Method and system for fuel production in an ebullated bed reactor

Abstract

Disclosed herein are methods and systems for producing hydrocarbon products through ebullated bed reactor platforms, where the feedstock to the ebullated bed reactor for hydrotreatment may be a renewable feedstock, circular feedstock, and or a blend of renewable and circular feedstocks. The disclosed methods and processes include a recycle pump system within the ebullated bed reactor vessel. This internal recycle dilutes olefins, thereby mitigating explosive olefin hydrogenation without limiting the flow of fresh feedstock to the ebullated bed reactor.

Description

Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)PROCESS AND METHOD FOR FUELS PRODUCTION THROUGH AN EBULLATED BED REACTOR PLATFORMCROSS-REFERENCE TO THE RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent ApplicationNo. 63 / 725,748, filed November 27, 2024, the disclosure of which is hereby incorporated in its entirety.BACKGROUND

[0002] Conventional renewable fuels production is often based on coker naphtha hydrotreating. Such processes utilize a potentially large product recycle to facilitate the large amounts of heat involved in hydrogenating highly olefinic biogenic feedstocks (for example, feedstocks such as fats, oils, and greases (FOG)) and to impede explosive olefins hydrogenation. In such traditional fixed bed technologies, the exceedingly fast olefin hydrogenation may trigger oligomerization and polymerization, which may further lead to gum formation and a pressure drop. Ebullated Bed (EB) reactor platforms, such as LC-FINING, are widely used to hydrocrack heavy fossil oil feedstock, but have not traditionally been applied to renewable and / or circular feedstocks. Processes and methods for applying EB reactor platforms to the processing of renewable and circular feedstocks to produce fuels (for example, fuels for transportation and / or power / steam generation) may be desired in the industry.SUMMARY OF THE INVENTION

[0003] Disclosed herein are methods and systems for producing hydrocarbon products (and, in some examples, fuels) through EB reactor platforms, where the feedstock to the EB reactor for hydrotreatment may be a renewable feedstock, circular feedstock, and or a blend of renewable and circular feedstocks. In some examples, it has been found that feeding 100% circular and / or renewable feedstocks to an EB reactor can result in effective, efficient, and complete or near-complete conversion of the circular and / or renewable feedstocks into hydrocarbon products. The disclosed methods and processes include a recycle pump system within the EB reactor. This internal recycle dilutes olefins, thereby mitigating explosive olefin hydrogenation without limiting the flow of fresh feedstock to the EB reactor.Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)

[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE FIGURES

[0005] Non-limiting and non-exhaustive examples are described with reference to the following Figures.

[0006] FIG. 1 depicts an example EB reactor system with an internal pump system, according to an example.

[0007] FIG. 2 depicts an example process including an example EB reactor system of FIG. 1.

[0008] FIG. 3 depicts an example method for processing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks in an EB reactor, according to an example.DETAILED DESCRIPTION

[0009] In the following detailed description, references are made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrations specific embodiments or examples. These aspects may be combined, other aspects may be utilized, and structural changes may be made without departing from the present disclosure. Examples may be practiced as methods, systems, or devices. It should be understood that this invention is not limited to the particular methodology, protocols, and reagents, etc., described herein and as such may vary. The terminology used herein is for the purpose of describing particular embodiments only. The following detailed description is therefore not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims and their equivalents.

[0010] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as those commonly understood to one of ordinary skill in the art to which this invention pertains.

[0011] For the purposes of this application the following terms shall have the following meanings:Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)

[0012] As used herein and in the claims, the singular forms “a,” “an”, and “the” include the plural reference unless the context clearly indicates otherwise.

[0013] Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein should be understood as modified in all instances by the term “about.” The term “about” when used herein in connection with numerical values means ± 20% and with percentages means ±1%.

[0014] As used herein, the term “comprising” refers to a composition, compound, formulation, or method that is inclusive and does not exclude additional elements or method steps.

