Process for making renewable products using noble metal catalysts

Abstract

Process for making a renewable product by hydroconversion of a feedstock, including biofeedstocks. The process comprises contacting a (bio)feedstock with a noble metal hydroconversion catalyst system under hydroconversion conditions to produce a renewable product. The hydroconversion catalyst system comprises a hydrodeoxygenation catalyst and a hydroisomerization catalyst. The hydrodeoxygenation catalyst comprises a support and the catalytically active metals Pt and Re or Pt and Ru while the hydroisomerization catalyst comprises a monometallic or bimetallic noble metal catalyst.

Description

RENEWABLE PRODUCTS USING NOBLE METAL CATALYSTSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 760,539, filed February 19, 2025, the disclosure of which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION

[0002] Process of making a renewable product by hydroconversion of an oxygen containing feedstock using noble metal catalysts.BACKGROUND

[0003] The use of renewable resources has garnered significant attention and effort in the drive to develop fossil fuel alternatives. The variety, availability, and versatility of various biofeedstocks has been of great interest, particularly certain lipid sources, leading to the development and commercial use of a number of bio-based fuel technologies. Ongoing economic interests, and the desire to reduce fossil fuel use, have provided incentives for improvements in existing technologies, and the development of new processes for utilizing renewable biofeedstocks to produce renewable fuels and other renewable products.

[0004] Renewable fuels (biofuels) and other products are seen as being important to reduce carbon and greenhouse emissions. Bioproducts derived from food are products typically made from food sources produced on arable land, while bioproducts derived from non-food sources are typically produced from lignocellulosic biomass like forestry residuals or agricultural residues and waste. Typical biofeedstocks in the food source category include a wide variety of lipids (e.g., vegetable oil, including used cooking oil, seed oils, animal fats, waste oils, algae oils, and the like). Typical non-food source feedstocks include wood, grasses, algae, crop byproduct, municipal solid waste, and the like. There remains an ongoing need for improvements in hydroconversion processes for all feedstock sources to produce renewable products.

[0005] Renewable feedstocks typically contain significant amounts of oxygen-containing compounds, which are not usually present in petroleum feedstocks. Removal of these compounds or deoxygenation is needed to convert renewable feedstocks into process streams and / or products such as fuels, like those derived from petroleum. Oxygen-containing compounds may be converted with the oxygen removed through hydroprocessing, also generally referred to as hydroconversion, or, in the case of oxygen removal, hydrodeoxygenation (HDO). By-products of the hydroconversion of renewable feedstocks include water, produced through HDO reactions, and carbon oxides, produced through hydrodecarbonylation and hydrodecarboxylation reactions. Removal of oxygen from a renewable feedstream is desirable since the loss of feedstream carbon content through the production of carbon oxides, principally CO and CO2, can be reduced to potentially result in higher product yields for desirable products such as renewable liquid fuels. For example, further hydroprocessing / hydroconversion toproduce final products, e.g., through dewaxing and / or hydroisomerization of intermediate HDO streams, to produce renewable products.

[0006] Current hydrodeoxygenation (HDO) and hydroisomerization processes for producing products from hydrocarbonaceous feedstocks generally include the use of base metal catalysts. Base metal hydrodeoxygenation catalysts need sulfur injection to maintain their performance, which introduces additional operation costs. Furthermore, their HDO selectivity decreases at high operation temperatures, leading to liquid product yield loss. While higher activity and lower operation cost can be achieved using noble metal catalysts than base metal catalysts, noble metal catalysts tend to have lower tolerance to reaction byproducts from biofeedstocks, such as CO and CO2. Current noble metal HDO catalysts also suffer from low HDO selectivity and high CO generation that may poison the catalysts.

[0007] Current dewaxing processes for producing products from hydrocarbonaceous feedstocks generally use base metal dewaxing catalysts, particularly in single stage hydroprocessing applications. Base metal dewaxing catalysts typically have low activity and selectivity, however, leading to higher product yield loss. While higher activity and selectivity can be achieved using noble metal catalysts than base metal catalysts, noble metal catalysts tend to have lower tolerance to reaction byproducts from biofeedstocks, such as CO and CO2.

[0008] A continuing need exists to improve hydroconversion catalysts, such as catalysts for HDO and combined HDO / hydroisomerization, in the processing of (bio)feedstocks containing oxygen, and in providing renewable products from such feedstocks. It would be a significant advantage if the higher activity and selectivity of noble metal catalysts could be maintained or improved utilizing a combined HDO and hydroisomerization process, particularly to produce renewable products, while also providing improved tolerance to reaction byproducts such as CO and / or CO2.SUMMARY OF THE DISCLOSURE

[0009] This disclosure relates to processes for making renewable products from feedstocks including biofeedstocks, e.g., feeds containing biocomponents of biological origin, and, in particular, renewable products produced during hydroconversion of biofeedstocks. Various renewable products may be produced, including diesel, aviation and other fuels and distillates, as well as base oils or components thereof, and process fluids.

[0010] The hydroconversion of biofeedstocks to produce renewable products generally produces water and carbon oxide byproducts, such as CO and CO2, in addition to the main renewable products of interest. The generation of CO and CO2 is undesirable since it lowers the yield of desirable renewable products and may lead to reduced catalyst performance or poisoning. While efforts have been made to reduce the carbon oxide content, the solutions generally provide a compromised result. For example, the use of base metal hydrotreating catalysts to lower CO and CO2 content by lowering decarbonylationand decarboxylation selectivity also sacrifices catalyst deoxygenation capability. A need thereof exists for alternative catalyst systems that reduce or avoid such problems.

[0011] Noble metal hydrodeoxygenation catalysts provide the potential for higher activity than base metal catalysts. Noble metal catalysts tend to have lower selectivity and little tolerance to reaction byproducts from biofeedstocks, such as CO and CO2, however. It would be desirable if improved noble metal catalysts and associated processes could be provided for making renewable products from (bio)feedstocks.

[0012] Described herein is a process for converting a hydrocarbon feedstock into a product. The process generally comprises contacting a feedstock, such as a renewable biofeedstock, with a hydrodeoxygenation catalyst under hydrodeoxygenation (HDO) conditions followed by contacting the deoxygenated feedstock with a hydroisomerization catalyst under hydroisomerization conditions to produce a product. The hydrodeoxygenation catalyst generally comprises a support and the catalytically active metals Pt and Re or Pt and Ru, while the hydroisomerization catalyst generally comprises a monometallic or bimetallic noble metal catalyst.

[0013] In some embodiments, products and precursors of final products, such as middle distillates, including naphtha, kerosene, jet fuel, and diesel fuel may be produced using the process. Other products such as base oils, lubricating oils, and / or process fluids may also be made according to the process. Certain performance characteristics may be improved by using the process, such as a reduced carbon oxide content, improved HDO activity and selectivity or improved yield of renewable hydrocarbon products. In some cases, the process may also provide a reduced level of catalyst deactivation / increased catalyst life.

[0014] Except where mutually exclusive, a feature described in relation to any aspect or embodiment described herein may be applied mutatis mutandis to any other aspect and / or embodiment.Furthermore, except where mutually exclusive, any feature described herein may be applied to any aspect / embodiment and / or combined with any other feature described herein.DETAILED DESCRIPTION

[0015] Although illustrative embodiments of one or more aspects are provided herein, the disclosed processes may be implemented using any number of techniques. The disclosure is not limited to the illustrative or specific embodiments, any drawings, and any techniques illustrated herein, including any exemplary designs and embodiments illustrated and described herein, and may be modified within the scope of the appended claims along with their full scope of equivalents.

[0016] The following description of embodiments provides non-limiting representative examples to particularly describe features and teachings of different aspects of the invention. The embodiments described should be recognized as capable of implementation separately, or in combination, with other embodiments from the description of the embodiments. A person of ordinary skill in the art reviewingthe description of embodiments is able to learn and understand the different described aspects of the invention. The description of embodiments should facilitate understanding of the invention such that other implementations, not specifically covered but within the ability of a person of skill in the art having read the description of embodiments, will be understood as being consistent with an application of the invention.

[0017] Unless otherwise indicated, the following terms have the meanings as defined hereinbelow.

[0018] The term "hydroconversion" refers to processes or steps performed in the presence of hydrogen for the hydrocracking, hydrogenation, hydroisomerization and / or dewaxing, hydrodeoxygenation, hydrodesulfurization, hydrodenitrogenation, hydrodemetallation, hydrodechlorination, hydrodecarboxylation, hydrodecarbonylation and / or hydrodearomatization of a hydrocarbon or biomass feedstock, and / or for the hydrogenation of unsaturated compounds in the feedstock. Depending on the type of hydroprocessing and the reaction conditions, products of hydroprocessing may have improved aromatic content, oxygen content, viscosities, viscosity indices, saturates content, cold flow and other low temperature properties, and volatilities, for example.

[0019] The term "hydrotreating" refers to processes or steps performed in the presence of hydrogen for the hydrodesulfurization, hydrodenitrogenation, hydrodeoxygenation, hydrodemetallation, and / or hydrodearomatization of components of a feedstock, and / or for the hydrogenation of unsaturated compounds in the feedstock. The term "hydrotreating catalyst" as used herein refers to a catalyst that facilitates the hydrotreatment of a feedstock or process stream, e.g., to facilitate the removal of impurities or contaminates such as compounds comprising nitrogen, sulfur, or metals.

