extent not inconsistent herewith, and in jurisdictions where permitted, all citations referred to herein are hereby incorporated by reference.

[0035] The following description of embodiments provides non-limiting representative examples referencing numerals to particularly describe features and teachings of different aspects of the invention. The embodiments described should be recognized as capable of implementation separately, or in combination, with other embodiments from the description of the embodiments. A person of ordinary skill in the art reviewing the description of embodiments is able to learn and understand the different described aspects of the invention. The description of embodiments should facilitate understanding of the invention such that other implementations, not specifically covered but within the ability of a person of skill in the art having read the description of embodiments, will be understood as being consistent with an application of the invention.

[0036] The following terms will be used throughout the specification and will have the following meanings unless otherwise indicated.

[0037] "Renewable feedstock" refers to feedstocks other than those obtained from fossil resources such as crude oil, coal, natural gas, sand oil , etc. meaning feedstock that includes a solid biomass component e.g., wood, algae, grass, vegetable fats / oils, animal fats / oils, and fish fats / oils. In one embodiment, the renewable feedstock is a triglyceride containing renewable feedstock. Renewable feedstocks may also be referred to as “bio-derived” feedstocks.

[0038] “Circular feedstock” refers to feedstocks that are derived from non-biomass waste materials such as waste polymers, waste plastics (e.g., polyethylene, polystyrene etc.) and waste rubbers.

[0039] "Oleochemical" refers to a chemical that is biologically-derived, i.e. , from a renewable resource of biological origin. Such a term is generally accepted as being exclusive of fossil fuels.

[0040] The term “hydroprocessing” generally encompasses all processes in which a hydrocarbon feedstock is reacted with hydrogen in the presence of a catalyst and under hydroprocessing conditions, typically, at elevated temperature and elevated pressure. Hydroprocessing includes, for example, processes such as hydrogenation, hydrodeoxygenation, hydrodesulfurization, hydrodenitrogenation, hydrodemetallization, hydrodearomatization, hydroisomerization, hydrodewaxing, hydrocracking and mild hydrocracking.

[0041] The term “hydroconversion” refers to processes or steps performed in the presence of hydrogen for the hydrocracking, hydrogenation, hydrodeoxygenation, hydrodesulfurization, hydrodenitrogenation, hydrodemetallation, hydrodechlorination, hydrodecarboxylation, hydrodecarbonylation and / or hydrodearomatization of a hydrocarbon or biomass feedstock, and / or for the hydrogenation of unsaturated compounds in the feedstock. Depending on the type of hydroprocessing and the reaction conditions, products of hydroprocessing may have improved aromatic content, oxygen content, viscosities, viscosity indices, saturates content, cold flow and other low temperature properties, and volatilities, for example.

[0042] The term “ppm” as used herein means parts-per-million and is a weight relative parameter. A part-per-million is a microgram per gram, such that a component that is present at 10 ppm is present at 10 micrograms of the specific component per 1 gram of the aggregate mixture.

[0043] The term, “hydrogen-containing gas” or the like, as used herein is not particularly limited and should be known or understood by a person of skill in the art. As used herein, hydrogen-containing gas refers to a gas that comprises hydrogen. For example, and without being limited thereto, the hydrogen-containing gas is hydrogen. In another example and without being limited thereto, the hydrogen-containing gas comprises hydrogen and another gas.

[0044] The term, “catalyst”, as used herein is not particularly limited and should be known or understood by a person of skill in the art. A catalyst refers to a substance that can increase the rate of a chemical reaction, or lowers the temperature or pressure needed to start one. The increase in reaction rate can occur as the catalyst allows for the reaction to occur by an alternative mechanism that can require a lower activation energy.

[0045] The term, “ebullated bed reactor”, as used herein is not particularly limited and should be known or understood by a person of skill in the art. Ebullated bed reactors are a type of fluidized bed reactor that utilizes ebullition, or bubbling, to achieve appropriate distribution of reactants and catalysts. Ebullated bed technology utilizes a three-phase reactor (liquid, vapor,and solid), and is most applicable for exothermic reactions and for feedstocks which are difficult to process in fixed-bed or plug flow reactors, including for feeds having higher levels of contaminants. Ebullated bed reactors generally provide high-quality, continuous mixing of liquid and catalyst particles and have the characteristics of stirred reactor type operation with a fluidized catalyst. The advantages of ebullated bed reactors include, e.g., good back-mixed bed performance, excellent temperature control, and low and constant pressure drops due to reduced bed plugging and channeling. Ebullated bed reactors are used in the hydroconversion of fossil fuel and renewable feedstocks.

[0046] The present disclosure is directed to a method and system for processing (and specifically hydroprocessing) of renewable feedstock or coprocessing of renewable and fossil fuel feedstocks in hydro-conversion reactors. As discussed above, in the typical processing of feedstock within hydro-conversion reactors, feedstock is premixed and heated to temperatures of about 300 °C before entering into the reactor. This is done to provide for easier pumping of the feedstock into the reactor and to facilitate a smaller change in temperature within the reactor when the feedstock is injected (i.e., to bring the temperature of the feedstock to closer to a temperature of the interior of the reactor.

[0047] When the feedstock to be injected into the hydroconversion reactor is a renewable feedstock, premixing and heating of the renewable feedstock to temperatures above the polymerization temperatures in the feedstock can result in at least partial polymerization of the renewable feedstock. This partial polymerization can cause fouling of the renewable feedstock or plugging of the reactor inlets by the polymerized feedstock portions of the renewable feedstock.

[0048] The method and system as disclosed herein provide a process for introducing renewable feedstock into a reactor without substantial heating / premixing of the renewable feedstock. In particular, the method and system provide a means for reconfiguring reactors to handle renewable feedstocks.

[0049] In an embodiment of the present disclosure, a method is provided for hydroprocessing a renewable feedstock within a reactor 10. The method for hydroprocessing the renewable feedstock comprises at least the step of injecting the renewable feedstock directly into a catalyst bed 22 of the reactor 10 to inhibit degradation of the reactor wall 12a of the reactor 10 by the renewable feedstock. In this embodiment, the catalyst bed 22 of the reactor 10 comprises at least one catalyst, and the renewable feedstock contacts the catalyst (when injected directly into the catalyst bed 22) to initiate the hydroprocessing of the renewable feedstock.