[0015] As used herein, the term “consisting of’ refers to a compound, composition, formulation, or method that excludes the presence of any additional component or method steps.

[0016] As used herein, the term “consisting essentially of’ refers to a composition, compound, formulation, or method that is inclusive of additional elements or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method.

[0017] Disclosed herein are methods and processes for producing fuels through EB reactor platforms that include a recycle pump system within the EB catalyst reactor, instead of a more traditional fixed bed catalyst reactor in trickle flow operation. The traditional fixed bed reactor systems may require a potentially large product recycle stream that dilutes the fresh feed to the reactor (in some examples, by about 50% to 70%). The disclosed utilization of the EB reactor platforms that include an internal recycle pump system to impose fluid circulation greatly increases the rate of fresh feed to the reactor (for example, does not require a large dilution of the feed with product). This more efficiently disperses heat within the EB reactor and dilutes the potentially explosive at-risk olefins, so that the EB reactor does not need to be derated. This enables a more consistent feed throughput and does not limit / reduce the flow of fresh feedstock. Additional efficiencies may be seen in the way of cost for these systems. For example, where feedstocks are expensive (e.g. renewable and / or biogenic feedstocks), the cost of the pump and associated systems / equipment and its operation may be less than the operational cost of operating a reactor with a high feed dilution rate.Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)

[0018] In particular, EB reactors as disclosed (for example, an LC-FINING reactor), treat hydrocarbons with hydrogen in the presence of a catalyst to produce reactor products. The products may be low-sulfur products. The products may further undergo downstream processing and refining. In examples, one or more of the disclosed EB reactors may be integrated into a larger process / system. One such example process is an LC-MAX process, wherein downstream systems include solvent de-asphalting systems.

[0019] The EB reactor as disclosed herein may be well-suited to handle many of the difficulties associated with processing a renewable and / or circular feedstocks. For example, renewable feeds may contain a large amount of oxygen that may need to be removed in order to make a suitable fuel. Ebullating bed reactors operate in a manner wherein gases such as hydrogen are typically well mixed throughout the fluidized bed. This effective mixing may reduce the amount of excess hydrogen needed in order to achieve full reaction with the oxygen in the renewable feed. Removing oxygen from a renewable feed is an exothermic reaction, and the heat generated has the potential to overwhelm the temperature control systems of a standard hydrotreatment (fixed bed) reactor. However, the mixing properties of the fluidized bed of the EB reactor minimize hot spots within the bed. Further, a recycle loop, such as the internal pumped recycle as disclosed herein, minimizes temperature increases due to reaction with a high oxygen content feedstock.

[0020] In accordance with principles of this disclosure, FIG. 1 depicts an example EB reactor system 100 with an internal pump system. Feed stream FS, a mixture of liquid feedstock and hydrogen gas (i.e., treat gas), enters reactor vessel 102 at an inlet nozzle 104. Feed stream FS enters into a first zone Z1 (for example, a bottom zone or plenum) of the reactor vessel 102. Zone Z1 may be substantially free of catalyst and may be located between the bottom of the reactor vessel 102 and a catalyst support 132.

[0021] In some examples, feedstock liquids may include a circular feedstock, renewable feedstock, or a mix of circular and renewable feedstock. 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 some examples, circular feedstock comprises liquified waste plastic (LVP), plastic pyrolysis oil, tire- derived oil (TDO), waste plastics, and any combinations thereof. Renewable feedstock is understood generally as referring to any feedstock that replenishes itselfAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) during certain processes. In some examples, the renewable feedstock comprises 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. The mix of circular and renewable feedstocks is understood generally as referring to any combination of circular and renewable feedstocks. In some examples, the mix 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 example.