[0020] The term "hydrodeoxygenation" refers to processes or steps performed in the presence of hydrogen for the hydrodeoxygenation of components of a (bio)feedstock, and / or for the hydrogenation of unsaturated compounds in the (bio)feedstock.

[0021] The term "hydroisomerization catalyst" as used herein refers to a catalyst that facilitates the skeletal isomerization of hydrocarbon molecules. In some embodiments, suitable hydroisomerization catalysts include catalysts comprising zeolite SSZ-91, SSZ-32, SSZ-32x, and the like. Other hydroisomerization catalysts may also be suitable, including, e.g., catalysts based on zeolite ZSM-48 and / or combinations of ZSM-48 with other hydroisomerization catalysts. In some embodiments, suitable hydroisomerization catalysts include catalysts comprising a non-zeolite support or wherein the support comprises alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof. Combinations of suitable hydroisomerization catalysts based on the same or different zeolite and / or non-zeolite supports may also be used.

[0022] The term "feedstock" as used herein refers to feedstocks that are from or are derived from a fossil or a biological source, including, e.g., feedstocks that are generally referred to as fossil feedstocks and biofeedstocks.

[0023] The term "fossil feedstock" as used herein refers to feedstocks that are from or are derived from a fossil source, including the remains of dead plants, animals, and other biological materials. Fossil feedstocks generally comprise hydrocarbonaceous compounds of carbon and hydrogen and may include other compounds, contaminates and inert materials and compounds.

[0024] The term "fossil fuel component" is used herein to refer to a component produced wholly or inpart from a fossil fuel source.

[0025] The term "biofeedstock" as used herein refers to biocomponent feeds that are from or are derived from a biological source. Exemplary biofeedstocks include lipids, pyrolysis oils, biomass derived feeds, and the like. Biofeedstocks may be partially processed or converted to products, e.g., partially processed intermediates or derivatives from renewable feedstocks may be used. Triglycerides are a component of some biofeedstocks, such as lipids. The hydroprocessed biofeedstock typically has a boiling range suitable for producing renewable products, including, e.g., diesel, aviation or other fuel, distillate, base oil, and / or process fluid therefrom. In the case of some biofeedstocks comprising triglycerides, such feedstocks have an "apparent" boiling temperature range (based on the GC elution time of the triglyceride peaks according to Simdist method ASTM D-2887) suitable for producing a diesel, aviation or other fuel, or distillate therefrom. The biofeedstock boiling range (or apparent boiling range) may also be suitable for producing a base oil or a component thereof. Suitable biofeedstocks are those which, upon hydrotreating, result in hydrocarbons with a boiling point range of about 250°F (121°C) to about 950°F (510°C), for example about 300°F (149°C) to about 950°F (510°C), or about 250°F (121°C) to about 800°F (427°C). While the apparent boiling range of the lipids before hydrotreatment may, in some cases, be higher than 950°F (510°C), upon hydrotreatment, such lipids are converted into hydrocarbons having lower boiling temperatures or temperature ranges, as described herein. In some cases, e.g., for typical lipids after hydrotreating, an upper boiling point of about 950°F (510°C) includes hydrocarbon molecules having a number of carbon atoms and chain length making them suitable for the applications described herein. In general, at least one biofeedstock, or a biocomponent thereof, used in the process typically has a C16+ content of at least about 10 wt.%.

[0026] The term "biocomponent feed" as used herein refers to a feedstock derived from a biocomponent-containing source, such as a plant-based oil or fat, an animal-based oil or fat, a fish-based oil or fat, or algae-based oil or fat. Biocomponent feeds may be partially processed or converted to products, e.g., partially processed intermediates or derivatives from renewable feedstocks. Such feedstocks are generally hydrotreated products derived from biological sources. In some embodiments, suitable biocomponent feeds may have a boiling point range of about 250°F (121°C) to about 950°F (510°C), for example about 300°F (149°C) to about 950°F (510°C), about 400°F to about 950°F (about 204°C to about 510°C), about 500°F to about 950°F (about 260°C to about 510°C), about 600°F (316°C) to about 950°F (510°C), or about 700°F (371°C) to about 950°F (510°C) at atmospheric pressure. Thebiocomponent feed may have a 90 % distillation temperature of less than about 1000°F (538°C), or 900°F (482°C), or 800°F (427°C) or 700°F (371°C), or less than about 650°F (343°C). In some embodiments, the biocomponent feed has a 90% distillation temperature in the range of about 550°F (288°C) to about 750°F (399°C), for example about 550°F (288°C) to about 700°F (371°C), or about 600°F (316°C) to about 700°F (371°C). The 90% distillation temperature may be determined in accordance with ASTM D-2887. In some embodiments, the biocomponent feed has a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C), for example about 300°F (149°C) to about 600°F (316°C), or about 400°F (about 204°C) to about 600°F (316°C). The 5 % distillation temperature may be determined in accordance with ASTM D 2887. In some embodiments, the biocomponent feed has a 90 % distillation temperature in the range of about 550°F (about 288°C) to about 750°F (about 399°C) and a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C). In some embodiments, the biocomponent feed has a 90% distillation temperature in the range of about 550°F (288°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 300°F (149°C) to about 600°F (316°C). In some embodiments, the biocomponent feed has a 90% distillation temperature which is greater than about 600°F (316°C), for example from about 605°F (about 318°C) to about 675°F (357°C), and a 5% distillation temperature which is less than about 600°F (316°C), for example from about 540°F (282°C) to about 580°F (304°C). In some embodiments, the biocomponent feed has a 90 % distillation temperature in the range of equal to or greater than about 600°F (316°C) to about 700°F (371°C) and a 5 % distillation temperature in the range of about 400°F (204°C) to equal to or less than about 600°F (316°C). In some cases, e.g., for typical lipids after hydrotreating, an upper boiling point of about 900°F (482°C) includes hydrocarbon molecules having a number of carbon atoms that makes them suitable for the applications described herein.

[0027] The term "renewable product" is used herein to refer to a product produced wholly or in-part from a non-fossil fuel source. Suitable feedstocks to produce renewable products are generally derived from materials of biological origin. Renewable products may comprise one or more renewable components, e.g., products derived from feedstocks from more than one biological source.

[0028] The term "Fischer-Tropsch feed" as used herein refers to refer to a synthetic feedstock produced via a Fischer-Tropsch process and generally having a 90 % distillation temperature of less than about 1350°F (732°C), or less than about 1100°F (593°C), or less than about 1000°F (538°C), or less than about 900°F (482°C), or less than about 800°F (427°C), or less than about 750°F (399°C), or less than about 700°F (371°C). In some embodiments, the Fischer-Tropsch feed has a 90 % distillation temperature in the range of about 550°F (288°C) to about 750°F (399°C), for example about 550°F (288°C) to about 700°F (371°C), or about 600°F (316°C) to about 700°F (371°C). The 90 % distillation temperature may be determined in accordance with ASTM D 2887. In some embodiments, the Fischer-Tropsch feed has a 5 % distillation temperature in the range of about 250°F (121°C) to about 600°F(316°C), for example about 300°F (149°C) to about 600°F (316°C), or about 340°F (171°C) to about 600°F (316°C), or about 340°F (171°C) to about 500°F (260°C), or about 340°F (171°C) to about 400°F (204°C). The 5% distillation temperature may be determined in accordance with ASTM D-2887. In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 550°F (288°C) to about 750°F (399°C) and a 5% distillation temperature in the range of about 250°F (121°C) to about 600°F (316°C). In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 550°F (288°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 300°F (149°C) to about 600°F (316°C). In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 600°F (316°C). In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 500°F (260°C). In some embodiments, the Fischer-Tropsch feed has a 90% distillation temperature in the range of about 600°F (316°C) to about 700°F (371°C) and a 5% distillation temperature in the range of about 340°F (171°C) to about 400°F (204°C). In some embodiments, a "Fischer-Tropsch feed" may have boiling points in the range of about 250°F (121°C) to about 900°F (482°C), for example about 250°F (121°C) to about 800°F (427°C) at atmospheric pressure.

[0029] The term "diesel fuel" is used herein to refer to a hydrocarbon product having boiling points in the range of about 300°F to about 800°F (about 149°C to about 427°C) at atmospheric pressure.

[0030] The term "process fluid" is used herein to refer to a fluid used as a working or other fluid in a process or device that is not generally part of a final or intermediate product made by the process or device, including devices used in chemical, electrical, and / or mechanical processes. While not limited thereto, process fluid examples include drilling fluids, transformer fluids, thermal oils, hydraulic fluids, transmission fluids and / or gear oils, metal working fluids, or a combination thereof.

[0031] The term "active source" means a reagent or precursor material capable of supplying at least one element in a form that can react, and which can be incorporated into the molecular sieve structure. The terms "source" and "active source" can be used interchangeably herein.

[0032] The term "support" is not intended to be limited to other than those supports that may be suitable for use in hydrodeoxygenation (HDO) catalysts, including amorphous, crystalline, structured and unstructured materials. While not limited thereto, such supports may include alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof. In some cases, the support may also comprise molecular sieve or zeolite materials.