[0050] In an additional embodiment, the catalyst in the catalyst bed 22 is selected such that the contacting of the catalyst with the renewable feedstock accelerates hydroprocessing of the renewable feedstock and at least partially neutralizes the renewable feedstock for reducing the acidity and corrosivity of renewable feedstock within the reactor 10. By injecting the renewable feedstock directly into the catalyst bed 22 of the reactor 10, the renewable feedstock will contactthe catalyst of the catalyst bed 22 as soon as the renewable feedstock enters the reactor 10. This immediate contacting of the renewable feedstock and the catalyst will accelerate the hydrodeoxygenation of the renewable feedstock, and thereby more rapidly reduce the acidity and corrosivity from the renewable feedstock.

[0051] By injecting the renewable feedstock directly into the catalyst bed 22 of the reactor 10, the renewable feedstock will also be diluted by the content of the catalyst bed 22 as soon as the renewable feedstock enters into reactor 10. This immediate dilution of the renewable feedstock by the contents of the catalyst bed 22 means that the dilution of the renewable feedstock is substantially complete prior to any of the renewable feedstock reaching an inner surface of the reactor wall 12a of the reactor 10. As a result of this dilution, the acidity of the compound within the catalyst bed 22 which eventually contacts the reactor wall 12a will be substantially reduced.

[0052] The renewable feedstock that is hydroprocessed using the method and system as disclosed herein can comprise various materials, compounds, and elements.

[0053] In an embodiment, the renewable feedstock is composed of at least one biodegradable material, and which has a Total acid number (TAN) of at least 5.

[0054] In at least some embodiments of the present disclosure, the chemical composition of the renewable feedstock is such that the renewable feedstock is easy to convert to useful oils and can be added to more than one type of reactor.

[0055] In at least some embodiments of the present disclosure, the renewable feedstock is a liquified renewable feedstock.

[0056] In an additional embodiment, the liquified renewable feedstock comprises at least one of tall oil, tall oil pitch, tire-derived pyrolysis oil, used cooking oil, etc.

[0057] In another, additional embodiment, the liquified renewable feedstock is formed from the liquefaction of at least one of a solid biomass and waste polymer. Non-limiting examples of the liquified renewable feedstock include oils such as pyrolysis bio-oil, hydrothermal liquefaction oil, waste plastic pyrolysis oil, etc. In this embodiment, the at least one of a solid biomass and waste polymer comprises at least one of algae, grass, waste polyethylene, and waste polystyrene.

[0058] Figures 1 to 3 provide an exemplary embodiment of the reactor that is used for hydroprocessing the renewable feedstock. The reactor 10 generally comprises a reactor vessel 12, a catalyst bed 22 that is contained within the reactor vessel 12, and at least one feed in line 18 that extends through the reactor vessel 10, into the interior thereof. The at least one feed in line 18 is structured for injecting the feedstock directly into the catalyst bed 22 of the reactor 10, to inhibit degradation of the reactor wall 12a of the reactor 10 by the feedstock. As provided above, the catalyst bed 22 comprises at least one catalyst.

[0059] Referring to Figures 1 to 2B provide an embodiment of the reactor 10 of the present disclosure. The reactor 10 has the reactor vessel 12, and the reactor vessel 12 that defines aninterior reaction chamber that contains the catalyst bed 22. The reactor also includes the at least one feed-in line 18 for injecting the renewable feedstock into the interior reaction chamber.

[0060] In an additional embodiment such as shown in Figures 1 to 2B, the catalyst bed 22 includes a first surface 22a, a second surface 22b, and a region 22c defined between the first surface 22a and the second surface 22b of the catalyst bed 22. When performing the method of the present disclosure, the renewable feedstock is injected into this region 22c of the catalyst bed 22.

[0061] In the specific embodiment provided in Figure 1, the reactor 10 is an ebullated bed reactor. The ebullated bed reactor further comprises a downcomer 26 that is contained within the reactor vessel. In the specific embodiment provided in Figures 1 to 2B, the downcomer 26 is a centrally positioned, where the catalyst bed 22 surrounds the downcomer 26. The catalyst bed 22 is contained in a space within the reactor vessel, and this space is defined between an inner surface of the reactor wall 12a (i.e., a reactor inner wall) and an outer surface 26a of the downcomer 26.

[0062] In the embodiments where the reactor 10 includes the downcomer 26, the feedstock is injected within the catalyst bed 22 at a position that is spaced from both the reactor wall 12a and the downcomer 26. The feedstock is injected into the catalyst bed 22 and mixes with the contents of the catalyst bed 22. The contents of the catalyst bed 22 include at least one liquid such that the feedstock is diluted by the at least one liquid when the feedstock is injected into the catalyst bed 22. Referring to Figure 3, there is provided an illustration of the flow of the renewable feedstock as it is injected directly into the catalyst bed 22 via the at least one feed in line 18. As the injection of the renewable feedstock occurs relatively far from the inner surface of the reactor wall 12a or the outer surface 26a of the downcomer 26, the renewable feedstock will be substantially diluted by the at least one liquid prior to reaching either of the reactor wall 12a of the reactor 10 vessel or an outer wall 26a of the downcomer 26.

[0063] By providing the dilution of the renewable feedstock prior to the feedstock reaching the reactor wall 12a, the need to upgrade the reactor 10 metallurgy of the reactor wall 12a is reduced. In the application of the system and method of the present disclosure, it may only be beneficial to the life of the reactor 10 to upgrade the metallurgy of the at least one feed in line 18. It is not necessarily beneficial to upgrade the metallurgy of the feed section of the reactor 10, the reactor vessel 12 itself, or the downstream components of the system, as the corrosivity of the renewable feedstock will have been substantially reduced due to the above-described dilution.

[0064] In an exemplary embodiment, the renewable feedstock is injected into the catalyst bed 22 at a position therewithin such that the feedstock is rapidly diluted by the at least one liquid in the catalyst bed, and such that the TAN of the liquid within the catalyst bed is less than about 1 at the reactor wall 12a of the reactor 10.

[0065] In an additional, exemplary embodiment, the renewable feedstock is injected into the catalyst bed 22 at a position therewithin such that the TAN of the at least one liquid in the catalyst bed is less than about 3 at the reactor wall 12a of the reactor 10.

