Coprocessing circular and renewable feedstocks in an ebullated-bed (EB) reactor platform

Abstract

Provided is a process for coprocessing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks with fossil feedstocks in one or more ebullated-bed (EB) reactors. At least a portion of the renewable and / or circular feedstocks is injected in at least one EB reactor above its catalyst grid, while a sufficient amount of all feedstocks is injected at the bottom of the EB reactor to create the fluidized bed.

Description

Attorney Docket No.: 70205-0697WOU1COPROCESSING CIRCULAR AND RENEWABLE FEEDSTOCKS IN AN EBULLATED-BED (EB) REACTOR PLATFORMCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and benefit of U.S. Provisional Patent Application No. 63 / 752,436 filed 31 January 2025, the complete disclosure of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present process relates to efficiently using an EB reactor platform in producing fuels from circular and renewable feedstocks.BACKGROUND

[0003] The production of fuels from non-fossil feedstock is becoming more and more important in reducing the fossil carbon footprint and tackling climate change. The industry is in need of new, useful, and more efficient processes for addressing the treatment of circular and renewable feedstocks. Ebullated-Bed (EB) reactor platforms, such as LC-FINING, are widely used to hydrocrack heavy fossil oil feedstock, but have not been applied to the processing of renewable and circular feedstocks commercially. To provide novel and more efficient processes for coprocessing renewable and circular feedstocks with fossil feeds to produce transportation fuels would be of great interest to the industry.SUMMARY

[0004] Against this backdrop the present process was developed. The claimed process offers a new efficient method of addressing the need to produce fuel from nonfossil feedstocks. In one embodiment the present process provides a new, useful, and efficient process of transforming circular, renewable, or a mix of circular and renewable feedstock into fuel. The process utilizes an EB reactor where the circular, renewable, or a mix of circular and renewable feedstock is added to the reactor separately or together with fossil fuels. In one embodiment of the present process, feedstock is injected at the bottom of the EB reactor, and above the catalyst support grid.

[0005] Among other factors, it has been found that feeding circular or renewable feedstocks to an EB reactor together with fossil fuels can result in effective, efficient,Attorney Docket No.: 70205-0697WOU1and complete conversion of the feedstocks into hydrocarbon products. The key is the use of an EB reactor, and the points of injection of the feedstocks. By injecting at least some of the renewable and / or circular feedstock above the catalyst grid in the EB reactor, while still injecting sufficient feedstock at the bottom of the EB reactor, the process can proceed more smoothly and efficiently. The hydrocarbon product can then be separated into various cuts of different fuels or further refined to a finished fuel. Fuels such as base oils, gasoline, diesel fuel, and jet fuel can ultimately be obtained via the EB reactor. This results in expedient coprocessing of the circular and / or renewable sources with fossil feed, which is beneficial to the industry.

[0006] The present process offers a new efficient method of addressing the need to produce fuel from non-fossil feedstocks.BRIEF DESCRIPTION OF THE FIGURES

[0007] FIG. 1 depicts an EB reactor with an internal recirculation pump.

[0008] FIG. 2 depicts an EB reactor with an external recirculation pump.

[0009] FIG. 3 illustrates one configuration of EB reactors.

[0010] FIG. 4 illustrates a second configuration of EB reactors.

[0011] FIG. 5 illustrates a third configuration of EB reactors.

[0012] FIG. 6 illustrates a fourth configuration of EB reactors.

[0013] FIG. 7 illustrates a fifth configuration of EB reactors.DETAILED DESCRIPTION

[0014] Before the present processes for producing fuel from non-fossil 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 the 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 "treating" may include reference to one or more of such treatment steps.Attorney Docket No.: 70205-0697WOU1As such, the step of treating can include multiple or repeated treatment of similar materials / streams to produce identified treatment products.

[0015] Numerical values with "about" 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.

[0016] Central to the present invention is the ebullated bed (EB) reactor. The functioning of the EB reactor, including the recycling of reactor liquids upwards through the stirred bed of catalyst, is generally well known. A mixture of feedstock and hydrogen is passed from the bottom upwards over a bed of catalytic particles at a flow rate such that the particles are 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 is 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.