[0033] The term "molecular sieve" and "zeolite" are synonymous and include (a) intermediate and (b) final or target molecular sieves and molecular sieves produced by (1) direct synthesis or (2) postcrystallization treatment (secondary modification). Secondary synthesis techniques allow for thesynthesis of a target material from an intermediate material by heteroatom lattice substitution or other techniques. For example, an aluminosilicate can be synthesized from an intermediate borosilicate by post-crystallization heteroatom lattice substitution of the Al for B. Such techniques are known, for example as described in U.S. Patent No. 6,790,433 to C.Y. Chen and Stacey Zones, issued September 14, 2004.

[0034] "Groups 7-11" refers to elemental metal(s) selected from Groups 7-11 of the Periodic Table of the Elements and / or to metal compounds comprising such metal(s).

[0035] The term "Periodic Table" refers to the version of IUPAC Periodic Table of the Elements dated 1 December 2018.

[0036] Unless otherwise specified, the "feed rate" of a feedstock being fed to a catalytic reaction zone is expressed herein as the volume of feed per volume of catalyst per hour, which may be referred to as liquid hourly space velocity (LHSV) with units of reciprocal hours (h-1).

[0037] For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained. It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," include plural references unless expressly and unequivocally limited to one referent. As used herein, the term "include" and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. As used herein, the term "comprising" means including elements or steps that are identified following that term, but any such elements or steps are not exhaustive, and an embodiment can include other elements or steps.

[0038] Unless otherwise specified, the recitation of a genus of elements, materials, or other components, from which an individual component or mixture of components can be selected, is intended to include all possible sub-generic combinations of the listed components and mixtures thereof. In addition, all number ranges presented herein are inclusive of their upper and lower limit values.

[0039] If a standard test is mentioned herein, unless otherwise stated, the version of the test to be referred to is the most recent at the time of filing this patent application.

[0040] The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Toan extent not inconsistent herewith, and in jurisdictions where permitted, all citations referred to herein are hereby incorporated by reference.

[0041] Biofeedstocks described herein comprise or are a biocomponent feed. In some embodiments, the biofeedstock comprises, consists essentially of, or consists of a biocomponent feed. In some embodiments, the biocomponent feed constitutes at least about 5 wt.% of the biofeedstock, for example, at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, at least about 60 wt.%, at least about 70 wt.%, at least about 80 wt.%, at least about 90 wt.%, at least about 95wt.%, at least about 98 wt.%, or at least about 99 wt.% of the biofeedstock. In some embodiments, the biocomponent feed constitutes 5 wt.% to 100 wt.% of the biofeedstock, for example 10 wt.% to 100 wt.%, 50 wt.% to 100 wt.%, 80 wt.% to 100 wt.%, or 95 wt.% to 100 wt.% of the biofeedstock.

[0042] In some embodiments, the biofeedstock comprises, consists essentially of, or consists of a biocomponent feed. For example, the biocomponent feed may constitute at least about 5 wt.% of the biofeedstock, such as at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, at least about 60 wt.%, at least about 70 wt.%, at least about 80 wt.%, at least about 90 wt.%, at least about 95 wt.%, at least about 98 wt.%, or at least about 99 wt.% of the biofeedstock. In some embodiments, the Fischer-Tropsch feed may constitute 5 wt.% to 100 wt.% of the biofeedstock, for example 10 wt.% to 100 wt.%, 50 wt.% to 100 wt.%, 80 wt.% to 100 wt.%, or 95 wt.% to 100 wt.% of the biofeedstock.

[0043] In some embodiments, the biofeedstock is a blended feedstock comprising a biocomponent feed, or also comprising a Fischer-Tropsch feed, in combination with another feedstock, such as a blend feed. For example, the blended feedstock may comprise a blend feed selected from gas oils, vacuum gas oils, long residues, vacuum residues, atmospheric distillates, heavy fuels, oils, waxes and paraffins, used oils, deasphalted residues or crudes, charges resulting from thermal or catalytic conversion processes, or a combination thereof. In some embodiments, the blend feed is selected from whole crude petroleum, reduced crudes, vacuum tower residua, cycle oils, synthetic crudes, gas oils, vacuum gas oils, foots oils, Fischer-Tropsch derived waxes, lubricating oil stocks, heating oils, heavy neutral feeds, hydrotreated gas oils, hydrocracked gas oils, hydrotreated lubricating oil raffinates, brightstocks, lubricating oil stocks, synthetic oils, high pour point polyolefins (for example, polyolefins having a pour point of about 0°C or above); normal alpha olefin waxes, slack waxes, deoiled waxes, microcrystalline waxes, residuum fractions from atmospheric pressure distillation processes, solvent-deasphalted petroleum residua, shale oils, cycle oils, petroleum wax, slack wax, and waxes produced in chemical plant processes. In some embodiments, the feedstock is a blended feedstock comprising a biocomponent feed and a Fischer-Tropsch feed. In some embodiments, the feedstock is a blended feedstock comprising a biocomponent feed, a Fischer-Tropsch feed and a blend feed (for example, a blend feed, supra). Theblended feedstock, blend feed, and / or biofeedstock may also comprise a recycled product and / or intermediate process stream. As previously noted, such biofeedstocks or biocomponents are generally hydrotreated products derived from biological sources, wherein the biocomponents are hydrotreated by themselves or hydrotreated together with other feedstock components.

[0044] In some embodiments, the feedstock is a blended feedstock comprising a biocomponent feed and a blend feed, where the blended feedstock comprises at least about 5 wt.% of the biocomponent feed and up to about 95 wt.% of a blend feed component, for example, at least about 10 wt.% of the biocomponent feed and up to about 90 wt.% of a blend feed component, at least about 50 wt.% of the biocomponent feed and up to about 50 wt.% of a blend feed component, at least about 80 wt.% of the biocomponent feed and up to about 20 wt.% of a blend feed component, or at least about 95 wt.% of the biocomponent feed and up to about 5 wt.% of a blend feed component.

[0045] The Fischer-Tropsch feed (if used) will typically have a paraffin content of at least about 90 wt.%, for example, at least about 95 wt.%, or at least about 97.5 wt.%. The Fischer-Tropsch (FT) feed typically comprises only very minor amounts of olefins and cycloparaffins, for example, less than about 1.0 wt.% olefin, or less than about 0.5 wt.% olefin, and / or less than about 1.0 wt.% cycloparaffin, less than about 0.5 wt.% cycloparaffin, or less than about 0.1 wt.% cycloparaffin. In some embodiments, the FT feed has a sulfur (S) content of less than about 50 ppm, for example less than about 20 ppm. In some embodiments, the FT feed has a nitrogen (N) content of less than about 50 ppm, for example less than about 20 ppm. In some embodiments, the FT feed has a metal content of less than about 10 ppm, for example less than about 5 ppm. The paraffin content and cylcoparaffin content of the FT feed may be determined by GC-FIMS analysis as described in "Diesel Fuel Analysis by GC-FIMS: Normal Paraffins, Isoparaffins and Cycloparaffins", Briker, Y., et al., Energy Fuels 2001, 15, 4, 996-1002. The nitrogen content of the FT feed may be determined in accordance with ASTM D3228-20. The sulfur content of the FT feed may be determined in accordance with ASTM D4629. The metal content of the FT feed may be measured by inductively coupled plasma atomic emission spectroscopy (ICP-AES).

[0046] In some embodiments, the feedstock is a blended feedstock comprising a Fischer-Tropsch (FT) feed in combination with a blend feed, where the blended feedstock comprises at least about 5 wt.% of the FT feed and up to about 95 wt.% of a blend feed, for example at least about 10 wt.% of the FT feed and up to about 90 wt.% of a blend feed, at least about 50 wt.% of the FT feed and up to about 50 wt.% of a blend feed, at least about 80 wt.% of the FT feed and up to about 20 wt.% of a blend feed, or at least about 95 wt.% of the FT feed and up to about 5 wt.% of a blend feed.

[0047] In some embodiments, the biofeedstock comprises, consists essentially of or consists of a biocomponent feed. Plant-based oils and fats include vegetable oils and fats, such as rapeseed (canola) oil, soybean oil, coconut oil, sunflower oil, palm oil, palm kernel oil, peanut oil, linseed oil, colza oil, tall oil, corn oil, castor oil, jatropha oil, jojoba oil, olive oil, flaxseed oil, hempseed oil, cottonseed oil,camelina oil, safflower oil, mustard oil, carinata oil, cuphea oil, curcas oil, crambe oil, babassu oil, tallow oil, and rice bran oil. Animal oils and fats, and other sources, include beef fat (tallow), hog fat (lard), turkey fat, fish fat / oil, and chicken fat), yellow and brown greases, including algae and fish fats / oils, fats in milk, sewage sludge, and the like.

[0048] In certain embodiments, the biofeedstock comprises or is a biocomponent feed selected from carinata oil, rapeseed oil, peanut oil, mustard oil, tallow, rice bran wax, carnauba wax, or a combination thereof. While not limited thereto, the biofeedstock or biocomponent may be obtained from a plant family selected from Brassicaceae (formerly Cruciferaceae), Limnanthaceae, Simmondsiaceae, Tropaeolaceae, Olocaceae, Copernicia, or a combination thereof.