[0066] In an embodiment, the reactor 10 that is used for hydroprocessing the renewable feedstock comprises one of a slurry bed reactor, an ebullated bed reactor, a recirculating reactor, or a fluid catalytic cracking (FCC) reactor. The use of the aforementioned reactor types for the hydroprocessing of feedstock is well-known in the art. It will be apparent to those skilled in the art that the embodiments of the method and / or system described herein (where these embodiments do not refer to specific structural features of a particular reactor type) can be applied to other reactor types beyond the scope of just ebullated bed reactors, slurry reactors, recirculating reactors, or FCC reactors.

[0067] The ebullated bed reactor also include an inlet end 14 and an extraction end 15. The inlet end 14 is positioned on the lower end of the reactor vessel 12 and the extraction end 15 is defined towards the top of the reactor vessel 12. The ebullated bed reactor also includes a recycle pan 27 that is disposed above the catalyst bed 22 in the reactor 10. The feed in line 18 includes a single feed-in line 18a that extends through a top of the reactor vessel 10 and down, substantially vertically, into the catalyst bed 22 such that a free end 18b of the single feed-in line 18a is disposed within the interior of the catalyst bed 22. In this way, the renewable feedstock can be injected directly into the interior of the catalyst bed 22.

[0068] The reactor vessel 12 of the ebullated bed reactor is fitted with an inlet conduit 16 for feeding reaction components and a hydrogen-containing gas. The reactor can include a conventional inlet line through which feedstock would normally be introduced. The reactor vessel can also include a gas introduction line for introducing the hydrogen-containing gas. This gas introduction line can be formed together within the conventional inlet line (as shown in Figure 1) to form the inlet conduit 16. Alternatively, the conventional inlet line and gas introduction line gas be formed as separate conduits.

[0069] In the specific embodiment provided in Figures 1 to 2B, the inlet conduit 16 is positioned towards the bottom end of the reactor vessel 12. The reactor vessel 12 also includes an outlet conduit 24 that is structured for withdrawing vapor and liquid through an outlet line 24a, and an exit conduit 17 for withdrawing spent catalyst.

[0070] In an additional embodiment, the reactor includes at least one catalyst addition line 19 that is structured for delivering a fresh supply of catalyst to the catalyst bed 22 within the reactor vessel 12. In the specific embodiment provided in Figures 1 to 2B, the reactor 10 includes a single catalyst addition line 19, and the single catalyst addition line 19 is mounted through a top of the reactor vessel 12. The single catalyst additional line 19 also defines the single feed-in line 18a.

[0071] In the specific embodiment provided in Figures 1 to 2B, the reactor vessel 12 of the ebullated bed reactor includes a lower chamber and an upper chamber within the interiorreaction chamber. The reactor includes a distributor plate 20, and the distributor plate 20 is mounted within the reactor vessel so as to define a boundary between the lower and upper chambers of the interior reaction chamber. The downcomer 26 extends between the lower chamber and the upper chamber and passes through a central aperture in the distribution plate 20.

[0072] In the operation of the reactor, feedstock may pass through the distributor plate 20 for distributing the fluids of the renewable feedstock from the lower chamber 40, up into the catalyst bed 22. As the fluids flow up into the catalyst bed 22, the catalyst particles are thereby forced into an ebullated movement by the gas flow and the liquid flow delivered by a recycle pump 23, which may be either internal or external to the reactor 10. The upward liquid flow delivered by this recycle pump 23 is sufficient to cause the mass of catalyst in the catalyst bed 22 to expand, thus permitting gas and liquid flow up through reactor 10.

[0073] Due to the upwardly directed flow provided by the pump 23 and the downward forces provided by gravity, the catalyst bed 22 particles reach an upward level of travel or ebullition while the lighter liquid and gas continue to move upward beyond that level. The upper level of catalyst or catalyst-liquid interface is shown at the surface 22a, and the catalytic reaction zone extends from transverse distributor plate 20 to the level of this surface 22a. Gases, vapors, and liquid product are withdrawn together through conduit 24.

[0074] In an additional embodiment, the recycle pan 27 is sized such that a maximum diameter of the recycle pan 27 is less than an interior diameter of the reactor vessel 12 of the reactor 10 such that a gap exists between the wall 12a of the reactor vessel 12 and the perimeter of the recycle pan 27. A majority of the gas and liquid within the reactor vessel 12 can move through risers mounted on the recycle pan 27 (not shown in the drawing). Upon passing through the recycle pan 27, most of the liquid reverses direction and flows downward to (and through) the downcomer 26 to the recycle pump 23 and is thereby recycled through the lower chamber of interior reaction chamber in the reactor 10.

[0075] While the direct injection of the renewable feedstock into the catalyst bed 22 of the reactor 10 is done to avoid or limit metallurgy upgrade requirements for the reactor 10, it may still be beneficial in at least some embodiments to provide a reactor 10 that is composed of at least one metallic material that will at least partially resist the corrosive and degrading effects of the renewable feedstock. In one such embodiment, the wall 12a of the reactor vessel 12 in the reactor 10 is formed of at least one corrosion resistant metal.

[0076] In at least some embodiments of the method for hydroprocessing the renewable feedstock, the step of injecting the renewable feedstock directly into the catalyst bed 22 is not done solely to inhibit the degradation of the reactor wall 12a. Rather, the renewable feedstock is injected directly into the catalyst bed 22 for inhibiting degradation of all parts of the reactor 10 that are likely to be degraded (i.e. , corroded and broken down) by the acidity of the renewable feedstock. In the method and system as disclosed herein, the renewable feedstock is introducedinto the reactor 10 in a position such that the renewable feedstock is diluted by the other contents of the reactor 10 prior to the renewable feedstock reaching the reactor wall 12a of the reactor 10. This dilution is significant enough to reduce the corrosion of various components of the reactor 10 by the renewable feedstock compared to a setup where non-diluted renewable feedstock is used within the reactor 10.

[0077] The parts of the reactor 10 that are likely to be degraded can include the reactor wall 12a but can also include other features of the reactor 10. For example, the direct injection of the renewable feedstock into the catalyst bed 22 can inhibit the degradation of one or more internal components of the reactor 10. In the various embodiments of the present disclosure, the one or more internal components may comprise at least some of the downcomer pipe, the reactor internal wall, the flow-through pan and the thermowell, as well as the support structures for those components.