[0022] The reactor fluid (including mixture of gasses and liquids, including the hydrogen and feedstock liquids) in zone Z1 travels upward through the catalyst support 132 into a second zone Z2 (for example, a catalyst zone). During operation, the reactor fluid flows upward through zone Z2. Zone Z2 may be located between the catalyst support 132 and an upper catalyst bed level BL. The reactor fluid flows through a bed 106 of catalytic particles within zone Z2 at a flow rate such that the particles are subjected to a forced random motion as the fluid passes through the catalytic bed 106 from the bottom upwards, fluidizing the catalytic bed 106. This fluidization leads to expansion of the size (e.g. volume and therefore level) of the bed as well as increased fluid mixing within the bed. The feedstock(s) and treat gas (hydrogen) typically react within the bed to form products, including liquid phase products and gas phase products.

[0023] The catalysts of catalytic bed 106 may be in the form of particles, for examples, extrudates or beads, whose diameter may be about 1mm. In some examples, the particles may have a diameter greater than about 1mm. In some examples, the particles may have a diameter less than about 1mm. The catalyst particles of catalytic bed 106 are supported on catalyst support 132 (for example, a grid), through which the feedstocks and gases flow upward from zone Z1 into zone Z2. The catalysts are not discharged with the products in effluent stream ES. The catalysts of catalytic bed 106 may be granular catalyst particles of a size (e.g. volume or diameter) smaller than that of catalyst particles typically used in an entrained bed reactor. The catalysts may contain at least one catalytically active element (for example, an hydro-dehydrogenating element) deposited on an amorphous support particle. In some examples, 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 ofAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)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 some examples, the catalysts may include CoMo / alumina and / or NiMo / alumina combinations. In some examples, other catalyst types and catalyst support particles may be contemplated.

[0024] In some examples, the catalytic activity of the catalytic bed 106 may be controlled (increased, decreased, or kept constant as desired) by online replacement of the catalyst particles. When online replacement of the catalyst particles is performed, it is not necessary to shut down the EB reactor system 100 (the EB reactor system 100 remains in operation) in order to change spent catalyst. When online replacement of the catalyst particles is performed, it is also not necessary to increase the reaction temperatures within reactor vessel 102 during the reactor cycle in order to compensate for deactivation of the catalyst over time. Online replacement of the catalyst particles contributes to obtaining constant or near-constant product yields and product qualities along the reactor cycle. Because the catalyst particles are kept in agitation (e.g. in a fluidized state) by the flow of reactor fluids in the catalytic bed 106 (including flow of reactor fluids as driven by the internal recycle pump 112), a pressure drop over the reactor vessel 102 remains low and constant, and the reaction exotherms may be rapidly averaged over the catalytic bed 106.

[0025] In some examples, spent catalyst may be at least partly replaced with fresh catalyst by withdrawing a stream of spent catalyst through catalyst withdrawal line 130 (for example, a tube or pipe) as catalyst withdrawal stream CW. The catalyst withdrawal line 130 may withdraw catalyst from the catalytic bed 106 near the bottom of the catalytic bed 106. The output of catalyst withdrawal line 130 may be at or near the bottom of reactor vessel 102. Fresh or new catalyst may be introduced into the reactor system 100 as catalyst addition stream CA at a catalyst addition nozzle 126. Catalyst addition nozzle 126 may define an entry for the catalyst into catalyst addition line 128. Catalyst addition line 128 facilitates the addition of the fresh / new catalyst into the catalytic bed 106.

[0026] Fresh or new catalyst may be introduced periodically when needed, periodically at regular time intervals, or in a continuous rate. The rate of replacement of the spent catalyst with fresh catalyst may be based on the particular reaction run and type of catalyst used. The required catalyst replacement rate can be easily monitored. The withdrawal and this addition / replacement may be performed usingAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) devices which enable continuous functioning of this hydroconversion reactions (for example, the reactor system 100 may remain in operation and does not need to be shut down).