[0049] In some embodiments, the biocomponent feed may include feed components selected from vegetable oils and animal fats comprising, or consisting essentially of, triglycerides and free fatty acids (FFA). In some embodiments, the biofeedstock comprises or is a biocomponent feed selected from lipids, vegetable oils, seed oils, and animal fats which comprise triglycerides and free fatty acids. For example, suitable biocomponent feeds may be selected from canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil and a combination thereof. The biofeedstock may comprise an oxygen-containing compound or an oxygen-containing compound derived from a biofeedstock.

[0050] In some embodiments, the triglycerides and FFAs contain aliphatic hydrocarbon chains in their structure having 6-32 carbon atoms (for example, 6 to 22, 24, 26, 28, 30, or 32 carbon atoms; 8 to 22, 24, 26, 28, 30, or 32 carbon atoms; 10 to 22, 24, 26, 28, 30, or 32 carbon atoms; 12 to 22, 24, 26, 28, 30, or 32 carbon atoms; 14 to 22, 24, 26, 28, 30, or 32 carbon atoms; 16 to 22, 24, 26, 28, 30, or 32 carbon atoms; and / or 18 to 22, 24, 26, 28, 30, or 32 carbon atoms). In some embodiments, the biocomponent feed may comprise triglycerides having the general formula (1):

[0051] where R, R1and R2are independently aliphatic hydrocarbon chains having from 6-32 carbon atoms (for example, 6 to 24, 8 to 24, 12 to 24, 16 to 32, 16 to 24, 18 to 24, 20 to 24, 6 to 20, 8 to 20, 10 to 20, 6 to 18, 8 to 18, 10 to 18, or 6 to 16, 8 to 16, 10 to 16 carbon atoms). In some embodiments, R, R1and R2are independently branched or un-branched, substituted or unsubstituted, completely saturated or contain one or more (for example 1-4, 1-3 or 1 or 2) unsaturated carbon-carbon bonds. In some embodiments, R, R1and R2are unsubstituted. In some embodiments, R, R1and R2are independentlycompletely saturated or contain one or more (e.g., 1 to 4, 1 to 3 or 1 or 2) unsaturated carbon-carbon bonds. In some embodiments, R, R1and R2are un-branched.

[0052] The biofeedstock or biocomponent feed component may comprise free fatty acids (FFAs) having aliphatic hydrocarbon tails (substituent groups) of 6 to 32 carbon atoms, for example 6, 8, 10, 12, 14, 16, or 18 to 24 carbon atoms, 6, 8, 10, 12, 14, 16, 18 or 20 to 32 carbon atoms, 6, 8, 10, or 12 to 20 carbon atoms, 6, 8, 10, or 12 to 18 carbon atoms, and / or 6, 8, or 10 to 16 carbon atoms, and the like. The FFAs may comprise unsaturated or saturated aliphatic hydrocarbon tails. The FFAs may comprise unbranched or branched aliphatic hydrocarbon tails.

[0053] The biofeedstock may comprise or be a biocomponent feed wherein the biofeedstock comprises one or more biocomponents having a C20+ content of at least about 10 wt.%. In some cases, the C20+ content of the biofeedstock and / or a biocomponent thereof may be less than about 80 wt.%, 70 wt.%, 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, or 20 wt.%. The C16+ content of the biofeedstock or a biocomponent may also be greater about 20 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, or 70 wt.%, or a combination thereof. In some cases, a content range for the biofeedstock or a biocomponent may include a C16+ content in the range of about 10 to 80 wt.%, 10 to 70 wt.%, 10 to 60 wt.%, 10 to 50 wt.%, 10 to 40 wt.%, 20 to 80 wt.%, 30 to 80 wt.%, 40 to 80 wt.%, 50 to 80 wt.%, 20 to 70 wt.%, 20 to 60 wt.%, 20 to 50 wt.%, 20 to 40 wt.%, 30 to 80 wt.%, 30 to 70 wt.%, 30 to 60 wt.%, 30 to 50 wt.%, 40 to 80 wt.%, 40 to 70 wt.%, 40 to 60 wt.%, 50 to 80 wt.%, 50 to 70 wt.%, or 60 to 80 wt.%.

[0054] In addition to the C16+ content of the biofeedstock and / or a biocomponent thereof, and in addition to or separate from the C16 content limits or ranges noted hereinabove, the C18 content of the biofeedstock or a biocomponent thereof may be less than about 70 wt.%, 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, 20 wt.%, 10 wt.%, or 5 wt.%. The C18 content of the biofeedstock or a biocomponent thereof may be greater than about 5 wt.%, 10 wt.%, 20 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, or 60 wt.%, or a combination thereof. The C18 content of the biofeedstock or a biocomponent thereof may be in the range of about 0 to 70 wt. %, 0 to 60 wt.%, 0 to 50 wt.%, 0 to 40 wt.%, 5 to 70 wt. %, 5 to 60 wt.%, 5 to 50 wt.%, 5 to 40 wt.%, 10 to 70 wt. %, 10 to 60 wt.%, 10 to 50 wt.%, 10 to 40 wt.%, 20 to 70 wt. %, 20 to 60 wt.%, 20 to 50 wt.%, or 20 to 40 wt.%.

[0055] In addition to the C16+ content of the biofeedstock and / or a biocomponent thereof, and in addition to or separate from the C18 content limits or ranges noted hereinabove, the C20 content of the biofeedstock or a biocomponent thereof may be less than about 70 wt.%, 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, 20 wt.%, 10 wt.%, or 5 wt.%. The C20 content of the biofeedstock or a biocomponent thereof may be greater than about 5 wt.%, 10 wt.%, 20 wt.%, 30 wt.%, 40 wt.%, 50 wt. %, or 60 wt.%, or a combination thereof. The C20 content of the biofeedstock or a biocomponent thereof may be in the range of about 0 to 70 wt. %, 0 to 60 wt.%, 0 to 50 wt.%, 0 to 40 wt.%, 5 to 70 wt. %, 5 to 60 wt.%, 5 to50 wt.%, 5 to 40 wt.%, 10 to 70 wt. %, 10 to 60 wt.%, 10 to 50 wt.%, 10 to 40 wt.%, 20 to 70 wt. %, 20 to 60 wt.%, 20 to 50 wt.%, or 20 to 40 wt.%.

[0056] In addition to the C16+ content of the biofeedstock and / or a biocomponent thereof, and in addition to or separate from the C18, and / or C20 content limits or ranges noted hereinabove, the C22+ content of the biocomponent may be less than about 70 wt.%, 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, 20 wt.%, 10 wt.%, or 5 wt.%. The C22+ content of the biofeedstock and / or a biocomponent thereof may be greater than about 5 wt.%, 10 wt.%, 20 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, or 60 wt.%, or a combination thereof. The C22+ content of the biofeedstock and / or a biocomponent thereof may be in the range of about 0 to 70 wt. %, 0 to 60 wt.%, 0 to 50 wt.%, 0 to 40 wt.%, 5 to 70 wt. %, 5 to 60 wt.%, 5 to 50 wt.%, 5 to 40 wt.%, 10 to 70 wt. %, 10 to 60 wt.%, 10 to 50 wt.%, 10 to 40 wt.%, 20 to 70 wt. %, 20 to 60 wt.%, 20 to 50 wt.%, or 20 to 40 wt.%.

[0057] In addition to the C16+ content of the biofeedstock and / or a biocomponent thereof, and in addition to or separate from the C18, C20, and / or C22+ content limits or ranges noted hereinabove, the C24+ content of the biofeedstock and / or a biocomponent thereof may be less than about 70 wt.%, 60 wt.%, 50 wt.%, 40 wt.%, 30 wt.%, 20 wt.%, 10 wt.%, or 5 wt.%. The C24+ content of the biofeedstock and / or a biocomponent thereof may be greater than about 5 wt.%, 10 wt.%, 20 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, or 60 wt.%, or a combination thereof. The C24+ content of the biofeedstock and / or a biocomponent thereof may be in the range of about 0 to 70 wt. %, 0 to 60 wt.%, 0 to 50 wt.%, 0 to 40 wt.%, 5 to 70 wt. %, 5 to 60 wt.%, 5 to 50 wt.%, 5 to 40 wt.%, 10 to 70 wt. %, 10 to 60 wt.%, 10 to 50 wt.%, 10 to 40 wt.%, 20 to 70 wt. %, 20 to 60 wt.%, 20 to 50 wt.%, or 20 to 40 wt.%.

[0058] In some cases, the C16 to C32 content of the biofeedstock and / or a biocomponent thereof may be at least about 10 wt.%, or 15 wt.%, or 20 wt.%, or 30 wt.%, or 40 wt.%, or 50 wt.%, or 60% wt.%, or 70 wt.%, or 80 wt.%, or in the range of about 10 to 80 wt.%, or 15 to 80 wt.%, or 20 to 80 wt.%, or 30 to 80 wt.%, or 40 to 80 wt.%, or 50 to 80 wt.%, or 60% to 80 wt.%, or 70 to 80 wt. %.