[0017] EB technologies use supported catalysts, generally in the form of extrudates or beads whose diameter is generally of the order of about 1 , or less than 1.5 mm. The catalysts are supported on a catalyst grid, through which the feeds and gases flow. The catalysts remain 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 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 inAttorney Docket No.: 70205-0697WOU1agitation 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.

[0018] 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.

[0019] 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 or external 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 which it contains is 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 (presulfurtization, activation, etc.), then to return this rejuvenated catalyst into the hydro-conversion step.

[0020] A fluidized bed reactor, such as an ebullating bed reactor, is well-suited to handle many of the difficulties associated with processing renewable or circular feedstocks. For example, renewable feeds typically contain a large amount of oxygen that may need to be removed in order to make a suitable fuel. Ebullating bed reactors can have an advantage in that 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 also an exothermic reaction, which has the potential to overwhelm the temperature control systems of a standard fixed-bed hydrotreatment reactor. In addition to the mixing advantages of a fluidized bed, which should minimize hot spots within the bed, ebullating bed reactors also typically operate with a recycle loop. Recycling of the feed can dampen any temperature increase due to reaction with a high oxygen content feedstock.

[0021] Turning to the figures of the drawing, FIG. 1 depicts one embodiment of an EB reactor with an internal recirculation pump, whereas FIG. 2 depicts one embodiment ofAttorney Docket No.: 70205-0697WOU1an EB rector with an external circulation pump. In the specific embodiments provided in FIG. 1 and FIG. 2, the residuum hydrocracking reactor 10 is an LC-Finning-type ebullated bed residuum hydrocracking rector 10a. The same numbers will refer to the same items in each figure.

[0022] In at least some embodiments, the residuum hydrocracking reactor 10 is capable of hydrocracking heavy residuum product. The residuum hydrocracking reactor 10 can have a reactor vessel 12, with the reactor vessel 12 defining an interior reaction chamber that contains the catalyst bed 22. The residuum hydrocracking reactor 10 also includes the at least one catalyst addition line 19 for injecting at least one catalyst (such as the at least one hydroprocessing catalyst) into the catalyst bed within the interior reaction chamber. The at least one catalyst addition line 19 is structured for delivering a fresh supply of the at least one hydroprocessing catalyst to the catalyst bed 22 within the reactor vessel 12.

[0023] The residuum hydrocracking reactor 10 can include a plurality of catalyst addition lines 19, and the plurality of catalyst addition lines 19 are mounted through a top of the reactor vessel 12 and extend down into the catalyst bed 22. In an additional embodiment, 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.

[0024] The reactor 10 can further comprise a downcomer 26 that is contained within the reactor vessel 12. The reactor 10 can 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 can be defined towards the top of the reactor vessel 12.

[0025] 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. The reactor vessel 12 of the ebullated bed residuum hydrocracking reactor 10a is fitted with an inlet conduit 16 for feeding reaction components and a hydrogen-containing gas.

[0026] The reactor vessel 12 includes a lower chamber and an upper chamber within the interior reaction chamber of the reactor vessel 12. The residuum hydrocracking reactor 10 includes a distributor plate 20, and the distributor plate 20 is mounted within the reactor vessel 12 so as to define a boundary between the lower and upper chambers ofAttorney Docket No.: 70205-0697WOU1the 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.

[0027] The residuum hydrocracking reactor 10 can, in some embodiments, include a conventional inlet line through which feedstock would normally be introduced. The reactor vessel can also include a gas introduction line for introducing a hydrogencontaining gas as part of the hydroprocessing reaction within the residuum hydrocracking reactor 10. This gas introduction line can be formed together within the conventional inlet line to form the inlet conduit 16. Alternatively, the conventional inlet line and gas introduction line gas be formed as separate conduits.