[0078] In various embodiments of the method for hydroprocessing the renewable feedstock described herein, the renewable feedstock is introduced into the reactor 10 in a position such that the renewable feedstock is diluted by the other contents of the reactor 10 prior to the renewable feedstock reaching the reactor wall 12a of the reactor 10. The specific position at which the renewable feedstock is injected may vary within the various embodiments of the present disclosure, so long as the renewable feedstock is still substantially diluted by the catalyst within the catalyst bed 22 prior to the renewable feedstock reaching the reactor wall 12a.

[0079] The renewable feedstock will generally be injected into the catalyst bed 22 at a position therewithin such that a concentration of renewable feedstock in the catalyst bed 22 is lower proximate the wall 12a of the reactor 10. It will also be the case that, when injecting the renewable feedstock into the catalyst bed 22, the concentration of renewable feedstock in the catalyst bed 22 will increase away from the wall of the reactor 10 such that the concentration of renewable feedstock in the catalyst bed 22 forms a gradient from the wall of the reactor 10.

[0080] In an embodiment of the method for hydroprocessing the renewable feedstock, the renewable feedstock is injected into the catalyst bed 22 of the reactor 10, at a distance from the wall 12a of the reactor 10, to inhibit degradation of the wall of the reactor 10 by the renewable feedstock.

[0081] In an additional embodiment of the method such as shown in Figures 2A and 2B, the renewable feedstock is injected into the catalyst bed 22 at a location that is closer to a middle line (ML) of the catalyst bed 22 than it is to the wall of the reactor 10. In this embodiment, the middle line (ML) of the catalyst bed 22 is defined at a substantially equidistance between the reactor wall 12a and the outer surface 26a of the downcomer 26.

[0082] In an alternate embodiment of the method such as shown in Figures 2A and 2B, the renewable feedstock is injected into the catalyst bed 22 at a location that is proximate the middle line (ML) of the catalyst bed 22, away from the wall 12a of the reactor 10.

[0083] Various structures can be utilized within the method and system of the present disclosure for injecting the renewable feedstock directly into the catalyst bed 22. In an embodiment of the method and system disclosed herein, the renewable feedstock is injected into the catalyst bed 22 of the reactor 10 via the at least one feed in line 18. The at least one feed in line 18 is structured as a conduit that facilitates the delivery of the renewable feedstock into the catalyst bed 22.

[0084] In an additional embodiment such as shown in Figures 1 to 3, the at least one feed in line 18 extends at least partially into the catalyst bed 22 of the reactor 10.

[0085] In an additional embodiment of the method of hydroprocessing the renewable feedstock via the reactor 10, the method further comprises a step of positioning the at least one feed in line 18 at least partially into the catalyst bed 22 of the reactor 10.

[0086] When injecting the renewable feedstock through the at least one feed in line 18, the temperature of the renewable feedstock within the at least one feed in line 18 will affect how the renewable feedstock flows within the feed in line 18 and will also affect the behavior of the renewable feedstock within the interior of the reactor vessel 12. It is generally desirable to provide the renewable feedstock to the at least one feed in line 18 with limited pre-heating so as to substantially inhibit any polymerization of the renewable feedstock within the feed in channel.

[0087] In an embodiment, the renewable feedstock in the system is fed in, along the at least one feed-in line 18 so that the feedstock in the system stays below the fouling temperature, i.e. threshold temperature for polymerization, before the feedstock gets into the reactor 10. The fouling temperature varies with the composition of the feedstock (e.g., about 65°C for fast pyrolysis bio oil, about 200°C for tall oil pitch). The renewable feedstock is generally kept at relatively low temperatures (i.e., in a range from about 80°C to about 200°C) to reduce fouling and corrosion.

[0088] Furthermore, because a portion of the feed in line 18 also extends into the interior of the reactor vessel 12, it is generally desirable to control the residence time of the renewable feedstock within the feed in line 18. The portion of the feed in line 18 that extends into the reactor vessel 12 will be exposed to heat within the interior of the reactor vessel 12, and this heat will be transferred through the portion of the feed in line 18, to the renewable feedstock within the feed in line 18. In order to substantially inhibit fouling (i.e., undesired polymerization) of the renewable feedstock in the feed in line 18 due to the heat from the reactor interior, the residence time of the renewable feedstock within the feed in line 18 is controlled to maintain relatively low temperatures of the renewable feedstock along the feed in line 18. Because the fouling temperature of the renewable feedstock will vary depending on the composition of the feedstock (e.g. 65°C for fast pyrolysis bio oil, about 200°C for tall oil pitch), the optimal residence time within the feed in line 18 will also vary depending on the nature of the feedstock.

[0089] In this embodiment, the renewable feedstock is injected into the catalyst bed 22 via the at least one feed in line 18 such that a maximum temperature of the renewable feedstock withinthe at least one feed in line 18 remains below a threshold polymerization temperature of at least one polymerizable component of the renewable feedstock. The maximum temperature of the renewable feedstock within the at least one feed in line can be any suitable temperature such that the renewable feedstock is not substantially polymerized within the feed in line 18. Similarly, the average temperature of the renewable feedstock within the at least one feed in line can be any suitable temperature such that the renewable feedstock is not substantially polymerized within the feed in line 18.

[0090] In an exemplary embodiment, the renewable feedstock is injected into the catalyst bed 22 via the at least one feed in line 18 such that an average temperature of the renewable feedstock is in a range from about 80°C to about 200°C.

[0091] In at least some embodiments, the temperature of the renewable feedstock that is fed in along the at least one feed in line 18 is controlled by controlling an input flow velocity of the renewable feedstock within the feed in line 18. The input flow velocity is controlled to reduce the residence time of the renewable feed within the at least one feed in line 18. Reducing the residence time will reduce the heat transfer from reactor 10 contents to the renewable feedstock prior to the renewable feedstock exiting the feed in line 18 (into the reactor 10).

[0092] In at least some embodiments of the method for hydroprocessing the renewable feedstock, the renewable feedstock is injected through the at least one feed in line 18 at a relatively high velocity. This relatively high velocity leads to a comparatively short residence time for the renewable feedstock within the feed in line 18 and results in less heating up of the feedstock in the line before the feedstock gets mixed with the contents of the reactor 10. The high velocity (and shorter residence time) reduces polymerization and decomposition of the renewable feedstock that may foul and plug the at least one feed in line 18. The relatively high velocity also produces high shear rates within the flow of the renewable feedstock, which further reduces fouling of the renewable feedstock within the feed in line 18. Lastly, the high velocity of the renewable feedstock in the feed in line 18 helps to maintain a relative homogeneity of the renewable feedstock, especially for those renewable feedstocks which exist as multiple phases.