[0059] In general, and in addition to the C16+ content of the biofeedstock and / or a biocomponent thereof, the C16 content of the biocomponent is about 0 to 70 wt.%; the C18 content of the biocomponent may be about 0 to 70 wt.%; the C20 content of the biocomponent may be about 0 to 70 wt.%; the C22 content of the biocomponent may be about 0 to 70 wt.%; the C22+ content of the biocomponent may be about 0 to 70 wt.%; the C24 content of the biocomponent may be about 0 to 70, 60, 50, or 40 wt.%; and the C24+ content of the biocomponent may be about 0 to 70, 60, 50, or 40 wt.%, or a combination thereof.

[0060] In general, the biofeedstock may comprise or be a biocomponent feed wherein the biofeedstock comprises one or more biocomponents having a C16+ content of at least about 10 wt.%. Suitable biocomponents may include, e.g., carinata oil, rapeseed oil, peanut oil, mustard oil, tallow, rice bran wax, carnauba wax, or a combination thereof. In some embodiments, the biocomponent feed is ormay comprise one or more other biocomponents that typically do not have a higher carbon chain length content (e.g., C20+ content), such as biocomponents that may include canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil, combinations thereof, and the like.

[0061] The biocomponent feed may have an oxygenate content of at least about 0.5 wt.% by total weight of the biocomponent feed, for example, at least about 1.0 wt.%, at least about 2.0 wt.%, at least about 3.0 wt.%, at least about 4.0 wt.%, or at least about 5.0 wt.% by total weight of the biocomponent feed. The biocomponent feed may, e.g., have an oxygenate content of up to about 15 wt.% by total weight of the biocomponent feed, or up to about 10 wt.% by total weight of the biocomponent feed, or up to about 5 wt.% by total weight of the biocomponent feed. In some embodiments, the biocomponent feed has an oxygenate content in the range of about 1-15 wt.% by total weight of the biocomponent feed, for example, in the range of about 5-15 wt.%, or about 10-15 wt.%, by total weight of the biocomponent feed. The oxygenate content of the biocomponent feed may be measured by neutron activation analysis, for example, in accordance with ASTM E385-90(2002).

[0062] The biocomponent feed may be hydrodeoxygenated prior to being contacted with a hydroconversion catalyst for further hydroprocessing, e.g., with a hydroisomerization / hydrodewaxing catalyst. In some cases, the biocomponent feed may have a sulfur (S) content of less than about 200 ppm, for example less than about 100 ppm, less than about 50 ppm or less than about 20 ppm. In some cases, the biocomponent feed may have a nitrogen (N) content of less than about 50 ppm, for example less than about 20 ppm, or less than about 10 ppm. In some cases, the hydrodeoxygenated biocomponent feed may have an oxygenate content that is typically about 0 wt.%, or, alternatively, less than about 2 wt.%, or 5 wt.%. The nitrogen content of the biocomponent feed may be determined in accordance with ASTM D4629. The sulfur content of the biocomponent feed may be determined in accordance with ASTM D2622.

[0063] In general, feedstock hydroprocessing according to the invention uses a hydrodeoxygenation catalyst that comprises a noble or precious metal catalyst as the hydrodeoxygenation catalyst. In some cases, the hydrodeoxygenation catalyst may be a noble or precious metal catalyst by itself. In some cases, the hydrodeoxygenation catalyst may be used with other catalysts, e.g., a base metal catalyst, or a noble or precious metal catalyst, or a combination of a base metal catalyst and a noble or precious metal catalyst. While not limited thereto, the base metal catalyst typically includes a base metal such as Mo, Ni, W, Co, and combinations thereof, or Mo, or a combination of Mo and Ni. Similarly, while not limited thereto, the noble or precious metal catalyst may include a noble metal such as Pt, Pd, Re, Ru, or a combination thereof. In some cases, the hydrodeoxygenation catalyst may be used together or in sequence with a hydrotreating catalyst and / or a hydroisomerization catalyst.

[0064] The hydrodeoxygenation catalyst generally comprises a support and the catalytically active metals Pt and Re or Pt and Ru. In general, the hydrodeoxygenation catalyst metals content may be 0.01to 15 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.1 to 2.0 wt.% (total catalyst weight basis). The catalyst Pt metal content is generally 0.01 to 5 wt.%, or may be 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% or 0.01 to 0.8 wt.%, or 0.1 to 1.0 wt.% (total catalyst weight basis). The catalyst Re or Ru metal content is generally 0.01 to 15 wt.%, or may be 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.5 wt.% or 0.01 to 1.0 wt.%, or 0.1-1.0 wt.% (total catalyst weight basis). In some cases, the catalyst Pt metal content is generally 0.01 to 5 wt.%, or may be 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% or 0.01 to 0.8 wt.%, or 0.1 to 1.0 wt.% and the Re or Ru metal content is generally 0.01 to 15 wt.%, or may be 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% or 0.01 to 0.8 wt.%, or 0.1 to 1.0 wt.% (total catalyst weight basis). In some cases, the molar ratio of Pt to Re or Ru may also be in the range of 5:1 to 1: 30, or 5:1 to 1:20, or 5:1 to 1:10, or 5:1 to 1:5, or 3:1 to 1:3, or 1:1 to 1:2, or 5:1 to 2:1, or 5:1 to 3:1, or 1:1 to 1:3, or 1:1 to 1:4.

[0065] In general, the hydrodeoxygenation catalyst may comprise 0.01 to 15.0 wt.%, or 0.01 to 3 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% of the catalytically active metals comprising Pt and Re or Pt and Ru, with the remainder comprising the support material.

[0066] While not limited thereto, the hydrodeoxygenation catalyst may comprise a support material. Suitable supports are not particularly limited and include any known in the art, such as silica and / or alumina based supports. In some cases, the support may be a catalyst support such as alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof.

[0067] The hydrodeoxygenation catalyst may further comprise a metal, e.g., a metal selected from Group 7-11 metals or combinations thereof. In some embodiments, the metal is selected from Group 8, 9 or 10 metals and combinations thereof, for example the metal may be selected from Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt and combinations thereof. In some embodiments, the metal is selected from Group 10 metals and combinations thereof. In some embodiments, the hydrodeoxygenation catalyst comprises platinum, palladium, or a combination thereof. In some cases, the catalyst may be a noble metal catalyst wherein the noble metals are the combination of Pt and Re or Pt and Ru. Catalysts comprising base metals, such as Mo, Ni, W, Co, and combinations thereof, may be included, e.g., in the form of additional process catalysts.

[0068] The hydrodeoxygenation catalyst may comprise from about 0.05 to about 15 wt.%, or 5 wt.% or 2.0 wt.% of a Group 7-11 metal (e.g., selected from Group 8, 9 and 10 metals, or a Group 8, 9 or 10 metal, for example a Group 10 metal such as platinum) by total weight of the catalyst, for example, about 0.1 to about 1.5 wt.%, or about 0.2 to about 1.5 wt.%, or about 0.1 to about 1 wt.%, by total weight of the catalyst. In some cases, e.g., where base metals are included, the metal content may be higher, e.g., at least about 5 wt.%, or 10 wt.%, or 15 wt.% or 20 wt.%, or 25 wt.%, or at least about 30 wt.%, or in the range of about 2 wt. % or 5 wt.% to about 25 wt.% or 30 wt.%.

[0069] The hydrodeoxygenation catalyst may be prepared by compositing the support, such as an oxide binder / support, to form an extrudate base; impregnating the extrudate base with an impregnation solution containing a Group 7-11 metal (e.g., a Group 8-10 metal such as Pt and the Group 7 or 8 metals Re or Ru), to form a metal-loaded extrudate; drying the metal-loaded extrudate; and calcining the dried metal-loaded extrudate.

[0070] The hydrodeoxygenation catalyst may be formed by extruding the support into a particle or extrudate having a wide range of physical shapes and dimensions. The extrudate or particle may be dried and calcined prior to metal loading. In some embodiments, the extrudate or particle is impregnated with a metal, e.g., a Group 7-11 metal (e.g., a Group 8-10 metal such as Pt and the Group 7 or 8 metals Re or Ru) and then dried and calcined. In some embodiments, the extrudate or particle is dried and calcined prior to metal loading.

[0071] The catalyst extrudate base may be dried (e.g., at a temperature in the range of about 100°F (38°C) to about 300°F (149°C) for about 0.1 to about 10 hours) and calcined (at a temperature in the range of about 390°F (199oC) to about 1200°F (649oC), or about 600°F (316°C) to about 1200°F (649°C) for about 0.1 to about 10 hours) prior to impregnation.

[0072] The extrudate base may be formed by compositing the support, dried and then calcined prior to impregnation. The dried and calcined extrudate base may be impregnated with an impregnation solution to form a metal-loaded extrudate before being dried and calcined again to form the catalyst.

[0073] The impregnated extrudate base may be dried at a temperature in the range of about 100°F (38°C) to about 300°F (149°C) for about 0.1 to about 10 hours. The dried metal-loaded extrudate may be calcined at a temperature in the range of about 600°F (316°C) to about 1200°F (649°C) for about 0.1 to about 10 hours. In some embodiments, calcination takes place in air.

