Ebullated bed reactor systems for coprocessing circular and renewable feedstock with fossil feedstock

Abstract

Disclosed herein are systems and processes for coprocessing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks with fossil feedstocks in an ebullated bed (EB) reactor. At least a portion of the renewable and / or circular feedstocks can be added to the EB reactor above its catalyst grid, alternatively feedstocks can be injected at the bottom of the EB reactor to create the fluidized bed.

Description

Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)EBULLATED BED REACTOR SYSTEMS FOR COPROCESSING CIRCULAR AND RENEWABLE FEEDSTOCK WITH FOSSIL FEEDSTOCKCROSS-REFERENCE TO THE RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No.63 / 725,829, filed November 27, 2024, the disclosure of which is hereby incorporated in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to processes and systems for coprocessing circular and / or renewable feedstocks using an EB reactor platform.BACKGROUND

[0003] Alternatives to fossil fuel feedstocks have become increasingly relevant for various industrial and commercial purposes. However, these alternative feedstocks, including circular feedstocks and renewable feedstocks, present new challenges under conventional feedstock processing systems which can include negative effects on catalyst performance and longevity, reactor health, and overall productivity. New and efficient processes for processing alternative feedstocks (e.g., circular and renewable feedstocks) have been the recent focus of development.

[0004] It would be advantageous to allow these alternative feedstocks to be processed alongside traditional fossil fuel feedstocks, simultaneously, and within legacy EB reactor systems. For instance, ebullated bed (EB) reactor platforms, such as were disclosed in WO 2022 / 204073, are widely used to hydrocrack heavy fossil oil feedstock, but have not been applied to coprocessing renewable and circular feedstocks. Processes and EB reactor systems that allow for the coprocessing of conventional fossil fuel feedstocks with circular / renewable feedstocks provide significant benefit and are the focus of this disclosure.SUMMARY

[0005] Against this backdrop the present invention was developed. Processes are disclosed herein for coprocessing a fossil feedstock with a circular feedstock and / or a renewable feedstock in an ebullated bed (EB) reactor system. In certain aspects, processes can comprise (i) flowing a first reactant stream from a first reactant feed into a mixing zoneAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) of the EB reactor, the first reactant stream comprising the fossil feedstock; (ii) flowing a second reactant stream from a second reactant feed into the EB reactor system at a position other than the mixing zone of the EB reactor (e.g., a catalytic reaction zone of the EB reactor, a first reactant feed, a product feed within the EB reactor system, a second EB reactor within the EB reactor system, an interstage flash vessel, a separator), the second reactant stream comprising the circular feedstock and / or the renewable feedstock; and (iii) contacting the fossil feedstock and the second feedstock in the catalytic reaction zone under hydroconversion conditions to produce a product stream.

[0006] EB reactor systems are also disclosed herein for the simultaneous coprocessing of fossil feedstocks with circular or renewable feedstocks into hydrocarbon products, without the need for separate processing facilities or independently run processes. In certain aspects, EB reactor systems can comprise an ebullated bed reactor comprising a mixing zone comprising a first reactor inlet, a catalytic reaction zone comprising a second reactor inlet, and a product separation zone comprising a reactor outlet. The EB reactor system can further comprise a first reactant feed terminating at the first reactor inlet into the mixing zone and a second reactant feed terminating at the second reactor inlet in the catalyst reaction zone. EB reactor systems disclosed herein can further comprise additional product feeds, waste feeds, interstage flash vessels, additional EB reactor systems arranged in series or in parallel, separation vessels, and combinations thereof.

[0007] Coprocessing feedstocks in the manner disclosed herein is achieved with reduced catalyst fouling, undesirable byproducts in the reactor, or other undesirable reactor conditions relative to methods relying on a single feedstock input location in the mixing zone of an EB reactor.BRIEF DESCRIPTION OF THE FIGURE

[0008] The Figure depicts a schematic drawing of a system comprising an example of an ebullated bed reactor system.DETAILED DESCRIPTION

[0009] Before the present processes and systems for coprocessing fossil and nonfossil feedstocks are disclosed and described, it is to be understood that this disclosure is not limited to the particular structures, process steps, or materials disclosed herein, but is extended to equivalents thereof as would be recognized by those ordinarily skilled in theAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in this specification, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a step" may include multiple steps, reference to "producing" or "products" of a reaction or treatment should not be taken to be all of the products of a reaction / treatment, and reference to "contacting" may include reference to one or more of such treatment steps. As such, the step of contacting can include multiple or repeated treatment of similar materials / streams to produce identified contact products.