[0028] In the specific embodiments provided in FIGS. 1 and 2, 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 therethrough, and a catalyst withdrawal conduit 17 for withdrawing spent catalyst from the interior of the reactor vessel 12.

[0029] In an additional embodiment such as provided in FIGS. 1 and 2, the residuum hydrocracking reactor 10 further comprises a liquid feed recirculation system that has a recirculation pump 23 that is fluidly connected between the interior of the downcomer 26 and inlet end of the reactor vessel 12. The operation of the recirculation pump 23 provides the required pressure differential for circulating the fluid in the residuum hydrocracking reactor 10.

[0030] In at least one embodiment, the recirculation pump 23 is configured as an internal recirculation pump as shown in FIG. 1.

[0031] In another embodiment, the recirculation pump 23 is configured as an external recirculation pump as shown in FIG. 2. The external recirculation pump is positioned separately, but fluidly connected, to the rest of the residuum hydrocracking reactor 10.

[0032] In an additional embodiment, the residuum hydrocracking reactor 10 includes a flow-through pan 27 that is disposed near a top end of the reactor vessel 12.

[0033] In the operation of the residuum hydrocracking reactor 10, the fluidized product may pass through the distributor plate 20 for distributing the product from the lower chamber, up into the catalyst bed 22. As the fluids flow up into the catalyst bed 22, the catalyst particles are thereby forced into an upward movement by the gas flow and the liquid flow. The upward liquid flow is sufficient to cause the mass of catalyst in the catalyst bed 22 to expand, thus permitting gas and liquid flow up through residuum hydrocracking reactor 10.Attorney Docket No.: 70205-0697WOU1

[0034] In an additional embodiment, the reactor 10 further comprises at least one secondary outlet. The at least one secondary outlet is positioned towards a bottom of residuum hydrocracking reactor 10 for removing sedimented particles from within the reactor 10. The at least one secondary outlet can be connected to various external structures or process elements for handling the sedimented particles. For example, the at least one secondary outlet can be connected to a control valve and a pressure transfer vessel for controlling the withdrawal of the sedimented particles. Alternatively, the at least one secondary outlet can be connected to a separator unit via a regular letdown connection.

[0035] In one embodiment, the system comprises the hydrocracking reactor 10, the recirculation pump 23 that is fluidly connected to the hydrocracking reactor 10 for circulating the product therethrough, and at least one controller that includes at least one processor and memory with instructions stored thereon. The instructions stored on the memory are executable by the at least one processor for controlling the operation of the hydrocracking reactor 10. As shown in FIG. 1, the system can also include at least one sensor element 30 for measuring at least one control variable within the residuum hydrocracking reactor 10.

[0036] In the present process, renewable and / or circular feedstock can also be injected above the catalyst grid. To facilitate use of lower quality feeds in the processes according to the invention, a modified ebullating bed reactor can be used. In a conventional ebullating bed reactor, both the feedstock and the treat gas (e.g., hydrogen) are typically introduced into the reactor from the bottom. A recycled feed containing a portion of the reactor effluent is also optionally but typically introduced into the bottom of the reactor. These streams typically flow upward into the reactor and pass through a catalyst support grid. The catalyst support grid is designed to inhibit / prevent catalyst from entering the areas at the bottom of the reactor where the feed pumps are located. The catalyst in the ebullating bed reactor is generally located above the catalyst support grid.

[0037] When the feedstock and gas flows reach the catalyst bed, the bed typically becomes fluidized, leading to expansion of the size of the bed as well as to mixing within the bed. The feed(s) and treat gas (hydrogen) typically react within the bed to form products, typically including liquid phase products and gas phase products. The flow in the reactor generally continues upward until an effluent is drawn off the reactor at the top. This gas phase effluent can typically be a combination of desired products, unreacted treat gas (hydrogen), and byproduct gases, generally including contaminant gases such asAttorney Docket No.: 70205-0697WOU1H2S or NH3 that were formed during the reaction. All, or more usually a portion, of the liquid phase effluent can be recycled to the bottom of the reactor. Generally, the gases are separated from the liquid product, and the hydrogen-containing gas can be recycled back to reactor, if desired.