[0027] In some examples, the spent catalyst withdrawn from the reactor as catalyst withdrawal stream CW may be processed at a downstream regeneration process, in which any carbon and sulfur contained in the spent catalyst are removed. The regenerated catalyst may be returned to the reactor system 100 as all or part of catalyst addition stream CA. In some examples, the spent catalyst withdrawn from the reactor as catalyst withdrawal stream CW may be processed at a rejuvenation process in which a treatment is performed that improves the activity of the catalyst (for example, presulfurtization, additivation, etc.). The rejuvenated catalyst may be returned to the reactor system 100 as all or part of catalyst addition stream CA.

[0028] Within the catalytic bed 106, feedstocks are exposed to the hydrogen treat gas in the presence of the catalyst. In some examples, the resulting reaction comprises hydrogenation, hydrocracking, hydrodesulfurization, hydrodenitrogenization, hydrodemetallization, hydrodeoxygenation, decarbonylation, or decarboxylation, depending on the catalyst used. Preferable processing conditions involve a liquid hourly space velocity of 0.1 to 1 hr- 1, pressure in the range of 800 - 300psig, temperature of 650 to 850° F, and a JL to feed ratio in the range of 1000- 8000 SCF / bbl.

[0029] The reactor fluid (for example, now containing at least some reaction product of the feedstock) passes through the catalytic bed 106 to reach a third zone Z3, which is substantially free of catalyst. At least some of the hydrogenated product exits the reactor at an outlet nozzle 108 as effluent stream ES. In some examples, gas phase effluent product may be a combination of desired products, unreacted treat gas (hydrogen), and / or byproduct gases, which may include contaminant gases such as H2S or NH3 formed during the reaction. In some examples, all or a portion of liquid phase effluent product may be returned to the bottom of the reactor system 100, to another EB reactor system downstream of reactor system 100 for further reaction / conversion, or to another type of process.

[0030] A fraction of the reactor fluids may be continuously and / or periodically recycled within the reactor vessel 102. Such recycled reactor fluids enter a pump inlet apparatus 110 (in some examples, a downcomer pipe) as recycle flow RF. Recycle flow RF flows downward within pump inlet apparatus 110 to an inlet of a pump 112.Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)Pump 112 pumps reactor fluid as pumped recycle stream PR into zone Zl, where the pumped recycle stream PR mixes with the fluids of feed stream FS. Pump 112 provides an additional driving force for the fluids of streams PR and FS to move upward through the catalytic bed 106. Additional driving force, in some examples, may be provided by reactor vessel 102 and / or feed stream FS pressure. The inlet 134 of the pump inlet apparatus 110 may be located within zone Z3, that is, above the upper catalyst bed level BL, to prevent catalyst particles from entering the pump 112 and from being pumped into zone Zl .

[0031] In some examples, pump 112 may be operated such that its outlet flow (pumped recycle stream PR) is maintained at a steady state, constant, flow rate. In some examples, pump 112 may be operated to maintain a steady state, constant, driving force.

[0032] The movement of the catalytic bed 106 may be controlled by a flow of the recycle liquid so that, during steady state operation of reactor system 100, the upper catalyst bed level BL does not rise above a definable level in the reactor vessel 102. The internal recycle flow contributes to the reactor system 100 operating at near isothermal conditions with only a slight axial temperature gradient.

[0033] In some examples, reactor system 100 includes a thermowell nozzle 114, via which a thermocouple may be inserted into thermowell 116. Thermowell 116 may extend into catalytic bed 106. The inserted thermocouple may be utilized to measure a temperature of the catalytic bed 106.

[0034] In some examples, reactor system 100 includes one or more skin thermocouples (for 25 examples, skin temperature indicators, transmitters, or indicating controllers) 124a, 124b, 124c.

[0035] Skin thermocouples 124a, 124b, 124c may be located on an external surface of reactor vessel 102.