[0010] Numerical values will be understood to include typical experimental variances. As used herein, the term "about" means within a statistically meaningful range of a value, such as a stated particle size, concentration range, time frame, molecular weight, temperature, or pH. Such a range can be within an order of magnitude, typically within 10%, and more typically within 5% of the indicated value or range. Sometimes, such a range can be within the experimental error typical of standard methods used for the measurement and / or determination of a given value or range. The allowable variation encompassed by the term "about" will depend upon the particular system under study, and can be readily appreciated by one of ordinary skill in the art. Whenever a range is recited within this application, every whole number integer within the range is also contemplated as an embodiment of the invention.

[0011] As used in this disclosure the word "comprises" or "comprising" is intended as an open-ended transition meaning the inclusion of the named elements, but not necessarily excluding other unnamed elements. The phrase "consists essentially of or "consisting essentially of is intended to mean the exclusion of other elements of any essential significance to the composition. The phrase "consisting of or "consists of is intended as a transition meaning the exclusion of all but the recited elements with the exception of only minor traces of impurities.EB REACTOR SYSTEMS

[0012] EB reactor systems disclosed herein are configured for coprocessing multiple feedstocks, each of which may have different components, properties, and ideal conditions for hydroconversion. As one of skill in the art will appreciate, different feedstocks may perform differently under similar reactor conditions. Conditions for any particular feedstock may be identified to maximize the reaction yield, minimize the amount ofAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) undesirable byproducts produced, and prolong catalyst lifetime and efficiency. EB reactor systems such as those disclosed in WO 2022 / 204073, are developed for the treatment of fossil feedstocks, and may be suitable for the processing of any singular feedstock under conditions that are variable. EB reactor systems disclosed herein comprise multiple feedstock feed streams fed to various positions within the reactor system to achieve ideal conditions for each feed stream within a single EB reactor system.

[0013] EB reactor systems disclosed herein for coprocessing a hydrocarbon / fossil feedstock and a circular or renewable feedstock, the system comprising an EB reactor, a first reactant feed, and a second reactant feed. In certain aspects, the EB reactor can comprise a mixing zone, a catalytic reaction zone, and a product separation zone, generally as described in WO 2022 / 204073.

[0014] For instance, the mixing zone can comprise a first reactor inlet to which the first reactant feed can be terminated and supply the mixing zone with a fossil feedstock. The catalytic zone can comprise a catalyst bed. Appropriate catalysts used to form the catalyst bed can include granular catalysts, or catalysts in the form of extrudates or beads. In other aspects, catalysts can contain at least one hydro-dehydrogenating element deposited on an amorphous support. Generally, the supported catalyst can comprise a group VIII metal chosen from the group formed by Ni, Pd, Pt, Co, Rh, and / or Ru, optionally a group of VIB metal chosen from the group Mo and / or W, on an amorphous mineral support chosen from the group formed by alumina, silica, silica-aluminas, magnesia, clays, and mixtures of at least two of these minerals. In further aspects, the catalytic zone can comprise a CoMo / alumina catalyst, a NiMo / alumina catalyst, or both.

[0015] The separation zone can operate to separate reaction products formed in the catalytic reaction zone into a liquid product and a mixed product consisting of both liquid product and gas product. Generally, the liquid product is at least 80% liquid by weight. The mixed product comprises about 80% to about 95%, or about 90% to about 95% % liquid by weight and about 5% to about 20%, or about 5% to about 10% gas by weight. A portion of the first liquid product can be pumped into the plenum mixing zone of the first ebullated bed reactor through a recirculation line. In certain aspects, the mixed product consisting of both liquid product and gas product can be routed to a product stream via a product outlet, and further to propagate through the EB reactor system, e.g., to an interstage flash vessel, a further separation vessel, other EB reactor within the system, and combinations thereof. Thus, in certain aspects, EB reactor systems can comprise a plurality of EB reactors (e.g., two EB reactors, three EB reactors, four EB reactors). It is also contemplated that EBAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) reactor systems disclosed herein may be combined with other types of reactors without limitation, in upstream or downstream orientation of any EB reactor, for further preprocessing of reagent streams and post-processing of crude products.

[0016] Systems disclosed herein may additionally comprise a second reactor inlet positioned within the catalytic reaction zone of the EB reactor. For instance, the second reactor inlet can be positioned within the catalyst bed to allow a second feedstock to be introduced separately from the first feedstock being introduced into the mixing zone of the EB reactor. In this manner the renewable and / or circular feed stock may be delivered directly within the catalytic reaction zone, bypassing the conditions of the mixing zone. In certain aspects, the second reactor inlet may be relatively near the beginning of the flow of the first reagent through the catalyst bed flowing from the mixing zone (e.g., near the bottom of the catalytic reaction zone depicted in the Figure of the Drawing). Alternatively, the second reactor inlet may be positioned toward the end of the catalyst bed (e.g., near the top of the catalytic reaction zone depicted in the Figure). Alternative arrangements are also contemplated herein, for instance where flow of the reagent proceeds concentrically from a central flow of reagent within the catalyst bed that moves radially outward toward a circumferential interface of the catalyst bed and the remaining volume of the catalytic reaction zone to which each reactant stream flows.