[0093] Generally, the renewable feedstock can be injected via the at least one feed in line 18 at any suitable average linear velocity. In one exemplary embodiment, the renewable feedstock is injected via the at least one feed in line 18 such that an average linear velocity of the renewable feedstock is at least about 3 ft / s, or at least about 5 ft / s.

[0094] In an alternate, exemplary embodiment, the renewable feedstock is injected via the at least one feed in line 18 such that an average linear velocity of the renewable feedstock is in a range from about 5 ft / s to about 15 ft / s.

[0095] The renewable feedstock may be injected via the at least one feed in line 18 at various average linear velocities. For example, the average linear velocity of the renewable feedstock may be at least about 3 ft / s, at least about 4 ft / s, at least about 5 ft / s, in a range from about 3 ft / s to about 15 ft / s, in a range from about 4 ft / s to about 14 ft / s, in a range from about 6 ft / s to about13 ft / s, in a range from about 7 ft / s to about 12 ft / s, in a range from about 8 ft / s to about 11 ft / s, or in a range from about 9 ft / s to about 10 ft / s.

[0096] The relatively low temperature of the renewable feedstock in the feed in line 18 (due to the short residence times) also reduces metallurgy upgrade needed for the at least one feed in line 18. A rate of corrosion of the at least one feed in line 18 will typically accelerate with increasing temperature, so reducing the overall temperature of the renewable feedstock within the feed in line 18 will reduce the rate of corrosion.

[0097] In an exemplary embodiment such as shown in Figure 3, the renewable feedstock is injected via the feed in line 18 that is mounted through the top of the reactor 10. The renewable feedstock is injected through the feed in line 18 such that an average maximum temperature of the renewable feedstock within the feed in line 18 is in a range from about 180°C to about 200°C. The average temperature of the renewable feedstock will rise about 200-250°C within the reactor 10 to bring the renewable feedstock to a target reactor 10 temperature. As described above, the renewable feedstock will also be diluted by the reactor 10 content once the renewable feedstock enters into the reactor 10.

[0098] The renewable feedstock may be injected via the at least one feed in line 18 such that various average maximum temperature of the renewable feedstock within the feed in line 18 are realized. For example, the average maximum temperature of the renewable feedstock within the feed in line 18 may be at least about 150°C, at least about 160°C, at least about 170°C, at least about 180°C, in a range from about 180°C to about 220°C, in a range from about 180°C to about 210°C, in a range from about 180°C to about 200°C, or in a range from about 190°C to about 200°C.

[0099] In an embodiment, the speed of the renewable feedstock injection through the at least one feed in line 18 is selected to control the temperature increase of the renewable feedstock within the at least one feed in line 18. This in turn can be used to control the impact of the temperature of the renewable feedstock on an internal temperature of the reactor 10.

[0100] In one such embodiment, the injection of the renewable feedstock into the reactor 10 is control such that the introduction of the renewable feedstock into the reactor 10 will result in a less than about 1°C increase in reactor temperature.

[0101] Although the renewable feedstock is fed into the reactor 10 via the at least one feed in line 18, and the at least one feed in line 18 is separate from the main inlet of the reactor 10, the renewable feedstock may be co-injected with some fossil fuel feedstock to assist in getting the renewable feedstock to flow at the target velocity within the at least one feed in line 18.

[0102] In an embodiment, the renewable feedstock is co-injected into the catalyst bed 22 with a secondary stream of at least one fossil fuel feedstock.

[0103] In an additional embodiment, the at least one fossil fuel feedstock includes at least one of a diluent or vacuum gas oil (VGO).

[0104] As provided above, the reactor 10 may include the at least one feed in line 18 for injecting the renewable feedstock into the catalyst bed 22. Because the renewable feedstock will contact the interior of at least one feed in line 18 for injecting the renewable feedstock directly into the catalyst bed 22, the metallurgy of the at least one feed in line 18 may need to be upgraded to withstand the corrosivity of the renewable feedstock.

[0105] In an embodiment, the at least one feed in line 18 of the reactor 10 is at least partially composed of at least one corrosion resistant metal.

[0106] In an additional embodiment, the at least one corrosion resistant metal includes at least one of SS317, SS317L, Alloy 625, SS904L, Alloy 825, C-276 and alloys or combinations thereof.

[0107] In the method and system of the present disclosure, the at least one feed in line 18 that is used for injecting the renewable feedstock can be an existing line within the reactor 10 (e.g. catalyst addition line from reactor 10 top, catalyst withdraw line close to reactor 10 top or bottom). Alternatively, the at least one feed in line 18 can be a dedicated, new feed in line 18 that is installed through the reactor vessel 12 and that is primarily used for the injection of the renewable feedstock directly into the catalyst bed 22. In at least some embodiments, the at least one feed in line 18 is a pre-existing line within the reactor vessel 12. In at least some other embodiments, the at least one feed in line 18 is a newly installed line in the reactor vessel 12 that is dedicated to the injection of the renewable feedstock. This has the effect of separating the feed of the renewable feedstock from the VR or main reactor 10 feed through the reactor 10 inlet.

[0108] In an embodiment such as shown in Figure 1 to 2B, the reactor 10 includes a catalyst addition line that is mounted through the reactor vessel 12, proximate or on the top (or the bottom) of the reactor vessel 12.

[0109] In a first additional embodiment such as shown in Figure 1 to 2B, the at least one feed in line 18 is defined through the catalyst addition line.

[0110] In an alternate additional embodiment not shown in the Figures, the at least one feed in line 18 is separate from the catalyst addition line.

[0111] In another, alternate embodiment, the reactor 10 further includes a catalyst withdrawal line that is mounted through the reactor vessel 12, proximate or on the bottom (or the top) of the reactor vessel 12.

[0112] In an additional, alternate embodiment, the at least one feed in line 18 is defined through the catalyst withdrawal line.