[0038] 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. In a conventional ebullating bed design, 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 circular feed can be introduced at the bottom of the reactor to overcome any fluidization and / or flow issues. The introduction of renewable feed and / or circular feed above the catalyst grid also allows the rapid interaction of these feeds with the catalyst and achieves efficient and fast removal of acid number, unstable olefins or contaminants such as oxygen, halogens, etc.

[0039] FIGS. 3-7 depict various configurations of EB reactors that are useful in the present process. Turning to FIG. 3, one embodiment of a configuration of EB reactors is shown for use in transforming circular, renewable, or a mix of circular and renewable feedstocks into fuel. In the figure, fossil feedstocks 52 can be added to the first EB reactor 51 at the low location 53. Renewable and / or circular feedstocks 54 can also be added at location 53. Optional injection points 55 of renewable and / or circular feedstocks are also shown at 56, 57, and 58. One or more of these injection points might also be used for adding renewable and / or circular feedstocks. As the reaction proceeds, reaction products are removed from the top of EB reactor 51 at 59 and passed to an inter-stage flash (ISF) unit 60. Product that flashes off is passed via 61 to further treatment or use. Product 62 from the bottom of the unit 60 is then passed to a second EB reactor 63, and added to the reactor at 64. Product is removed from the top of EB rector 63 and passed via 65 to a separation and fractionation unit 66, which is generally a distillation column, from which various cuts can be made. In FIG. 3, light products 67 are removed from the top of unit 66, while unconverted oil is removed from the bottom, for example, vacuum tower bottoms (VTB). Both are passed onto further treatment or use in making commercial products.

[0040] FIG. 4 shows another embodiment in which a configuration of two EB reactors is employed, but with different points of injection of renewable and / or circularAttorney Docket No.: 70205-0697WOU1feedstocks. The same numbers in FIG. 4 as in FIG. 3 refer to the same units. The same configuration as in FIG. 3 is employed except that renewable and / or circular feedstocks 70 are added to the second EB rector 63 at 64. Optional injection points 71 for the renewable and / or circular feedstocks into the second EB reactor 63 are shown at 72, 73, and 74.

[0041] Turning to FIG. 5, an embodiment in which a configuration of three EB reactors is shown. In the figure, fossil feedstocks 82 can be added to the first EB reactor 81 at the low location 83. Renewable and / or circular feedstocks 84 can also be added at location 83. Optional injection points 85 of renewable and / or circular feedstocks into unit 81 are also shown at 86, 87, and 88. One or more of these injection points might also be used for adding renewable and / or circular feedstocks. As the reaction proceeds, reaction products are removed from the top of EB reactor 81 at 89 and passed to a second EB reactor 100, and added to the reactor 100 at 101. Products is removed from the top of EB reactor 100 at 102 and passed to an ISF unit 103. Product that flashes off is passed via 104 to further treatment or use. Product 105 from the bottom of the unit 103 is then passed to a third EB reactor 106, and added to the reactor at 107. Product is removed from the top of EB rector 106 and passed via 108 to a separation and fractionation unit 109, which is generally a distillation column, from which various cuts can be made. In FIG. 5, light products 110 are removed from the top of unit 109, while unconverted oil 111 is removed from the bottom. Both are passed onto further treatment or use in making commercial products.

[0042] FIG. 6 shows another embodiment in which a configuration of three EB reactors is employed, but with different optional points of injection of renewable and / or circular feedstocks. The same numbers in FIG. 5 as in FIG. 6 refer to the same units. The same configuration as in FIG. 5 is employed except that renewable and / or circular feedstocks 120 are added to the third EB reactor 106 at 107. Optional injection points 121 for the renewable and / or circular feedstocks into the third EB rector 106 are shown at 122, 123, and 124. One or more of these injection points might also be used for adding renewable and / or circular feedstocks.