[0017] In systems comprising a plurality of EB reactors, any or each of the EB reactors within the system can be configured as described above to comprise a first reactant feed and a second reactant feed in independent locations allowing each feedstock to be subjected to a unique set of hydroconversion conditions as it passes through the EB reactor. As shown in the Figure and discussed below, systems disclosed herein can comprise a second reactant feed at various positions within the EB reactor system, e.g., a catalytic reaction zone, an interstage flash vessel. In certain aspects the second reactant feed can be a split feed comprising a plurality of terminations at any of the positions disclosed herein. For example, the second reactant feed can be a split feed having a first termination in the catalytic reaction zone of a first ebullated bed reactor and a second termination in an interstage flash vessel positioned between first and second EB reactors within the system. Alternatively, the second reactant feed can comprise a termination at a reactor inlet in a plurality of EB reactors, an interstage flash vessel, a separator, or any combination thereof. In certain aspects, one or more EB reactors within the system may further comprise a third reactant feed terminating at a third reactor inlet in the mixing zone.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)

[0018] A block flow diagram for a system and processes in accordance with the embodiments disclosed herein is illustrated in the Figure.

[0019] The ebullated bed reactor system depicted in the Figure comprises a first ebullated bed reactor 110, an inter-stage flash vessel 120, a second ebullated bed reactor 130, and high-pressure / high temperature separation vessel 140. The first ebullated bed reactor 110 comprises plenum mixing zone 110A, catalytic reaction zone 110B, and separation zone HOC. Catalyst particles reside in catalytic reaction zone HOB. Gas products and liquid products formed in catalytic reaction zone 110B move into separation Zone 110C where they are at least partially separated. A portion of the liquid product from separation zone 110C may be recycled back (i.e., recirculated) into mixing zone 110A.

[0020] First reactant feed 101 can be mixed with a liquid product generated in separation zone 110C, by continuously recycling the liquid product back into the mixing zone 110A. The combined feed then passes into catalytic reaction zone 110B. In certain embodiments, the ebullated bed reactor can further comprise a distribution grid between mixing zone 110A and catalytic reaction zone 110B, through which any feed streams introduced to the reactor in the mixing zone may enter the catalytic reaction zone. It will be understood that the second reactant feed 103 entering the catalytic reaction zone can remain independent from the feed passing through the distribution grid.

[0021] Gas products and the remaining liquid product from separation zone HOC leaves first ebullated bed reactor 110 as first mixed stream 111 and is routed to the interstage flash vessel 120 where the gases and liquids are separated. Interstage gas product 121 exits interstage flash vessel 120 and combines with gas product 141, which is formed from flashing inside high pressure / high temperature separation vessel 140, and combined stream 142 is routed outside of the system to a gas recovery, purification and compression system (Section 3).

[0022] The reactor system of the Figure further comprises a second ebullated bed reactor 130 with analogous features to those of first ebullated bed reactor 110, comprising a mixing zone 130A, catalytic reaction zone 130B, and separation zone 130C. The reactor system also further comprises an interstage flash vessel 120, configured to receive a product stream 111 from the first ebullated reactor and delivering a product stream 123. Inter-stage liquid product 123 exits interstage flash vessel 120 and combines with an intermediate feed 511 (e.g., a solvent comprising water) from Section 5 to form blended stream 124, which is then fed into the second ebullated bed reactor 130 through mixing zone 130A.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)

[0023] Catalyst particles reside in the catalytic reaction zone 130B. The catalyst particles in catalytic reaction zone 130B may be the same or different type of catalyst particles as those contained in catalytic reaction zone HOB. Gas products and liquid products formed from the interaction of the hydrocarbons, hydrogen and catalyst particles in the second ebullated bed reactor 130 flow from catalytic reaction zone 13 OB into separation zone 130C.

[0024] Gas products and liquid products are at least partially separated in separation zone 130C. A portion of the liquid product from separation zone 130C can be recycled back into mixing zone 130A as mentioned above. Gas products and the remaining liquid product from separation zone 130C leaves second ebullated bed reactor 130 as second mixed stream 131 and then routed to the high-Pressure / high temperature separation vessel 140 where the gases and liquids are separated. Gas product 141 exits high-pressure / high temperature separation vessel 140 and combines with gas product 121, which is formed from flashing inside inter-stage flash vessel 120, and is routed outside of the system to a gas recovery, purification and compression (Section 3) as described earlier.

[0025] Liquid product 143 exits the high-pressure / high-temperature separation vessel and is routed outside of the system for further separation and distillation (Section 4).

[0026] Fresh catalyst from Section 2 catalyst handling may be injected into either catalytic reaction zone 110B or catalytic reaction zone 130B via a top reactor nozzle, 211 A / 21 IB or bottom reactor nozzle 213A / 213B.