[0113] In an exemplary embodiment, the reactor 10 includes a catalyst withdrawal line that is structured for periodically removing spent catalyst from the reactor 10. The reactor 10 also includes the catalyst addition line for adding catalyst to the reactor. The catalyst addition line is mounted through a top of the reactor 10. In this same embodiment, the at least one feed in line 18 is defined through the catalyst addition line. The catalyst addition line is specifically formedas a length of 2” pipe. A bottom tip of the catalyst addition line is located at 1220 mm below a top, expanded bed surface of the catalyst bed 22, and 736 mm from the inner surface of the reactor wall 12a.

[0114] The at least one feed in line 18 of the reactor 10 may, in some embodiments, be structured for further optimizing the dilution of the renewable feedstock within the catalyst bed 22 to provide for even lower corrosivity of the renewable feedstock by the time the renewable feedstock reaches the inner surface of the reactor wall 12a.

[0115] In one such embodiment, the at least one feed in line 18 further comprises an injection nozzle. The injection nozzle of the at least one feed in line 18 is structured for expelling the renewable feedstock from the at least one feed in line 18. The injection nozzle is generally positioned on an end portion of the at least one feed in line 18. The injection nozzle is structured to expel the renewable feedstock from the at least one feed in line 18 in a particular, controlled manner so as to optimize the dilution of the renewable feedstock within the catalyst bed 22.

[0116] In a first, additional embodiment, the injection nozzle of the at least one feed in line 18 is oriented within the catalyst bed 22 such that the nozzle is directed inwards, towards a longitudinal centerline of the catalyst bed 22.

[0117] In a second, alternate embodiment, the injection nozzle of the at least one feed in line 18 is oriented at an acute angle relative to the longitudinal centerline of the catalyst bed 22.

[0118] In a third, alternate embodiment, the injection nozzle of the at least one feed in line 18 is oriented substantially parallel to the middle line of the catalyst bed 22.

[0119] The embodiments described herein are exemplary (e.g., in terms of materials, shapes, dimensions, and constructional details) and do not limit by the claims appended hereto and any amendments made thereto. Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the following examples are only illustrations of one or more implementations. The scope of the disclosure, therefore, is only to be limited by the claims appended hereto and any amendments made thereto.

[0120] Examples

[0121] The following examples are presented to enable those skilled in the art to understand and to practice embodiments of the present disclosure. They should not be considered as a limitation on the scope of the disclosure, but merely as being illustrative and representative thereof.Example 1 - Reaction Simulation

[0122] In order to verify the hydroprocessing performance of the reactor 10 in diluting and then hydroprocessing the injected renewable feedstock, a number of CFD simulations were performed to analyze the mixing behavior between the renewable feedstock and bulk gas / liquid within the catalyst bed of the reactor 10. Using these simulations, the regions of the catalyst bedwith the highest concentrations of renewable feedstock could be identified, in order to address potential corrosion concerns at the metal surfaces within the reactor 10. For some of these simulations, a simplified, three-dimensional model of the interior of the reactor vessel 12 was utilized.

[0123] Two distinct sets of reaction conditions were simulated and analyzed to verify reactor performance. These two sets of reaction conditions are described below and are illustrated in Figures 4 to 5C and 6 to 7C, respectively.Example 2 - First Reaction Conditions

[0124] For the first reaction conditions, a renewable feedstock feed rate of about 1000 BPSD for the renewable feedstock through the reaction was utilized and the renewable feedstock entering the reactor 10 was assumed to have a uniform temperature of about 120°C and a uniform acidity (i.e. , acid number) of about 80. The velocity of the renewable feedstock in the feed in line 18 was assumed to be about 5.3 ft / s. Within the reactor 10, the gas liquid upflow was assumed to occur at a uniform temperature of about 418°C, with a negligible acidity (i.e., acid number is zero). The average gas upflow velocity was held constant at about 2.8 cm / s and the average liquid upflow velocity was held constant at about 4.8 cm / s. Simulation was done with G / L two phase flow, with the presence of catalyst in the three-phase zone, mixing intensity is higher and acid number close to the wall is expected to be lower.

[0125] Referring to Figures 5A to 5C, there is provided three graphical representations of the simulated reaction zone based on the first reaction conditions. Each of Figures 5A to 5C shows a graphical representation of the mass fraction of the renewable feedstock within the reaction zone at a distinct time point during the injection of the renewable feedstock. Figure 5A provides a snapshot of the distribution of the renewable feedstock shortly after injection of the renewable feedstock has started, and Figures 5B and 5C show the evolution of the distribution of the renewable feedstock within the reaction zone (the snapshot at Figure 5C was taken after the snapshot at Figures 5B and 5A). As can be seen from each of Figures 5A to 5C, the mass flow rate of the renewable feedstock is at its highest in the area immediately surrounding the outlet of the feed in line 18. As the renewable feedstock exits the feed in line 18 and dispersed around the tip of the feed in line 18, the concentration of the renewable feedstock rapidly drops such that the concentration of the renewable feedstock is substantially lower in regions spaced apart from, but still close to, the tip of the feed in line 18.

[0126] Figures 5A to 5C illustrate how the mass fraction of the renewable feedstock at either of the boundaries of the reaction zone (i.e., either the reactor wall 12a of the reactor vessel 12 or the outer wall of the downcomer) remains relatively low through the injection of renewable feedstock and hydroprocessing of the renewable feedstock within the reactor 10. Because the mass fraction of the renewable feedstock remains relatively low at these boundaries, the acidity (i.e., corrosivity) of the renewable feedstock at the reaction zone boundaries will also remainlow. These graphical representations show the effective dilution of the renewable feedstock by the contents of the catalyst bed 22.

[0127] Referring to Figure 4, there is provided a graphical illustration of the Maximum Acid Number at the reactor wall 12a of the reactor 10 over the duration of the first simulation. This plot further illustrates the effective dilution of the renewable feedstock by the reactor 10 contents after the renewable feedstock has been injected into the catalyst bed 22. The average acid number at wall is well below 1, although momentarily the Maximum Acid Number can rise to about 1.5.Example 3 - Second Reaction Conditions

[0128] For the second reaction conditions, a renewable feedstock feed rate of 2000 BPSD for the renewable feedstock through the reaction was utilized and the renewable feedstock entering the reactor 10 was assumed to have a uniform temperature of about 120°C and a uniform acidity (i.e. , acid number) of about 80. The velocity of the renewable feedstock in the feed in line 18 was assumed to be about 12.5 ft / s. Within the reactor 10, the gas liquid upflow was assumed to occur at a uniform temperature of about 418°C, with a negligible acidity (i.e., acid number is zero). The average gas upflow velocity was held constant at about 2.8 cm / s and the average liquid upflow velocity was held constant at about 4.8 cm / s. Simulation was done with G / L two phase flow, with the presence of catalyst in the three-phase zone, mixing intensity is higher and acid number close to the wall is expected to be lower.