[0036] In some examples, reactor system 100 includes a radiation source nozzle 118, via which a density detector radiation source may be inserted into radiation source well 120. Radiation source well 120 may extend into catalytic bed 106. One or more density detectors 122a, 122b, 122c may function in conjunction with the density detector radiation source to measure the density of the contents of the reactor vessel 102 at points along the reactor vessel 102, and thereby to determine an upper bed level BL of the catalytic bed 106.Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)

[0037] FIG. 2 depicts an example process 200 including an example EB reactor system 100. One or more EB reactor systems may be utilized in conjunction with other unit operations and systems in a wide variety of process configurations.Example process 200 illustrates just one of these examples. In example process 200, two EB reactor systems 202 and 204, which may have the properties of EB reactor system 100 as described above, operate in series. In some example, one, two, or more than two EB reactor systems may operate in series or in parallel in various processes.

[0038] In the example depicted, fresh feedstock (including treat gas) enters a first EB reactor system 202 and is processed therein. The effluent stream SI from reactor system 202 enters a second EB reactor system 204 and is processed therein. This increases the overall conversion of the feedstock to desired product. The effluent stream S2 from reactor system 204 enters a downstream system 206 (in some examples, a separator, other reactor type, or other unit type as desired). A bottoms stream S3 from system 206 (for example, unconverted feedstocks or other materials) is further processed in downstream system 208 (for example, a solvent de-asphalting process or other process as desired). A reject stream RS from system 208 may be discarded or further processed. An effluent stream S4 from process 208 may be further processed at a third EB reactor 210 (or, in some examples, at a separator, other reactor type, or other unit type as desired). In the example shown, the effluent from reactor system 210 is further processed at system 206. The product effluent PE from system 206 may be gathered, transported, and / or further processed as desired.

[0039] FIG. 2 depicts just one example of several EB reactor systems as disclosed integrated into a larger process. Incorporating one or more EB reactor systems as disclosed herein into a process may increase the overall efficiency and conversion rates of feedstocks in the process.

[0040] In some examples, optional pretreatment steps may be performed on the feedstock prior to entering into reactor system 202. In such a pretreatment step, the circular, renewable, or mix of circular and renewable feedstocks 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 circular, renewable, or mix of circular and renewable feedstocks and stabilizes said feedstocks by saturating the olefins.

[0041] In some examples, unreacted hydrogen (treat gas) may be recycled back to the fresh feedstock stream FF and reactor system 202. This may improve theAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) overall efficiency of the process. In some examples, one or more separation steps are performed to separate effluent products of stream PE (for example, into heavy and light hydrocarbon products). This may be achieved in some examples by fractionation. In some examples, a hydrotreatment system further treats distillate and vacuum gas oil (VGO) products in an integrated hydrotreater. Such a process may further remove contaminates such as sulfur, nitrogen, and / or oxygen. In some examples, hydrotreated VGO may be further hydrocracked in a hydrocracker or fluid catalytic cracking (FCC) process after separation. In some embodiments the separation process may be fractionation. In some embodiments, effluent products may be processed in an isomerization system, for example, to produce jet and diesel products if desired. In some examples, a heavy effluent product can be further refined by the separation of heavy liquid and solid in the heavy product, for example, by filtration, centrifugation, and other similar systems.

[0042] FIG. 3 depicts an example method 300 for processing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks in an ebullated bed reactor. At operation 302, a feed stream is introduced to a first zone (for example, Zl) of the ebullated bed reactor (for example, a reactor such as that described with regards to reactor system 100). The feed stream comprises a first mixture of a feedstock (for example, the circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks) and a treat gas (for example, hydrogen). The first zone of the ebullated bed reactor may be essentially free of catalyst particles.

[0043] At operation 304, a driving force provided by a pump causes (at least in part), the first mixture of the feedstock and the treat gas to flow into a second zone (for example, Z2) of the ebullated bed reactor. A pump outlet of the pump may be located in the first zone of the ebullated bed reactor. The second zone of the ebullated bed reactor may a plurality of catalyst particles. The second zone may comprise a catalytic bed (for example, catalytic bed 106).