[0027] First ebullated bed reactor 110 further comprises a first reactor inlet in the mixing zone 110A configured to deliver the first reactant stream 1A into the ebullated bed reactor. First reactant feed 101 can terminate within the mixing zone 110A, at a first reactor inlet. In certain aspects, first reactant stream 1A comprises a fossil feedstock and can be provided into the mixing zone 110A of the first ebullated bed reactor 110 through the first reactor inlet.

[0028] First ebullated bed reactor 110 also can comprise a second reactor inlet in the catalytic reaction zone 110B. In certain aspects, second reactant feed 103 terminates at the second reactor inlet 104 and allows second reactant stream IB to be delivered to directly into catalytic reaction zone 110B of the ebullated bed reactor 110, without first passing through the mixing zone 110A. In this manner, the first and second reactant streams 1 A and IB can be fed to ebullated bed reactor 110 independently at separate locations.

[0029] Without being bound by theory, it is believed that the introduction of second reactant stream IB comprising circular and / or renewable feedstocks into the catalytic zoneAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) without first being mixed with the first reactant stream comprising fossil feedstocks prevents a significant amount of fouling solids from being generated by the reaction. Allowing fossil feedstocks to contact the first reactant stream prior to the introduction of circular and / or renewable feedstocks may result in a lesser amount of fouling solids produced during the process, while also improving or maintaining the observed hydroconversion.

[0030] Alternatively, the second reactant stream IB may be introduced at locations within the EB reactor system other than catalyst mixing zone 110B, or outside of the first EB reactor 110 altogether. As shown by dashed lines of the Figure, the second reactant stream IB alternatively may be provided within the EB reactor system via second reactant feed 105 directly into the first reactant feed 101. In this arrangement, independent control of first and second reactant streams 1A and IB into second ebullated reactor 130 can be maintained.

[0031] In a further aspect, the second feed stream IB may be introduced into the EB reactor system through feed 107 directly into an interstage flash vessel 120 operating as described above. The interstage flash vessel 120 also can receive the gaseous product mixture from first EB reactor 110 via feed 111, allowing both the fossil reactant stream 1A and the second reactant stream IB to be processed within the interstage flash vessel prior to feeding each together into second EB reactor 130 through feed 124.

[0032] In a still further alternative, the second reactant stream IB may be introduced into the EB reactor system by second reactant feed 108, directly into feed 123 carrying the product stream exiting interstage flash vessel 120 toward the second EB reactor 130. In this manner, the product from the first EB reactor 110 can be processed independently from second reactant stream IB, but each may be fed to the second EB reactor (e.g., to the mixing zone 130A of second EB reactor 130) in concert. Further still, the second reactant stream IB may be introduced directly into the catalytic reaction zone 130B of the second EB reactor 130 by second reactant feed 109, whereas the processed product stream exiting interstage flash vessel 120 may be introduced within mixing zone 130A.PROCESSES FOR COPROCESSING FEEDSTOCKS IN EB REACTOR SYSTEMS

[0033] The hydroconversion of fossil feedstocks in EB reactors and suitable conditions are generally well known, and the processes described herein can further comprise any suitable and compatible features of those known processes. For instance, processes generally can comprise recycling of reactor liquids upwards through the stirredAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) bed of catalyst. A mixture of the fossil feedstock and hydrogen can be passed from the bottom upwards over a bed of catalytic particles at a flow rate such that the particles can be subjected to a forced random motion whereas the liquid and gas pass through the bed from the bottom upwards. The movement of the catalytic bed can be controlled by a flow of recycle liquid so that, in the steady state, the mass of the catalyst does not rise above a definable level in the reactor. Vapors and liquid being hydrogenated pass through the upper level of the bed of catalytic particles to reach a zone substantially free of catalyst, and they are then discharged from the upper part of the reactor. A fraction of the reactor liquids can be continuously recycled into the reactor.

[0034] Processes disclosed herein can comprise contacting the respective feedstocks in the catalytic reaction zone under hydroconversion conditions. Hydroconversion conditions can include maintaining a temperature in the catalytic reaction zone in a range from 300 °C to 500 °C, from 370 °C to 440 °C, from 400 °C to 440 °C, from 410 °C to 440 °C, or from 420 °C to 430 °C. Hydroconversion conditions can include maintaining an operating pressure of the EB reactor in a range from 50 to 200 bar (725 to 2900 psig), 100 to 190 bar (1450 to 2750 psig), or 110 to 180 bar (1600 to 2600 psig). Conditions may further include a liquid hourly space velocity in a range from 0.1 to 1 hr-1.