[0129] Referring to Figures 7A to 7C, there is provided three graphical representations of the simulated reaction zone based on the second reaction conditions. Each of Figures 7A to 7C shows a graphical representation of the mass fraction of the renewable feedstock within the reaction zone at a distinct time point during the injection of the renewable feedstock. Figure 7A provides a snapshot of the distribution of the renewable feedstock shortly after injection of the renewable feedstock has started, and Figures 7B and 7C show the evolution of the distribution of the renewable feedstock within the reaction zone (the snapshot at Figure 7C was taken after the snapshot at Figure 7B and 7A). Figures 7A to 7C illustrate how the mass fraction of the renewable feedstock at either of the boundaries of the reaction zone (i.e., either the reactor wall 12a of the reactor vessel 12 or the outer wall of the downcomer) remains relatively low through the injection of renewable feedstock and hydroprocessing of the renewable feedstock within the reactor 10. Because the mass fraction of the renewable feedstock remains relatively low at these boundaries, the acidity (i.e., corrosivity) of the renewable feedstock at the reaction zone boundaries will also remain low. These graphical representations show the effective dilution of the renewable feedstock by the contents of the catalyst bed 22.

[0130] Referring to Figure 6, there is provided a graphical illustration of the Maximum Acid Number at the reactor wall 12a of the reactor 10 over the duration of the second simulation. This plot further illustrates the effective dilution of the renewable feedstock by the reactor 10 contents after the renewable feedstock has been injected into the catalyst bed 22. The average acidnumber at wall is well below 1, although the Maximum Acid Number can momentarily rise to about 3.5.

[0131] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the above-described embodiments are intended to be examples of the present disclosure and alterations and modifications may be affected thereto, by those of skill in the art, without departing from the scope of the disclosure that is defined solely by the claims appended hereto.

Claims

WHAT IS CLAIMED IS:

1. A method for hydroprocessing an at least partially renewable feedstock within a reactor, the method comprising: injecting the at least partially renewable feedstock directly into a catalyst bed of the reactor to inhibit degradation of the wall of the reactor by the at least partially renewable feedstock; wherein the catalyst bed comprises a catalyst; and wherein the at least partially renewable feedstock contacts the catalyst to initiate hydroprocessing of the at least partially renewable feedstock.

2. The method of claim 1, wherein the at least partially renewable feedstock is injected into the catalyst bed of the reactor, at a distance from a wall of the reactor, to inhibit degradation of the wall of the reactor by the at least partially renewable feedstock.

3. The method of claim 1 or 2, wherein when the at least partially renewable feedstock is injected into the catalyst bed, the at least partially renewable feedstock within the catalyst bed has a Total Acid Number (TAN) of at least about 5.

4. The method of any one of claims 1 to 3, wherein the at least partially renewable feedstock is injected into the catalyst bed at a position therewithin such that the at least partially renewable feedstock is rapidly diluted, and the TAN of the at least partially renewable feedstock in the catalyst bed is less than about 3 mg-KOH / g at the reactor wall of the reactor.

5. The method of any one of claims 1 to 4, wherein the catalyst is selected such that the contacting of the catalyst with the at least partially renewable feedstock accelerates hydroprocessing of the at least partially renewable feedstock and at least partially neutralizes the at least partially renewable feedstock for reducing the acidity and corrosivity of at least partially renewable feedstock within the reactor.

6. The method of any one of claims 1 to 5, wherein the reactor includes a downcomer, and wherein the catalyst bed is contained in a space between the reactor wall and an outer surface of the downcomer.

7. The method of claim 6, wherein the at least partially renewable feedstock is injected into the catalyst bed at a location that is closer to a middle line of the catalyst bed than it is to the wall of the reactor, the middle line of the catalyst bed being defined at a substantially equidistance between the reactor wall and the outer surface of the downcomer.

8. The method of claim 7, wherein the at least partially renewable feedstock is injected into the catalyst bed proximate the middle line of the catalyst bed, away from the wall of the reactor.

9. The method of any one of claims 1 to 8, wherein the at least partially renewable feedstock is injected into the catalyst bed of the reactor via at least one feed line.

10. The method of claim 9, wherein the at least one feed line extends at least partially into the catalyst bed of the reactor.

11. The method of claim 9, further comprising: positioning the at least one feed line at least partially into the catalyst bed of the reactor.

12. The method of any one of claims 9 to 11 , wherein the at least one feed line is at least partially composed of at least one corrosion resistant metal.

13. The method of any one of claims 1 to 12, wherein the at least partially renewable feedstock is an at least partially liquified renewable feedstock that includes at least one of tall oil, tall oil pitch, polymer-derived pyrolysis oil, pyrolysis bio-oil, and hydrothermal liquefaction oil.

14. The method of any one of claims 1 to 13, wherein the at least partially renewable feedstock is formed from the liquefaction of at least one of a solid biomass and waste polymer.

15. The method of claim 14, wherein the at least one of a solid biomass and waste polymer includes at least one of algae, grass, waste polyethylene, and waste polystyrene.

16. The method of any one of claims 1 to 15, wherein the reactor is one of a slurry bed reactor and an ebullated bed reactor.

17. The method of any one of claims 9 to 12, wherein the at least partially renewable feedstock comprises at least one polymerizable component.

18. The method of claim 17, wherein the at least partially renewable feedstock is injected via the at least one feed line such that a maximum temperature of the at least partially renewable feedstock remains below a threshold polymerization temperature of at least one polymerizable component of the at least partially renewable feedstock.

19. The method of claim 18, wherein the at least partially renewable feedstock is injected via the at least one feed line such that an average temperature of the renewable feedstock is in a range from about 50°C to about 200°C.

20. The method of any one of claims 9 to 12 and 18 to 19, wherein the at least partially renewable feedstock is injected via the at least one feed line such that an average linear velocity of the renewable feedstock is at least about 3 ft / s.