[0044] At operation 306, the feedstock is reacted with the treat gas in the presence of the catalyst particles within the second zone of the ebullated bed reactor to produce at least a reaction product. In some examples, unanticipated or undesired reaction byproducts may also be generated.

[0045] At operation 308, the driving force causes (at least in part), a second mixture comprising at least the reaction product, unreacted feedstock, and unreactedAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) treat gas to flow into a third zone of the ebullated bed reactor. The third zone of the ebullated reactor may be substantially free of catalyst particles.

[0046] At operation 310, a first portion of the second mixture is received at a pump inlet apparatus within the third zone of the ebullated bed reactor that provides a flow path for the first portion of the second mixture to flow into a pump inlet of the pump.

[0047] At operation 312, the first portion of the second mixture is pumped into the first zone of the ebullated bed reactor via the pump outlet. In some examples, the first portion of the second mixture is mixed with the first mixture within the first zone of the ebullated bed reactor to create a third mixture. The driving force (at least in part) may cause the third mixture to flow into the second zone of the ebullated bed reactor.

[0048] In some examples, a second portion of the second mixture (for example, comprising a reaction product, unreacted treat gas, unreacted feedstock, and / or byproducts) may be received at an outlet nozzle (for example, outlet nozzle 108) of the third zone of the ebullated reactor.

[0049] Although specific aspects were described herein, the scope of the technology is not limited to those specific aspects. One skilled in the art will recognize other aspects or improvements that are within the scope of the present technology. Therefore, the specific structure, acts, or operations are disclosed only as illustrative aspects. The scope of the technology is defined by the following claims and any equivalents therein. Therefore, the specific structure, acts, or operations are disclosed only as illustrative aspects. The scope of the technology is defined by the following claims and any equivalents therein. Examples of the disclosure may be described according to the foregoing aspects.

[0050] While particular uses of the technology have been illustrated and discussed above, the disclosed technology can be used with a variety of environments in accordance with many examples of the technology. The above discussion is not meant to suggest that the disclosed technology is only suitable for implementation within the environments shown and described above. As should be appreciated, the various aspects described with respect to the figures herein are not intended to limit the technology to the particular aspects described. Accordingly, additional configurations can be used to practice the technology herein and / or some aspectsAtorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) described can be excluded without departing from the methods and systems disclosed herein.

[0051] This disclosure described some aspects of the present technology with reference to the accompanying drawings, in which only some of the possible aspects were shown. Other aspects can, however, be embodied in many different forms and should not be construed as limited to the aspects set forth herein. Rather, these aspects were provided so that this disclosure was thorough and complete and fully conveyed the scope of the possible aspects to those skilled in the art.

[0052] Similarly, where operations of a process are disclosed, those operations are described for purposes of illustrating the present technology and are not intended to limit the disclosure to a particular sequence of operations. For example, the operations can be performed in differing order, two or more operations can be performed concurrently, additional operations can be performed, and disclosed operations can be excluded without departing from the present disclosure. Further, each operation can be accomplished via one or more sub-operations. The disclosed processes can be repeated.

[0053] Although specific aspects were described herein, the scope of the technology is not limited to those specific aspects. One skilled in the art will recognize other aspects or improvements that are within the scope of the present technology. Therefore, the specific structure, acts, or operations are disclosed only as illustrative aspects. The scope of the technology is defined by the following claims and any equivalents therein.