[0043] FIG. 7 shows another embodiment in which a configuration of three EB reactors is employed, but with additional optional points of injection of renewable and / or circular feedstocks. The same numbers in FIG. 7 as in FIGS. 5 and 6 refer to the same units. The same configuration as in FIGS. 5 and 6 is employed except that additional optional injection points are available for renewable and / or circular feedstocks forAttorney Docket No.: 70205-0697WOU1injection into the third EB reactor 106. Renewable and / or circular feedstocks 130 are added to the third EB rector 106 at 107. Optional injection points 121 for the renewable and / or circular feedstocks into the third EB rector 106 are shown at 122, 123, and 124, and as in FIG. 6., optional injection points 85, as in FIG. 5, are also possible. One or more of these injection points might also be used for adding renewable and / or circular feedstocks. Thus, in the embodiment of FIG. 7, optional injection points exist for both the first EB rector 81 and the third EB rector 106.

[0044] Catalysts used in an EB reactor are widely marketed. The catalyst is usually in the form of extrudates or beads. Typically, they contain at least one hydrogenating element deposited on an 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.

[0045] Generally, in step a) of the present process a fossil feedstock is added to an EB reactor. Fossil feedstock is understood as generally referring to any feedstock that is formed in the ground from the remains of dead plants and animals by exposure to heat and pressure. In various embodiments of the present invention fossil feedstock comprises vacuum gas oil, FCC cycle oil, atmospheric residue, vacuum residue, bitumen, asphalt, deasphalted oil, deasphalter pitch, tar, shale oil residue, coal-derived oil residue, and any combinations thereof.

[0046] Generally, in step b) of the present process, a circular, renewable, or a mix of circular and renewable feedstock is added to the EB reactor. 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 process 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 itself during certain processes. In various embodiments of the present process renewable feedstock comprises municipal waste, crude tall oils, tall oil pitch (TOP), 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 ofAttorney Docket No.: 70205-0697WOU1circular and renewable feedstocks is understood generally as referring to any combination of circular and renewable feedstocks. In various embodiments 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 embodiment.

[0047] In one embodiment, in step b), the circular, renewable, or a mix of circular and renewable feedstocks are injected into the EB reactor via the same feed line as the fossil fuel. In step b) of other embodiments the circular, renewable, or a mix of circular and renewable feedstocks are heated in a separate heat exchanger and subsequently injected into the EB reactor via a feedline separate from the fossil fuel. In step b) of still another embodiment some renewable feedstocks can be injected into the EB reactor in small quantities via the EB catalyst addition pipe. When a series of EB reactors is used, for all embodiments the circular, renewable, or a mix of circular and renewable feedstocks can be injected into the first EB reactor or can be injected into the second EB reactor or last EB reactor. Additionally, depending on the difficulty of the feedstock, embodiments of the present invention allow for one type of circular, renewable, or a mix of circular and renewable feedstock to be injected into the first EB reactor, while another type of circular, renewable, or a mix of circular and renewable feedstock can be injected into the second EB reactor or last EB reactor. As discussed above, however, the present process does inject at least a portion of the renewable and / or circular feed above the catalyst grid of any EB reactor in which it is injected, either via a new port, the catalyst addition pipe, or a new pipe to the recycle pan or the recycle downcomer.

[0048] In one embodiment an optional pretreatment step can occur prior to step b). In this pretreatment step, the circular, renewable, or a mix of circular and renewable feedstocks are 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 a mix of circular and renewable feedstocks and stabilizes said feedstocks by saturating the olefins.