[0074] While not limited thereto, the hydroisomerization catalyst may comprise a support material. Suitable supports are not particularly limited and include any known in the art, such as silica and / or alumina based and / or zeolitic supports. In some cases, the support may be a catalyst support such as alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof.

[0075] The hydroisomerization catalyst may comprise a support material including a zeolite and / or non-zeolite support. Suitable zeolites include any generally known in the art, e.g., zeolite SSZ-91, SSZ-32, SSZ-32x, and / or another suitable zeolite supports. Suitable non-zeolite supports are not particularly limited and include any known in the art, such as silica and / or alumina based supports. In some cases, the catalyst may comprise from about 5 to about 95 wt.% zeolite (e.g., SSZ-91, SSZ-32, SSZ-32x, or a combination thereof) by total weight of the catalyst, or from about 10 to about 95 wt.% zeolite, from about 20 to about 90 wt.% zeolite, or from about 25 to about 85 wt.% zeolite, or from about 30 to about 80 wt.% zeolite, or from about 35 to about 75 wt.% zeolite, or from about 35 to about 65 wt.% zeolite,or from about 35 to about 55 wt.% zeolite, or from about 45 to about 75 wt.% zeolite, or from about 55 to about 75 wt.% zeolite by total weight of the catalyst.

[0076] The hydroisomerization catalyst comprises a metal selected from Group 7-11 metals or combinations thereof. In some embodiments, the metal is selected from Group 8, 9 or 10 metals and combinations thereof, for example the metal may be selected from Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt and combinations thereof. In some embodiments, the metal is selected from Group 10 metals and combinations thereof. In some embodiments, the hydroisomerization catalyst comprises platinum, palladium, or a combination thereof. In some cases, the catalyst may be a noble metal catalyst. Base metals, such as Mo, Ni, W, Co, and combinations thereof, may be included in the catalyst.

[0077] The hydroisomerization catalyst may comprise from about 0.05 to about 10 wt.%, or 5 wt.% or 2.0 wt.% of the metal (e.g., selected from Group 7-11 metals, e.g., Group 8, 9 and 10 metals, or a Group 10 metal such as platinum) by total weight of the catalyst, for example, about 0.1 to about 1.5 wt.%, or about 0.2 to about 1.5 wt.%, or about 0.1 to about 1 wt.%, by total weight of the catalyst. In some cases, e.g., where base metals are included, the metal content may be higher, e.g., at least about 5 wt.%, or 10 wt.%, or 15 wt.% or 20 wt.%, or 25 wt.%, or at least about 30 wt.%, or in the range of about 2 wt. % or 5 wt.% to about 25 wt.% or 30 wt.%.

[0078] The hydroisomerization catalyst may further comprise an oxide binder. Suitable oxide binders include an inorganic oxide, e.g., the oxide binder may be selected from alumina, silica, ceria, titania, tungsten oxide, zirconia, and combinations thereof. The catalyst may comprise an oxide binder comprising alumina. Suitable aluminas are commercially available, including, e.g., Catapal® aluminas and Pural® aluminas from Sasol® or Versal® aluminas from UOP®. In general, the alumina can be any alumina known for use as a matrix material in a catalyst base. For example, the alumina can be boehmite, bayerite, g-alumina, h-alumina, q-alumina, d-alumina, c-alumina, or a mixture thereof. The catalyst may comprise from about 5 to about 95 wt.% oxide binder by total weight of the catalyst, for example about 5 to about 80 wt.% oxide binder, about 10 to about 70 wt.% oxide binder, about 20 to about 70 wt.% oxide binder, for example about 25 to about 65 wt.% oxide binder by total weight of the catalyst.

[0079] The hydroisomerization catalyst may comprise from about 5 to about 95 wt.% zeolite SSZ-91, from about 0.05 to about 2.0 wt.% of a Group 8-10 metal; and from about 5 to about 95 wt.% oxide binder by total weight of the catalyst. The catalyst may comprise from about 30 to about 80 wt.% zeolite SSZ-91, from about 0.1 to about 1.5 wt.% of a Group 8-10 metal; and from about 20 to about 70 wt.% oxide binder by total weight of the catalyst.

[0080] Zeolite SSZ-91 and methods for making zeolite SSZ-91 are described in US-A-9920260 which is incorporated herein by reference in its entirety. Zeolite SSZ-91 may also be referred to as SSZ-91 molecular sieve. Zeolite SSZ-91 has a SiO2 / AI2O3 mole ratio (SAR) of 40 to 220. In some embodiments, zeolite SSZ-91 has a SiO2 / AI2O3 mole ratio (SAR) of 40 to 200, for example, 70 to 200, 80 to 200, 70 to180, 80 to 180, 70 to 160, 80 to 160, 70 to 140, 80 to 140, 100 to 160, 100 to 140, or 120 to 140. The SAR is determined by inductively coupled plasma (ICP) elemental analysis.

[0081] The process of hydroconverting a biofeedstock comprises contacting a feedstock with a hydroconversion catalyst under hydroconversion conditions. Hydroconversion takes place in the presence of hydrogen and may include hydrodeoxygenation, hydrotreating and / or hydroisomerization processes. Hydroconversion may include other processes as well, including hydrocracking.

[0082] The process generally makes use of a feedstock, e.g., a fossil feedstock and / or a biofeedstock comprising one or more biocomponents having a C16+ content of at least about 10 wt.% and wherein the hydroconversion catalyst comprises hydrodeoxygentation catalyst. In some cases, the biofeedstock may comprise one or more biocomponents having a C16 to C24 content of at least about 10 wt.%. While not limited thereto, the C16 to C24 content of the biocomponent may be at least about 15 wt.%, or 20 wt.%, or 30 wt.%, or 40 wt.%, or 50 wt.%. The biofeedstock may contain only renewable biocomponents and / or may exclude, or not purposely include, fossil fuel components. The biofeedstock may also be utilized by itself, i.e., wherein no fossil fuel component or other non-biofeedstock component is added along with the biofeedstock.

[0083] The process may also be a single stage or a two-stage process, e.g., wherein no intermediate and / or final products are removed between stages or catalyst beds. The process may be advantageously carried out within a single reactor in some embodiments. The process may also be carried out in two or more reactors connected in series, e.g., with a first reactor, or catalyst section, comprising a hydrotreating section and a reactor, or catalyst section, and a section or reactor downstream from the first reactor or catalyst section comprising a hydrodeoxygenation section. The hydrodeoxygenation process may be carried out in two or more reactors, reactor sections, or reactor layers connected in a flow-through sequence, with a first reactor, reactor section, or reactor layer comprising the catalyst system upstream of a second reactor, reactor section, or reactor layer. The skilled artisan will appreciate that various reactor configurations and catalyst loading arrangements are possible according to the invention.

[0084] The hydrodeoxygenation conditions may typically comprise a temperature in the range of about 300°F to about 800°F (149°C to 427°C); a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); a feed rate of biofeedstock in the range from about 0.1 to about 20 h-1 LHSV; and hydrogen and biofeedstock feed rates in a ratio from about 1000 or 1500, or 2000 to about 10,000 standard cubic feet H2 per barrel biofeedstock (from about 180 to about 1800 m3 H2 / m3 feed).

[0085] In some cases, the hydrodeoxygenation conditions may include a temperature in the range of about 300°F to about 800°F (149°C to 427°C), e.g., or 325°F (163°C), or 350°F (177°C), or 375°F (191°C), or 390°F (199°C), or 400°F (204°C) or 450°F (232°C) or 550°F (288°C) to about 730°F (388°C) or 750°F(399°C) or 800°F (427°C), or about 550°F to about 700°F (288oC to 371oC) or 750°F (399°C), or about 570°F to about 675°F (299°C to 357°C). The conditions may include a pressure in the range of about 0, or 15 to about 3000 psig (0 or 0.10 to 20.68 Mpa gauge), e.g., about 100 to about 2500 psig (0.69 to 17.24 Mpa), or 0 to 2700 psig (0 to 18.62 MPa), or 0 to 2200 psig (0 to 15.17 MPa), or 0 to 1800 psig (0 to 12.41 MPa), or 0 to 1300 psig (0 to 8.96 MPa). The conditions may include a feed rate of the biofeedstock to the reactor containing the hydrodeoxygenation catalyst at a rate in the range from about 0.1 to about 20 h-1 LHSV, e.g., from about 0.1 to about 5 h-1 LHSV.

[0086] In some cases, the hydrodeoxygenation conditions may include hydrogen and biofeedstock fed to the reactor in a ratio from about 1000, or 1500, or 2000 to about 10,000 standard cubic feet H2 per barrel feedstock (from about 180 to about 1800 m3 H2 / m3 feed, e.g., from about 2500 to about 5000 scf H2 per barrel feedstock (from about 440 to about 890 m3 H2 / m3 feed).