Claims

Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)What is claimed is:

1. A method for processing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks in an ebullated bed reactor, the method comprising: introducing a feed stream to a first zone of the ebullated bed reactor, the feed stream comprising a first mixture of a feedstock and a treat gas, and the first zone of the ebullated bed reactor being essentially free of catalyst particles; causing, via a driving force provided by a pump, the first mixture of the feedstock and the treat gas to flow into a second zone of the ebullated bed reactor, a pump outlet of the pump being located in the first zone of the ebullated bed reactor, and the second zone of the ebullated bed reactor comprising a plurality of catalyst particles; reacting the feedstock with the treat gas in the presence of the catalyst particles within the second zone of the ebullated bed reactor to produce at least a reaction product; causing, via the driving force, a second mixture comprising at least the reaction product, unreacted feedstock, and unreacted treat gas to flow into a third zone of the ebullated bed reactor, wherein the third zone of the ebullated reactor is substantially free of catalyst particles; receiving a first portion of the second mixture at a pump inlet apparatus within the third zone of the ebullated bed reactor that provides a flow path for the first portion of the second mixture to flow into a pump inlet of the pump; pumping the first portion of the second mixture into the first zone of the ebullated bed reactor via the pump outlet; mixing the first portion of the second mixture with the first mixture within the first zone of the ebullated bed reactor essentially free of catalyst particles to create a third mixture; and causing, via the driving force, the third mixture to flow into the second zone of the ebullated bed reactor.

2. The method of claim 1 , wherein the treat gas comprises hydrogen.Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01)3. The method of claim 1, further comprising receiving a second portion of the second mixture at an outlet nozzle of the third zone of the ebullated reactor.

4. The method of claim 1, wherein a thermocouple is inserted into the catalyst particles of the second zone.

5. The method of claim 1 , wherein the ebullated bed reactor comprises density detectors.

6. The method of claim 1 , further comprising operating the pump at a steady state flow rate.

7. The method of claim 1 , further comprising operating the pump to maintain a steady state driving force.

8. The process of claim 1 , wherein the circular, renewable, or mix of circular and renewable feedstocks are pretreated physically or chemically.

9. The method of claim 1 , wherein the circular feedstock comprises at least one of liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), or waste plastics.

10. The method of claim 1 , wherein the renewable feedstock comprises at least one of bio crudes, lipids, or bio-residual oils.

11. The method of claim 10, wherein bio crudes comprise at least one of fast-pyrolysis bio-oil (pyoil or FPBO) or hydrothermal liquefaction oil (HTL oil).

12. The method of claim 10, wherein lipids comprise at least one of vegetable oils, used cooking oil, tallow, animal fats, or greases.

13. A system for processing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks, comprising:Atorney Docket No. 70205.0701WQU1 (T-12419-P2-WO01) an ebullated reactor vessel having a first zone, a second zone, and a third zone; a feed inlet nozzle, wherein a feed stream comprising a first mixture of a feedstock and a treat gas flows through the feed inlet nozzle into the first zone, wherein the first zone is essentially free of catalyst particles; a catalyst support configured to allow the first mixture to flow therethrough, the catalyst support located between the first zone and the second zone; a plurality of catalyst particles supported by the catalyst support and located within the second zone, wherein the feedstock reacts with the treat gas in the presence of the catalyst particles within the second zone to produce at least a reaction product; a pump inlet apparatus located within the third zone, the pump inlet apparatus receiving a first portion of a second mixture, wherein the second mixture comprises at least the reaction product, unreacted feedstock, and unreacted treat gas; a pump having a pump inlet and a pump outlet, wherein: the pump inlet apparatus defines a flow path for the first portion of the second mixture to flow into the pump inlet, and the pump outlet directs the pumped first portion of the second mixture into the first zone; and an effluent outlet nozzle, wherein an effluent stream comprising a second portion of the second mixture flows out of the third zone therethrough.

14. The system of claim 13, wherein the treat gas comprises hydrogen.

15. The system of claim 13, wherein each of the plurality of catalyst particles comprises at least one catalytically active element deposited on an amorphous support particle.

16. The system of claim 13, wherein the circular feedstock comprises at least one of liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), or waste plastics.

17. The system of claim 13, wherein the renewable feedstock comprises at least one of bio crudes, lipids, or bio-residual oils.

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