21. The method of any one of claims 9 to 12 and 18 to 19, wherein the at least partially renewable feedstock is injected via the at least one feed line such that an average linear velocity of the renewable feedstock in the at least one feed line is in a range from about 3 ft / s to about 15 ft / s.

22. The method of any one of claims 9 to 12 and 18 to 21, wherein the at least one feed line further comprises an injection nozzle.

23. The method of claim 22, wherein the injection nozzle is structured for expelling the at least partially renewable feedstock from the at least one feed line.

24. The method of claim 22 or 23, wherein the injection nozzle is oriented within the catalyst bed such that the nozzle is directed inwards, towards a middle line of the catalyst bed.

25. The method of claim 24, wherein the injection nozzle is oriented at an acute angle relative to the middle line of the catalyst bed.

26. The method of claim 22, wherein the injection nozzle is oriented substantially parallel to a middle line of the catalyst bed.

27. The method of any one of claims 22 to 26, wherein the injection nozzle is positioned on an end portion of the at least one feed line.

28. The method of any one of claims 9 to 12 and 18 to 27, wherein the at least one feed line is mounted through a top of the reactor.

29. The method of any one of claims 9 to 12 and 18 to 28, wherein the reactor includes a catalyst addition line that is mounted through a top of the reactor; and wherein the at least one feed line is separate from the catalyst addition line.

30. The method of any one of claims 9 to 12 and 18 to 28, wherein the reactor includes a catalyst addition line that is mounted through a top of the reactor; and wherein the at least one feed line is the catalyst addition line.

31. The method of any one of claims 1 to 30, wherein the at least partially renewable feedstock is co-injected into the catalyst bed with a secondary stream of at least one fossil fuel feedstock.

32. The method of claim 31, wherein the at least one fossil fuel feedstock includes at least one of a diluent or vacuum gas oil (VGO).

33. A system for hydroprocessing a feedstock, the system comprising: a reactor that comprises a catalyst bed and at least one feed line; wherein the at least one feed line is structured for injecting the feedstock directly into the catalyst bed of the reactor, to inhibit degradation of the wall of the reactor by the feedstock; wherein the catalyst bed comprises a catalyst; and wherein the feedstock contacts the catalyst to initiate hydroprocessing of the feedstock.

34. The system of claim 33, wherein the at least one feed in line is structured for injecting the feedstock into the catalyst bed of the reactor at a distance from a wall of the reactor to inhibit degradation of the wall of the reactor by the feedstock35. The system of claim 33 or 34, wherein the at least one feed line of the reactor is structured for injecting the feedstock into the catalyst bed such that a concentration of feedstock in the catalyst bed is lower proximate the wall of the reactor.

36. The system of any one of claims 33 to 35, wherein the reactor includes a downcomer, and wherein the catalyst bed is contained in a space between the reactor wall and an outer surface of the downcomer.

37. The system of claim 36, wherein the feedstock is injected into the catalyst bed at a location that is closer to a middle line of the catalyst bed than it is to the wall of the reactor, the middle line of the catalyst bed being defined at a substantially equidistance between the reactor wall and the outer surface of the downcomer.

38. The method of claim 37, wherein the feedstock is injected into the catalyst bed proximate the middle line of the catalyst bed, away from the wall of the reactor.

39. The system of any one of claims 33 to 38, wherein the feedstock is injected into the catalyst bed at a position therewithin such that the feedstock is rapidly diluted, and the TAN of the feedstock is less than about 3 at the reactor wall of the reactor.

40. The system of any one of claims 33 to 39, wherein the at least one feed line extends at least partially into the catalyst bed of the reactor.

41. The system of any one of claims 33 to 40, wherein the at least one feed line is at least partially composed of at least one corrosion resistant metal.

42. The system of any one of claims 33 to 41 , wherein the feedstock is an at least partially liquified, at least partially renewable feedstock that includes at least one of tall oil, tall oil pitch, and tire-derived pyrolysis oil.

43. The system of any one of claims 33 to 42, wherein the feedstock is formed from the liquefaction of at least one of a solid biomass and waste polymer.

44. The system of claim 43, wherein the at least one of a solid biomass and waste polymer includes at least one of algae, grass, waste polyethylene, and waste polystyrene.

45. The system of any one of claims 33 to 44, wherein the reactor is one of a slurry bed reactor, an ebullated bed reactor, and a fluid catalytic cracking (FCC) reactor.

46. The system of any one of claims 33 to 45, wherein the wall of the reactor is formed of at least one corrosion resistant metal.

47. The system of any one of claims 33 to 46, wherein the feedstock is injected via the at least one feed line such that a maximum temperature of the feedstock remains below a threshold polymerization temperature of at least one polymerizable component of the feedstock.

48. The system of claim 47, wherein the feedstock is injected via the at least one feed line such that an average temperature of the feedstock is in a range from about 80°C to about 200°C.

49. The system of any one of claims 33 to 48, wherein the feedstock is injected via the at least one feed line such that an average linear velocity of the feedstock is at least about 3 ft / s.

50. The system of any one of claims 33 to 48, wherein the feedstock is injected via the at least one feed line such that an average linear velocity of the feedstock is in a range from about 3 ft / s to about 15 ft / s.

51. The system of any one of claims 33 to 50, wherein the at least one feed line further comprises an injection nozzle.

52. The system of claim 51, wherein the injection nozzle is structured for expelling the feedstock from the at least one feed line.

53. The system of claim 51 or 52, wherein the injection nozzle is oriented within the catalyst bed such that the nozzle is directed inwards, towards a middle line of the catalyst bed.

54. The system of claim 53, wherein the injection nozzle is oriented at an acute angle relative to the middle line of the catalyst bed.

55. The system of claim 52, wherein the injection nozzle is oriented substantially parallel to a middle line of the catalyst bed.

56. The system of any one of claims 51 to 55, wherein the injection nozzle is positioned on an end portion of the at least one feed line.

57. The system of any one of claims 33 to 56, wherein the at least one feed line is mounted through a top of the reactor.

58. The system of any one of claims 33 to 57, wherein the reactor includes a catalyst addition line that is mounted through a top of the reactor; and wherein the at least one feed line is separate from the catalyst addition line.

59. The system of any one of claims 33 to 57, wherein the reactor includes a catalyst addition line that is mounted through a top of the reactor; and wherein the at least one feed line is the catalyst addition line.

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