[0087] In some cases, the hydroisomerization conditions may include a temperature in the range of about 300°F to about 800°F (149°C to 427°C), e.g., 400°F (204°C) or 450°F (232°C)to about 730°F (388°C) or 800°F (427°C), or about 550°F to about 700°F (288oC to 371oC). The conditions may include a pressure in the range of about 0, or 15 to about 3000 psig (0 or 0.10 to 20.68 Mpa gauge), for example about 100 to about 2500 psig (0.69 to 17.24 Mpa), or 0 to 2700 psig (0 to 18.62 MPa), or 0 to 2200 psig (0 to 15.17 MPa), or 0 to 1800 psig (0 to 12.41 MPa), or 0 to 1300 psig (0 to 8.96 MPa). The conditions may include a feed rate of the biofeedstock to the reactor containing the hydroisomerization catalyst at a rate in the range from about 0.1 to about 20 h-1 LHSV, e.g., from about 0.1 to about 5 h-1 LHSV.

[0088] In some cases, the hydroisomerization conditions may include hydrogen and biofeedstock fed to the reactor in a ratio from about 1000, or 1500, or 2000 to about 10,000 standard cubic feet H2 per barrel feedstock (from about 180 to about 1800 m3 H2 / m3 feed, e.g., from about 2500 to about 5000 scf H2 per barrel feedstock (from about 440 to about 890 m3 H2 / m3 feed).

[0089] In some embodiments, the hydroisomerization conditions are as follows: temperature in the range of about 300°F (149°C), or 325°F (163°C), or 350°F (177°C), or 375°F (191°C), or 390°F (199°C) to about 800°F (427°C), e.g., about 550°F to about 750°F (288°C to 399°C), or 570°F to about 675°F (299°C to 357°C); pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge), e.g., about 100 to about 2500 psig (0.69 to 17.24 MPa); feed rate of feedstock to the reactor containing the hydroisomerization catalyst at a rate in the range from about 0.1 to about 20 h-1 LHSV, e.g., from about 0.1 to about 5 h-1 LHSV; and hydrogen and feedstock fed to the reactor in a ratio from about 1000, or 1500, or 2000 to about 10,000 standard cubic feet H2 per barrel feedstock (from about 180 to about 1800 m3 H2 / m3 feed, e.g., from about 2500 to about 5000 scf H2 per barrel feedstock (from about 440 to about 890 m3 H2 / m3 feed).

[0090] The process may be generally used to provide a variety of renewable products, including both liquid and gas products. In some cases, renewable products such as fuels, such as renewable jet,renewable diesel and renewable naphtha, base oils, base oil components, lubricating oils, process fluids, or a combination thereof may be produced. Other products may also be produced during the process. While not limited thereto, process fluids that may be produced include drilling fluids, transformer fluids, thermal oils, hydraulic fluids, transmission fluids, metal working fluids, or a combination thereof.Renewable gas products may also be produced including renewable methane and other hydrocarbons.Example 1

[0091] A representative noble metal catalyst system comprising a hydrodeoxygenation and a hydroisomerization catalyst according to the disclosure was used to process a biofeedstock (e.g., soybean oil, canola oil, or an equivalent thereof) into primarily renewable diesel (including middle distillates in general, renewable naphtha, jet fuel, etc.) and to demonstrate the improved product performance and product characteristics resulting from use of the hydroconversion process.

[0092] The catalyst system included noble metal hydrodeoxygenation and dewaxing catalysts, arranged so the biofeedstream contacted the noble metal catalyst. Suitable noble metals comprised monometallic or bimetallic combinations of Pt, Pd, Re and / or Ru. The system was operated under a pressure of 900 psig, and at a catalyst temperature of 550-730-°F for the noble metal catalyst. The biofeedstock LHSV was 0.15-0.8 hr-1, and the gas to oil ratio was 12,000 standard cubic feet H2 per barrel (SCFB) feed.

[0093] The hydrodeoxygenation catalysts comprised of Pt and Re showed higher HDO selectivity than commercial base metal and Pt and Pd catalysts under the same operation conditions during bio-feed hydroprocessing as shown by the lower carbon oxide formation when using the Pt / Re catalyst.

[0094] Table 1 shows the product gas compositions after soybean oil was fully hydrodeoxygenated by commercial base metal hydrodeoxygenation catalysts, PtRe HDO catalyst and PtPd HDO catalyst. As shown, PtRe HDO catalyst generated less CO in the unit and provided higher HDO yield to help maintain the liquid renewable product yield.

[0095] To achieve similar renewable diesel cloud point, the noble metal catalyst system provided overall higher renewable fuel yield than base metal catalyst systems in both single-stage and two-stage hydroprocessing. Table 2 shows the renewable diesel product yields and cloud point improvement in single-stage hydroprocessing by noble metal and base metal catalyst system, respectively, for the same target cloud point of approx. -15°C. The renewable diesel yield is calculated on soybean oil basis. The oxygen contents are completely removed after processing with the HDO catalyst. The noble metal and comparative base metal dewaxing catalysts both used SSZ-91 zeolite supports.Table 1. Effluent gas compositions from base metal and noble metal HDO catalysts.Catalyst CO, vol.% CO2, vol.% CH4, vol.% C2H6, vol.% C3H8, vol.% NiMo catalyst 0.18 0.26 0.06 0.06 1.44 PtRe catalyst 0 0.19 0.30 0.12 1.05 PtPd catalyst 4.47 0.43 0.50 0.68 0.87Table 2. Renewable diesel product yield by noble metal and base metal catalystsDO HDO Oxygen Dewaxing Cloud point Overall renewable cataiyst removal,cata|tDewaxingdjese| je|d on bjofeedmetals %meta,sCAT, FRePt 650 100 Pt 660 29 84.3 NiMo 650 100 NiW 730 32 64.2

[0096] From Table 2, it may be noted that the noble metal catalyst combined HDO / hydroisomerization process is able to operate at significantly lower temperature, potentially providing improved catalyst life. The cloud point improvement for the noble metal catalyst system was similar to that obtained for the base metal catalyst system. Significantly, the overall renewable diesel yield for the noble metal catalyst system was, however, improved by 20.1% over the comparative base metal catalyst system.

[0097] Similar or other performance and catalyst run period improvements may be realized using noble metal hydrodeoxygenation catalysts described herein, such as increased catalyst life, and according to the process conditions described in this disclosure, including a temperature in the range of about 300°F to about 800°F (149°C to 427°C); a pressure in the range of about 15 to about 3000 psig (0.10 to 20.68 MPa gauge); a feed rate of biofeedstock in the range from about 0.1 to about 20 h-1 LHSV; hydrogen and biofeedstock feed rates in a ratio from about 1000 to about 20,000 standard cubic feet H2 per barrel biofeedstock (from about 180 to about 1800 m3 H2 / m3 feed); or a combination thereof.