[0035] Processes disclosed herein can incorporate any suitable pre-processing steps in preparation for the hydroconversion. For instance, the reactant streams can be pretreated before flowing the respective streams into the EB reactor systems. Pretreatment of the reactant streams may be particularly advantageous where the reactant stream is injected directly into the catalytic reaction zone. In certain aspects, the first and second reagent streams may be pretreated physically or chemically via filtration, water washing, hydrothermal cleanup, or mild-hydrotreating. This enables the removal of large solids or contaminants from the reactant streams and stabilizes said feedstocks by saturating the olefins.

[0036] The novel EB reactor systems as described above may be operated to conduct processes for coprocessing a fossil feedstock and a circular and / or renewable feedstock. In certain aspects, processes can comprise flowing a first reactant stream comprising the fossil feedstock from a first reactant feed into a mixing zone of an EB reactor within the EB reactor system. Separately, processes can comprise flowing a second reactant stream comprising a second feedstock (e.g., a renewable feedstock, a circular feedstock) from a second reactor feed into the EB reactor system at a position other than the mixing zone of the EB reactor. Processes further can comprise contacting the fossil feedstock and theAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) second feedstock in the catalytic reaction zone under hydroconversion conditions to produce a product stream.

[0037] In this manner, it is contemplated that the hydroconversion of the fossil feedstock and the second feedstock can be integrated within the hydroconversion processes as described above with ideal conditions for each feedstock to allow for the highest hydroconversion yield and lowest amount of undesirable byproducts (e.g., fouling solids) for each respective feedstock, without need for independent runs of EB reactor systems, or independent EB reactor systems for each feedstock.

[0038] In certain aspects, the second feedstock can be introduced directly to the first reactant feed, a product feed, a product feed exiting the EB reactor, an EB reactor within the EB reactor system, an interstage flash vessel, a separator vessel, or any combination thereof. It will be appreciated that introducing the second feedstock to combinations of locations within the EB reactor system may be accomplished through use of a split feed from a second feedstock stream, such as is described for EB reactor systems above. In aspects where the second feedstock stream is flowed to an EB reactor, the processes can comprise flowing the second reactant stream from the second reactant feed to any suitable zone of the EB reactor. For instance, in certain aspects, flowing the second reactant stream from the second reactant feed can comprise flowing the second reactant stream into a catalytic reaction zone of the EB reactor. More particularly, processes disclosed herein can comprise flowing the second reactant stream to a position of the catalytic reaction zone (e.g., within the first 20% of the catalyst bed, within the last 20% of the catalyst bed, as defined by the direction of flow).

[0039] Fossil feedstocks referred to herein generally can be any feedstock derived from a natural and non-renewable source. Certain processes disclosed herein can comprise flowing a first reactant stream comprising a fossil feedstock selected from coal, coal products, natural gas, derived gas, crude oil, petroleum products, non-renewable wastes, and combinations thereof.

[0040] In certain aspects, the second reactant stream can be a circular feedstock, a renewable feedstock, or a mixture of circular and renewable feedstocks. Circular feedstock is understood as generally referring to any feedstock that is considered as a waste or processing residue that has not been energetically used. In various embodiments of the present invention circular feedstock comprises liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), waste plastics, and any combinations thereof.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)

[0041] Renewable feedstock is understood generally as referring to any feedstock that replenishes itself during certain processes. In various embodiments of the present invention the renewable feedstock comprises materials such as bio crudes such as fast-pyrolysis biooil (pyoil or FPBO) and hydrothermal liquefaction oil (HTL oil), lipids such as vegetable oils, used cooking oil, tallow, animal fats and greases, bio-residual oils from other conversion process, or any combinations thereof.

[0042] The renewable feedstocks that can be used include any of those which comprise triglycerides. The feedstock generally originates from a biomass source selected from the group consisting of crops, vegetables, microalgae, animal fats, and combinations thereof. The renewable feedstock generally can comprise at least 25 wt. % triglycerides (e.g., at least 50 wt. %, 75 wt. %, 90 wt. %, or 95 wt. % triglycerides). Those of skill in the art will recognize that generally any biological source of lipids can serve as the biomass from which the feedstock can be obtained. It will be further appreciated that some such sources are more economical and more amenable to regional cultivation, and also that those sources from which food is not derived can be additionally attractive (so as not to be seen as competing with food).

[0043] A mixture of circular and renewable feedstocks will be understood generally as referring to any combination of circular and renewable feedstocks. In various embodiments, a mixture of circular and renewable feedstocks comprises a combination of at least one of any circular and at least one of any renewable feedstocks disclosed in any aforementioned embodiment.

[0044] In the present process the composition of reagent streams introduced to the catalytic reaction zone is not limited in their proportion to one another, with respect to the amount of feedstock contained therein. In certain aspects, the amount of fossil feedstock can be greater than the amount of circular and renewable feedstock. In other aspects, a ratio of the amount of the fossil feedstock to the amount of circular and renewable feedstock processed by the EB reactor (by weight) can be in a range from 1 : 1 to 1000: 1, from 1 : 1 to 500:1, from 5:1 to 100:1, or from 10:1 to 50:1.