[0049] In the present process there exists a plurality of options regarding the amount of circular feedstock, renewable feedstock, or a mix of renewable and circular feedstocks that can be added to the fossil feedstock. In various embodiments the amount of circular feedstock, renewable feedstock, or amount of the combined renewable and circular feedstock as of the volume of the total combined feedstocks, including fossil feedstock, ranges from 1-90%, 3-70%, 3-50%, 3-40%, 3-30%, 3-20%, 3-15%, 3-10%, 5-30%, 5-20%, 5-15%, 5-10%, or 10-20%. Preferably 5-20%, 5-15% or 5-10%.Attorney Docket No.: 70205-0697WOU1

[0050] In step c) of the present process a reaction step is performed in the EB reactor wherein the feedstocks from step a) and b) are exposed to hydrogen and an EB catalyst. In some embodiments the reaction in step c) comprises hydrogenation, hydrocracking, hydrodesulfurization, hydrodenitrogenation, hydrodemetallization, hydrodeoxygenation, decarbonylation, or decarboxylation. Preferable processing conditions involve a liquid hourly space velocity of 0.1 to 5 hr- 1, pressure in the range of 800-3000 psig, temperature of 650 to 850 °F, and a FL to feed ratio in the range of 2000-10000 SCF / bbl.

[0051] In one embodiment, unreacted hydrogen can be recycled back to the front-end reactor. Such recycling of the hydrogen can greatly improve the overall efficiency and economics of the process.

[0052] In step d) of the present process, a separation step is performed to separate the products of step c) into heavy and light hydrocarbon products. The number of cuts of hydrocarbon products can vary and will depend on the ultimate product goal of the reaction.

[0053] In one embodiment a hydrotreatment step e) occurs. In this hydrotreatment step distillate and vacuum gas oil (VGO) products can be further hydrotreated in an integrated hydrotreater. Doing so further removes contaminates such as sulfur, nitrogen, and oxygen. In another embodiment after the optional hydrotreatment step e) occurs, hydrotreated VGO can be further hydrocracked in a hydrocracker or fluid catalytic cracking (FCC) process after separation. In some embodiments the separation process can be fractionation.

[0054] In one embodiment a hydrotreatment step f) occurs. In this hydrotreatment step heavy product can be hydrotreated in a heavy oil hydrotreater to produce very low sulfur fuel oil (VLSFO).

[0055] In some embodiments, isomerization is subsequently needed after step e). In one embodiment isomerization is needed to produce jet and diesel products.

[0056] In some embodiments additional liquid circular or renewable feedstocks can be added to an existing integrated hydrotreater in an EB unit without affecting its overall performance. In one embodiment the amount of additional liquid circular or renewable feedstocks is from 3-20% of the original capacity.

[0057] It has been found that feeding circular or renewable feedstocks to an EB reactor together with fossil fuels can result in effective, efficient, and complete conversion of the feedstocks into hydrocarbon products. By injecting at least some of the renewable and / or circular feedstock above the catalyst grid in the EB reactor, while still injecting sufficientAttorney Docket No.: 70205-0697WOU1feedstock at the bottom of the EB reactor, the process proceeds smoothly and efficiently. The hydrocarbon product can then be separated into various cuts of different fuels or further refined to a finished fuel. Fuels such as gasoline, diesel and jet fuel, or base oils can ultimately be obtained via the EB reactor. This results in expedient coprocessing of the circular and / or renewable sources with fossil feed, which is beneficial to the industry.

[0058] The present examples are provided in order to further illustrate the present process and its benefits. The examples are not meant to be limiting.Examples 1-6:

[0059] A pilot plant test was used to coprocess tall oil pitch (TOP) with fossil vacuum residue (VR) in a 2-reactor Mini-Ebullated Bed Upflow unit (MEBU), a lab-version of a commercial EB unit. Table 1 lists the feedstocks tested in a MEBU campaign to demonstrate the coprocessing of fossil feedstock with a renewable feedstock. The fossil VR (Example 1) had an API gravity of 2 degrees and contained high S, N, and MCR (micro carbon residue), but it had low acid number and bromine number. Its oxygen content was less than 0.5%, based on elemental balance. The renewable feedstock TOP (Example 2) had API gravity at 10.7 degrees. TOP had low S and N content, but it had very high acid number and bromine number. Its oxygen content was 8.8%, based on elemental balance. TOP contained more Fe, Na and Si than the VR.