[0045] In certain aspects, processes can comprise preheating the second reactant stream to a temperature in a range from 100 to 350 °C. It is contemplated herein that the second reactant stream may be pretreated in a different circuit from the primary reactant stream. In this manner, the temperature of the second reactant stream can be maintained at a lower range to prevent polymerization of more feedstocks that are more sensitive to high temperatures. In aspects where the second reactant stream comprises fast pyrolysisAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) bio-oil, the temperature of the feed may be maintained below 250°C, or below 200 °C (e.g., in range from 100 to 250 °C). This pretreatment may occur within the EB reactor system or within the second reactant feed, making use of the EB reactor system architecture described above. Reactant streams also may further comprise hydrogen prior to introduction to the EB reactor system and particularly the catalytic zone where hydrogen can be fed and continually recycled.

[0046] Processes disclosed herein may further comprise any suitable steps processing typical to EB reactors and EB reactor systems. In certain aspects, processes can comprise flowing a product stream from the EB reactor where the first and second reactant streams are contacted to a separate component of the EB reactor system, for instance a product feed, an interstage flash vessel, a second EB reactor, a separation vessel, or any combination of these (or each of these in series, as shown by the EB reactor system of the Figure).

[0047] Certain aspects may further comprise flowing the product stream to a separator, and separating the product stream into a liquid stream consisting of liquid products and gas products. In such aspects, at least a portion of the liquid products can be returned to either (or both) of the first reactant stream or the mixing zone of an EB reactor. Other aspects may further comprise flowing at least a portion of the product stream into a second EB reactor. In such aspects, the product stream can be flowed into the second EB reactor with the second reactant stream.

[0048] In certain aspects, flowing the first and second reactant stream to the EB reactor can comprise flowing the reactant streams to the first EB reactor in a series of EB reactors of an EB reactor system. In other aspects, the second reactant stream can be flowed to the second, or third reactor in the series of EB reactors. In still further aspects, flowing the reactant streams into the EB reactor system can comprise flowing one of the first or second reactant streams to the first EB reactor, and the other of the first or second reactant streams to a different EB reactor in a series of EB reactors within the EB reactor system (e.g., a second EB reactor, a third EB reactor). Additionally, or alternatively, processes disclosed herein can comprise flowing the second reactant stream into a product stream exiting the EB reactor, a product stream exiting an interstage flash vessel, or a separator.

[0049] In the present process, at least a portion of the renewable and / or circular feed to the ebullating bed reactor can be introduced at a location that is downstream from the catalyst support grid, i.e., above the catalyst grid. In a conventional ebullated bed design,Attorney Docket No. 70205.0692WOU1 (T-12455-WO01) introducing feed downstream from the catalyst support grid is not desirable, as such a feed would be less effective in creating the fluidized bed and flow patterns that are desired for proper ebullating bed operation. However, a sufficient amount of renewable feed and / or recycled feed can be introduced at the bottom of the reactor to overcome any fluidization and / or flow issues.

[0050] In certain aspects, the catalytic reaction zone comprises a catalyst supported on a catalyst grid, which the feeds and gases flow upward. The catalyst remains inside the reactors and are not discharged with the products. The catalytic activity can be kept constant by online replacement of the catalyst. It is thus not necessary to shut down the unit in order to change the spent catalyst, or to increase the reaction temperatures along the cycle in order to compensate for deactivation. Furthermore, working under constant operating conditions makes it possible to obtain constant product yields and qualities along the cycle. Also, because the catalyst is kept in agitation by a significant recycling of liquid, the pressure drop on the reactor remains low and constant and the reaction exotherms are rapidly averaged over the catalytic bed.

[0051] In one embodiment the spent catalyst is partly replaced with fresh catalyst by withdrawal from the bottom of the reactor and introducing, either at the top of the reactor or at the bottom of the reactor, fresh or new catalyst at regular time intervals, for example in bursts or almost continuously. Fresh catalyst can be introduced, for example, every day. The rate of replacement of the spent catalyst with fresh catalyst will be based on the particular reaction run and catalyst used. The required rate can be easily monitored, as is known in the industry. This withdrawal and this replacement are performed using devices which enable continuous functioning of this hydro conversion step. The unit usually includes an internal recirculation pump for maintaining the catalyst in an ebullated bed by continuous recycling of at least a portion of the liquid withdrawn at the top of the reactor and reinjected into the bottom of the reactor. It is also possible to send the spent catalyst withdrawn from the reactor to a regeneration zone, in which the carbon and sulfur which it contains are removed, and then to return this regenerated catalyst into the hydro conversion step. It is also possible to send the regenerated catalyst to a rejuvenation zone in which a treatment is performed aimed at improving the activity of the catalyst (presulfurization, additivation, etc.), then to return this rejuvenated catalyst into the hydro conversion step.