[0060] Table 2 compares the operating conditions, conversion and liquid oil yield for the coprocessing of fossil VR and TOP in the MEBU. Examples 3 and 5 were base cases with 100% VR, while Examples 4 and 6 were coprocessing cases with 17% TOP. For the coprocessing cases, the liquid hourly space velocity (LHSV) was about 17% higher than the base cases, because the VR rate did not change during the coprocessing tests. Almost the same conversion for S, 1075°F+ (580°C+) and metal (V+Ni) was obtained with and without TOP coprocessing, suggesting that TOP was effectively converted and its addition did not affect the VR conversion. For the liquid oil yield, higher yields of diesel (482-680°F) (250-360°C) and less VGO (680-1075°F) (360-580°C) were obtained.Table 1. Feedstocks processed in a Mini Ebullated-Bed Upflow (MEBU) pilot plant.Attorney Docket No.: 70205-0697WOU1<<<<<<Table 2. Operating conditions, conversion and liquid oil yield for the coprocessing of fossil VR and TOP in MEBU"Attorney Docket No.: 70205-0697WOU1Examples 7 and 8:

[0061] A case study was performed to evaluate coprocessing of fossil VR with liquified waste plastics (LWP) in a commercial EB unit with three EB reactors. Table 3 lists the operating conditions and yields from the study. Example 7 is the base case with 100% fossil feed. For the coprocessing case Example 8, LWP is added to the first reactor and accounts for 10% of total feed. About 2% LWP (as of total feed) is added to the bottom of the reactor, while about 8% LWP (as of total feed) is injected to the reactor above the catalyst grid. Higher distillate yields (300°F-, 300-500°F and 500-680°F) (149°C-, 149-260°C and 260-360°C) and less heavy product yield (680-1050°F and 1050°F+) (360-565°C and 565°C+) are obtained.Table 3. Case study of coprocessing fossil VR with liquified waste plastics (LWP) in a commercial EB unit with three EB reactorsAttorney Docket No.: 70205-0697WOU1Examples 9 and 10:

[0062] Another case study was performed to evaluate coprocessing of fossil VR with soybean oil and plastics pyrolysis oil (Pyoil) in a commercial EB unit with three EB reactors. Table 4 lists the operating conditions and yields from this case study. Example 9 is the base case with 100% fossil feed at 806°F and 0.18 hr1LHSV. For the coprocessing case in Example 10, 80% fossil feedstock is injected to the first EB reactor from bottom. A total of 10% soybean oil is added to the first EB reactor, while half of the soybean oil is injected to the reactor bottom and another half of soybean oil is added to the catalyst bed above the catalyst grid. Ten percent of plastics Pyoil is added to the third reactor, with half of the plastic pyoil is injected to the reactor bottom and another half of plastics Pyoil is added to the recycle pan on the top of the reactor. Relative to the base case (Example 9), significantly higher yields of jet fuel (293-500°F) (145-200°C) and diesel (500-690°F) (260-365°C) are achieved, while the yields of VGO (690-1022°F) (365-550°C) and VTB (1022°F+) (550°C+) are significantly reduced.Table 4. Case study of coprocessing fossil VR with liquified waste plastics (LWP) in a commercial EB unit with three EB reactors

[0063] 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 anyAttorney Docket No.: 70205-0697WOU1essential 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.

[0064] 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-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.: 70205-0697WOU1What is claimed is:

1. A process for coprocessing circular feedstocks, renewable feedstocks, or a mix of both renewable and circular feedstocks with a fossil feed in an ebullated-bed (EB) reactor, comprising:a) adding fossil feedstock to said EB reactor;b) adding one or more of the circular, renewable, or mix of circular and renewable feedstocks to the EB reactor, with at least a portion added above a catalyst grid of the EB reactor;c) performing a catalytic reaction in said EB reactor wherein the feedstocks from step a) and step b) are exposed to hydrogen and an EB catalyst; andd) separating the products of the reaction in step c) into heavy and light hydrocarbon products.

2. The process of claim 1, wherein, a pretreatment step occurs before step b) wherein the circular, renewable, or mix of circular and renewable feedstocks are pretreated physically or chemically.