[0052] Catalysts used in EB reactors can be in the form of extrudates or beads. Typically, they contain at least one hydro-dehydrogenating element deposited on anAttorney Docket No. 70205.0692WOU1 (T-12455-WO01) amorphous support. Generally, the supported catalyst comprises a group VIII metal chosen from the group formed by Ni, Pd, Pt, Co, Rh, and / or Ru, optionally a group of VIB metal chosen from the group Mo and / or W, on an amorphous mineral support chosen from the group formed by alumina, silica, silica-aluminas, magnesia, clays and mixtures of at least two of these minerals. CoMo / alumina and NiMo / alumina catalysts are the most common.

[0053] Advantages to the hydroconversion of carbon-containing feedstocks may be realized by the processes disclosed herein. In certain aspects, the efficiency of the hydroconversion may be improved, for instance, as measured by the amount of undesirable byproducts formed during the process. In certain aspects, fouling solids may be produced during hydroconversion of the feedstock that can reduce efficiency of the process. Processes disclosed herein may result in a lesser amount of fouling solids generated, for instance, in the mixing zone of the EB reactor. In certain aspects, an amount of fouling solids in the mixing zone can be less for processes where the second reactant stream is introduced into the EB reactor system at a place other than the mixing zone of the EB reactor. In such aspects, the amount of fouling solids in the mixing zone can be less than that of otherwise identical processes wherein each of the first reactant stream and the second reactant stream are introduced within the mixing zone of the EB reactor.

[0054] Efficiency of processes disclosed herein also may be measured according to the purity of products in the product stream exiting the EB reactor. As above, processes disclosed herein may yield a product stream with higher purity than otherwise identical processes wherein each of the first reactant stream and the second reactant stream are introduced within the mixing zone of the EB reactor. The amount of hydroconversion provides an additional efficiency metric where processes disclosed herein may outperform processes wherein each of the first reactant stream and the second reactant stream are introduced within the mixing zone of the EB reactor. In certain aspects, the hydroconversion of the first and second reactant streams can be in a range from 50 wt. % to 99 wt. %, from 60 wt. % to 95 wt. %, from 60 wt. % to 80 wt. %, from 60 wt. % to 90 wt. %, or from 80 wt. % to 90 wt. %.

[0055] All patents and publications referenced herein are hereby incorporated by reference to the extent not inconsistent herewith. It will be understood that certain of the above-described structures, functions, and operations of the above-described embodiments are not necessary to practice the present invention and are included in the description simply for completeness of an exemplary embodiment or embodiments. In addition, it will be understood that specific structures, functions, and operations set forth in the above-Attorney Docket No. 70205.0692WOU1 (T-12455-WO01) described referenced patents and publications can be practiced in conjunction with the present invention, but they are not essential to its practice. It is therefore to be understood that the invention may be practiced otherwise that as specifically described without actually departing from the spirit and scope of the present invention as defined by the appended claims.

Claims

Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)What is claimed is:

1. A process for coprocessing a fossil feedstock and a circular feedstock and / or a renewable feedstock in an ebullated bed (EB) reactor system, the process comprising: flowing a first reactant stream comprising the fossil feedstock from a first reactant feed into a mixing zone of an EB reactor within the EB reactor system; flowing a second reactant stream comprising the circular feedstock and / or the renewable feedstock from a second reactant feed into the EB reactor system at a position other than the mixing zone of the EB reactor; and contacting the fossil feedstock and the circular feedstock and / or the renewable feedstock in the catalytic reaction zone of the EB reactor under hydroconversion conditions to produce a product stream.

2. The process of claim 1 , wherein flowing the second reactant stream from a second reactant feed into the EB reactor system comprises flowing the second reactant stream to a catalytic reaction zone of the EB reactor, a first reactant feed, a product feed within the EB reactor system, a second EB reactor within the EB reactor system, an interstage flash vessel, a separator, or any combination thereof.

3. The process of claim 1 , comprising flowing the second reactant stream from a second reactant feed into a catalytic reaction zone of the EB reactor.

4. The process of claim 1, wherein the second reactant stream comprises a circular feedstock selected from liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), waste plastics, and any combinations thereof.

5. The process of claim 1, wherein the second reactant stream comprises a renewable feedstock selected from bio crudes such as fast-pyrolysis bio-oil (pyoil or FPBO) and hydrothermal liquefaction oil (HTL oil), lipids such as vegetable oils, used cooking oil, tallow, animal fats and greases, bio-residual oils from other conversion process, or any combinations thereof.

6. The process of claim 1, wherein the second reactant stream comprises a circular feedstock and a renewable feedstock.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)7. The process of claim 1, wherein the fossil feedstock is selected from coal, coal products, natural gas, derived gas, crude oil, petroleum products and non-renewable wastes.