3. The process of claim 1, wherein the circular feedstock comprises liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), or waste plastics.

4. The process of claim 1 , wherein the renewable feedstock comprises crude tall oils, tall oil pitch (TOP), bio crudes, lipids, or bio-residual oils from other conversion processes.

5. The process of claim 4, wherein the renewable feedstock comprises tall oil pitch or lipids.

6. The process of claim 4, wherein bio crudes comprise fast-pyrolysis bio-oil (pyoil or FPBO), or hydrothermal liquefaction oil (HTL oil).

7. The process of claim 4 or 5, wherein lipids comprise vegetable oils, used cooking oil, tallow, animal fats and greases.Attorney Docket No.: 70205-0697WOU18. The process of claim 1, wherein the mix of circular and renewable feedstocks comprises a combination of liquified waste plastic (LVP), plastic pyrolysis oil, tire-derived oil (TDO), or waste plastics, and crude tall oils, tall oil pitch (TOP), bio crudes, lipids, or bio-residual oils from other conversion process.

9. The process of claim 1, wherein the fossil feedstock comprises vacuum gas oil, FCC cycle pol, atmospheric residue, vacuum residue, bitumen, asphalt, deasphalted oil, deasphalter pitch, tar, shale oil residue, or coal-derived oil residue.

10. The process of claim 1 , wherein unreacted hydrogen is recycled back to the front end of the reactor.

11. The process of claim 1 , wherein the combined amount of renewable and circular feedstocks, as of the volume of the total combined feedstocks, ranges from 1-90%, 3-70%, 3-50%, 3-40%, 3-30%, 3-20%, 3-15%, 3-10%, 5-30%, 5-20%, 5-15%, 5-10%, or 10-20%.

12. The process of claim 1, wherein step b) further comprises injecting the circular, renewable, or mix of circular and renewable feedstocks into the EB reactor via the same feed line as the fossil fuel.

13. The process of claim 1 , wherein step b) further comprises heating the circular, renewable, or mix of circular and renewable feedstocks in a separate heat exchanger and subsequently injecting into the EB reactor via a separate feed line from the fossil fuel.

14. The process of claim 1, wherein step b) further comprises adding renewable feedstock into the EB reactor via the EB catalyst addition pipe.

15. The process of claim 1, wherein a hydrotreatment step e) occurs, and distillate and vacuum gas oil (VGO) products are further hydrotreated in an integrated hydrotreater.Attorney Docket No.: 70205-0697WOU116. The process of claim 10, wherein, the hydrotreated VGO is further hydrocracked in a hydrocracker or fluid catalytic cracking (FCC) process after separation.

17. The process of claim 1, wherein a hydrotreatment step e) occurs, and heavy product is hydrotreated using a heavy oil hydrotreater.

18. The process of claim 1, wherein the products are subjected to an isomerization step to produce jet and diesel products.

19. The process of claim 1, wherein additional circular or renewable feedstocks are added into an existing integrated hydrotreater in an EB unit.

20. The process of claim 19, wherein the amount of additional circular or renewable feedstocks are in the range of from 3-20% of the original EB unit capacity.

21. The process of claim 1 , wherein a series of EB reactors is used.

22. The process of claim 21, wherein the series comprises two EB reactors.

23. The process of claim 22, wherein the circular and / or renewable feedstocks are added to a first EB reactor in the series and / or in the second EB reactor in the series.

24. The process of claim 23, wherein the circular and / or renewable feedstocks are added to an EB reactor at more than one injection point.

25. The process of claim 21 , wherein the series comprises three EB reactors.

26. The process of claim 25, wherein the circular and / or renewable feedstocks are added to a first EB reactor in the series and / or a third EB reactor in the series.

27. The process of claim 26, wherein the circular and / or renewable feedstocks are added to an EB rector at more than one injection point.Attorney Docket No.: 70205-0697WOU128. The process of claims 21-27, wherein the product recovered from the last EB reaction in the series is passed to separation and fractionation into light products and unconverted oil.

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