8. The process of claim 1, wherein the first reactant stream further comprises hydrogen.

9. The process of claim 1, wherein an operating pressure of the ebullated bed reactor is in the range of about 110 to about 180 bar.

10. The process of claim 1, wherein a temperature of the catalytic reaction zone is in a range of about 370 °C to about 440 °C, about 400 °C to about 440 °C, or about 410 °C to about 440 °C.

11. The process of claim 1 , wherein a temperature of the second reactant stream is in a range from 100 °C to 350 °C.

12. The process of claim 1, wherein the EB reactor is the first EB reactor in a series of EB reactors.

13. The process of claim 1 , wherein the EB reactor is the second EB reactor in a series of EB reactors.

14. The process of claim 1, further comprising flowing the product stream from the EB reactor into an interstage flash vessel.

15. The process of claim 14, further comprising flowing the second reactant stream into the interstage flash vessel.

16. The process of claim 14, further comprising flowing the second reactant stream into a product stream exiting the interstage flash vessel.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)17. The process of claim 1, further comprising flowing the product stream into a separator and separating the product stream into a liquid stream and a mixed stream consisting of liquid products and gas products.

18. The process of claim 17, comprising returning at least a portion of the liquid stream to either of the first reactant stream or into the mixing zone.

19. The process of claim 1, further comprising flowing at least a portion of the product stream into a second EB reactor.

20. The process of claim 19, wherein flowing the second reactant stream from a second reactant feed into the EB reactor system comprises flowing the second reactant stream to the second EB reactor.

21. The process of claim 1 , further comprising flowing the second reactant stream into the first reactant feed.

22. The process of claim 1 , wherein an amount of fouling solids in the mixing zone is less than that of an otherwise identical process wherein each of the first reactant stream and the second reactant stream is flowed into the mixing zone of the EB reactor.

23. The process of claim 1 , wherein a purity of the product stream is increased relative to that of an otherwise identical process wherein each of the first reactant stream and the second reactant stream is flowed into the mixing zone of the EB reactor.

24. The process of claim 1, wherein a hydroconversion of the fossil feedstock, the circular feedstock, the renewable feedstock, or any combination thereof is greater than that of an otherwise identical process wherein each of the second reactant stream is from a second reactant feed into the mixing zone.

25. The process of claim 1, wherein the hydroconversion of the fossil feedstock, the circular feedstock, the renewable feedstock, or any combination thereof, is in a range from 60 to about 80 weight %, about 60 to about 90 weight %, or about 80 to about 90 weight %.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)26. The process of claim 1 , wherein a ratio of an amount of the fossil feedstock to an amount of the circular feedstock and renewable feedstock (by weight) is in a range from 5:1 to 100:1.

27. The process of claim 1, wherein the second reactant stream is flowed into the catalytic reactant zone at a liquid hourly space velocity in a range from 0.1 to 1 hr1.

28. A system for coprocessing a hydrocarbon / fossil feedstock and a renewable feedstock, the system comprising: an ebullated bed reactor, the ebullated bed reactor comprising: a mixing zone comprising a first reactor inlet; a catalytic reaction zone comprising a second reactor inlet; a product separation zone comprising a reactor outlet; a first reactant feed terminating at the first reactor inlet into the mixing zone; a second reactant feed terminating at the second reactor inlet in the catalyst reaction zone.

29. The system of claim 28, wherein the first reactant feed comprises a feed distributor.

30. The system of claim 28, wherein the second reactor feed comprises a feed nozzle.

31. The system of claim 28, wherein the catalytic reaction zone comprises a catalyst bed.

32. The system of claim 31 , wherein the second reactor inlet is positioned in the catalyst bed.

33. The system of claim 28, further comprising a product outlet in the product separation zone.Attorney Docket No. 70205.0692WOU1 (T-12455-WO01)34. The system of claim 28, further comprising a product feed extending from the product outlet.

35. The system of claim 28, further comprising a separation vessel.

36. The system of claim 28, comprising a plurality of ebullated bed reactors.

37. The system of claim 36, comprising two ebullated bed reactors.

38. The system of claim 36, wherein each ebullated bed reactor comprises a first reactant feed and a second reactant feed.

39. The system of claim 38, further comprising a third reactant feed terminating at a third reactor inlet in the mixing zone.

40. The system of claim 36, further comprising an interstage flash vessel between at least two the plurality of ebullated bed reactors.

41. The system of claim 40, wherein the interstage flash vessel comprises a reactant feed.

42. The system of claim 38, wherein the second reactant feed is a split feed comprising a plurality of terminations.

43. The system of claim 42, wherein the second reactant feed further comprises a termination at a reactor inlet in a plurality of ebullated bed reactors, an interstage flash vessel, a separator, or any combination thereof.

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