[0098] For the avoidance of doubt, the present disclosure is directed to the subject-matter described in the following numbered paragraphs 1 to 24:1. A process for converting a feedstock into a product, the process comprisingcontacting a feedstock with a hydrodeoxygenation catalyst under hydrodeoxygenation conditions to produce a deoxygenated feedstock, the catalyst comprising a support and the catalytically active metals Pt and Re or Pt and Ru; andcontacting the deoxygenated feedstock with a hydroisomerization catalyst under hydroisomerization conditions to produce a product;wherein, the hydroisomerization catalyst comprises a monometallic or bimetallic noble metal catalyst.2. The process of paragraph 1, wherein a renewable feedstock, e.g., a biofeedstock, is used in the process.3. The process of paragraph 1 or 2, wherein a renewable product is produced by the process.4. The process of paragraph 1-3, wherein the hydrodeoxygenation catalyst metals content is 0.01-15.0 wt.%, or 0.01-3.0 wt.%, or 0.01-2.0 wt.%, or 0.1-2.0 wt.% based on the total catalyst weight.5. The process of paragraphs 1-4, wherein the hydrodeoxygenation catalyst Pt metal content is 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.6. The process of paragraphs 1-5, wherein the hydrodeoxygenation catalyst Re or Ru metal content is 0.01 to 15 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.5 wt.% or 0.01-1.0 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.7. The process of paragraphs 1-6, wherein the hydrodeoxygenation catalyst Pt metal content is 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% and the Re or Ru metal content is 0.01- to 15 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.8. The process of paragraphs 1-7, wherein the hydrodeoxygenation catalyst molar ratio of Pt to Re or Ru is in the range of 100:1 to 1:100, or 50:1 to 1:50, or 30:1 to 1:30, or 20:1 to 1:20, or 10:1 to 1:10, or 100:1 to 1:50, or 100:1 to 1:30, or 100:1 to 1:20, or 100:1 to 1:10, or 100:1 to 1:5, or 50:1 to 1:30, or 50:1 to 1:20, or 50:1 to 1:10, or 0:1 to 1:5, or 30:1 to 1:20, or 30:1 to 1:10, or 30:1 to 1:5, or 20:1 to 1:10, or 20:1 to 1:5, or 10:1 to 1:5, or 5:1 to 1:30, or 5:1 to 1:20, or 5:1 to 1:10, or 5:1 to 1:5, or 3:1 to 1:3, or 1:1 to 1:2, or 5:1 to 2:1, or 5:1 to 3:1, or 1:1 to 1:3, or 1:1 to 1:4.9. The process of paragraphs 1-8, wherein the hydrodeoxygenation catalyst support is a non-zeolite support or wherein the support is selected from alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof.10. The process of paragraphs 1-9, wherein the hydrodeoxygenation catalyst comprises 0.01 to 5.0 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% of the catalytically active metal, and 0.1 to 99 wt.% of the, or 1 to 99 wt.% of the support material.11. The process of paragraphs 1-10, wherein the hydroisomerization catalyst comprises a metal selected from Groups 7-11 of the Periodic Table.12. The process of paragraphs 1-11, wherein the hydroisomerization catalyst metals content is 0.01-15.0 wt.%, or 0.01-3.0 wt.%, or 0.01-2.0 wt.%, or 0.1-2.0 wt.% based on the total catalyst weight.13. The process of paragraphs 1-12, wherein the hydroisomerization catalyst comprises Pt and / or Pd metal in an amount of 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.14. The process of paragraphs 1-13, wherein the hydroisomerization catalyst comprises a support, wherein the support comprises a zeolite and / or a non-zeolite support, or wherein the hydroisomerization catalyst comprises a support, wherein the support comprises a zeolite comprising SSZ-32, SSZ-32x, SSZ-91, or a combination thereof and / or a non-zeolite support comprising alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof15. The process of paragraphs 2-14, wherein the renewable feedstock comprises or is a biocomponent feed selected from lipids, vegetable oils and animal fats which comprise triglycerides and free fatty acids, for example wherein the biocomponent feed is selected from canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil and a combination thereof; or wherein the biofeedstock comprises a biofeedstock-derived oxygen containing compound.16. The process of paragraphs 2-15, wherein the renewable feedstock comprises or is a biocomponent feed selected from canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil, carinata oil, rapeseed oil, soybean oil, colza oil, tall oil, sunflower oil, hempseed oil, olive oil, linseed oil, coconut oil, castor oil, peanut oil, palm oil, mustard oil, cottonseed oil, tallow, yellow and brown greases, lard, train oil, fats in milk, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, crambe oil, and the like.17. The process of paragraphs 2-16, wherein the renewable feedstock is a biofeedstock containing only renewable biocomponents; or wherein a fossil feedstock is not used as a component of the renewable feedstock; or wherein an added sulfur component is not added to the process to maintain the catalyst activity.18. The process of paragraphs 1-16, wherein the feedstock comprises a fossil feedstock.19. The process of paragraph 18, wherein the fossil feedstock comprises gas oil; vacuum gas oil; long residue; vacuum residue; atmospheric distillate; heavy fuel; oil; wax and paraffin; used oil; deasphalted residue or crude; charges resulting from thermal or catalytic conversion processes; shale oil; cycle oil; animal and vegetable derived fats, oils and waxes; petroleum and slack wax; or a combination thereof.20. The process of paragraphs 1-19, wherein the process is carried out in a single or multiple stage reactor system.21. The process of paragraphs 1-20, wherein the process is carried out in a single stage reactor system, e.g., in a single reactor.22. The process of paragraphs 1-21, wherein the process is carried out in two or more reactors, reactor sections, or reactor layers connected in a flow-through sequence, preferably with the second reactor, reactor section, or reactor layer comprising the hydrodeoxygenation catalyst.23. The process according to paragraphs 1-22, wherein the hydrodeoxygenation and / or hydroisomerization catalytic conditions comprise:a temperature in the range of about 400°F (204°C), or 450°F (232°C) to about 730°F (388°C), or 800°F (439°C);a pressure in the range of about 0 to about 3000 psig (0 to 20.68 MPa), or 0 to 2700 psig (0 to 18.62 MPa), or 0 to 2200 psig (0 to 15.17 MPa), or 0 to 1800 psig (0 to 12.41 MPa), or 0 to 1300 psig (0 to 8.96 MPa).24. The process according to paragraphs 1-23, wherein the process provides an overall renewable diesel yield for the noble metal catalyst system that is greater than a base metal catalyst system, or is at least 5%, or 10% or 20% greater than the base metal catalyst system.

[0099] It will be understood that the invention is not limited to the embodiments described above and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.

[0100] The foregoing description of one or more embodiments of the invention is primarily for illustrative purposes, it being recognized that variations might be used which would still incorporate the essence of the invention. Reference should be made to the following claims in determining the scope of the invention.

[0101] For the purposes of U.S. patent practice, and in other patent offices where permitted, all patents and publications cited in the foregoing description of the invention are incorporated herein by reference to the extent that any information contained therein is consistent with and / or supplements the foregoing disclosure.

Claims

WHAT IS CLAIMED IS:

1. A process for converting a feedstock into a product, the process comprisingcontacting a feedstock with a hydrodeoxygenation catalyst under hydrodeoxygenation conditions to produce a deoxygenated feedstock, the catalyst comprising a support and the catalytically active metals Pt and Re or Pt and Ru; andcontacting the deoxygenated feedstock with a hydroisomerization catalyst under hydroisomerization conditions to produce a product;wherein, the hydroisomerization catalyst comprises a monometallic or bimetallic noble metal catalyst.

2. The process of claim 1, wherein a renewable feedstock, e.g., a biofeedstock, is used in the process.

3. The process of claim 1 or 2, wherein a renewable product is produced by the process.

4. The process of claim 1-3, wherein the hydrodeoxygenation catalyst metals content is 0.01-15.0 wt.%, or 0.01-3.0 wt.%, or 0.01-2.0 wt.%, or 0.1-2.0 wt.% based on the total catalyst weight.

5. The process of claims 1-4, wherein the hydrodeoxygenation catalyst Pt metal content is 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.

6. The process of claims 1-5, wherein the hydrodeoxygenation catalyst Re or Ru metal content is 0.01 to 15 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.5 wt.% or 0.01-1.0 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.

7. The process of claims 1-6, wherein the hydrodeoxygenation catalyst Pt metal content is 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% and the Re or Ru metal content is 0.01- to 15 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.

8. The process of claims 1-7, wherein the hydrodeoxygenation catalyst molar ratio of Pt to Re or Ru is in the range of 100:1 to 1:100, or 50:1 to 1:50, or 30:1 to 1:30, or 20:1 to 1:20, or 10:1 to 1:10, or 100:1 to 1:50, or 100:1 to 1:30, or 100:1 to 1:20, or 100:1 to 1:10, or 100:1 to 1:5, or 50:1 to 1:30, or 50:1 to 1:20, or 50:1 to 1:10, or 0:1 to 1:5, or 30:1 to 1:20, or 30:1 to 1:10, or 30:1 to 1:5, or 20:1 to 1:10, or 20:1 to 1:5, or 10:1 to 1:5, or 5:1 to 1:30, or 5:1 to 1:20, or 5:1 to 1:10, or 5:1 to 1:5, or 3:1 to 1:3, or 1:1 to 1:2, or 5:1 to 2:1, or 5:1 to 3:1, or 1:1 to 1:3, or 1:1 to 1:4.

9. The process of claims 1-8, wherein the hydrodeoxygenation catalyst support is a non-zeolite support or wherein the support is selected from alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof.

10. The process of claims 1-9, wherein the hydrodeoxygenation catalyst comprises 0.01 to 5.0 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01 to 1.0 wt.% of the catalytically active metal, and 0.1 to 99 wt.% of the, or 1 to 99 wt.% of the support material.

11. The process of claims 1-10, wherein the hydroisomerization catalyst comprises a metal selected from Groups 7-11 of the Periodic Table.

12. The process of claims 1-11, wherein the hydroisomerization catalyst metals content is0.01-15.0 wt.%, or 0.01-3.0 wt.%, or 0.01-2.0 wt.%, or 0.1-2.0 wt.% based on the total catalyst weight.

13. The process of claims 1-12, wherein the hydroisomerization catalyst comprises Pt and / or Pd metal in an amount of 0.01 to 5 wt.%, or 0.01 to 3.0 wt.%, or 0.01 to 2.0 wt.%, or 0.01-1.0 wt.% or 0.01-0.8 wt.%, or 0.1-1.0 wt.% based on the total catalyst weight.

14. The process of claims 1-13, wherein the hydroisomerization catalyst comprises a support, wherein the support comprises a zeolite and / or a non-zeolite support, or wherein the hydroisomerization catalyst comprises a support, wherein the support comprises a zeolite comprising SSZ-32, SSZ-32x, SSZ-91, or a combination thereof and / or a non-zeolite support comprising alumina, silica, aluminosilicate, titania, zirconia, carbon (e.g., graphite), ceria, magnesia, or a combination thereof 15. The process of claims 2-14, wherein the renewable feedstock comprises or is a biocomponent feed selected from lipids, vegetable oils and animal fats which comprise triglycerides and free fatty acids, for example wherein the biocomponent feed is selected from canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil and a combination thereof; or wherein the biofeedstock comprises a biofeedstock-derived oxygen containing compound.

16. The process of claims 2-15, wherein the renewable feedstock comprises or is a biocomponent feed selected from canola oil, corn oil, soy oils, castor oil, camelina oil, palm oil, carinata oil, rapeseed oil, soybean oil, colza oil, tall oil, sunflower oil, hempseed oil, olive oil, linseed oil, coconut oil, castor oil, peanut oil, palm oil, mustard oil, cottonseed oil, tallow, yellow and brown greases, lard, train oil, fats in milk, fish oil, algal oil, sewage sludge, cuphea oil, camelina oil, jatropha oil, curcas oil, babassu oil, palm kernel oil, crambe oil, and the like.

17. The process of claims 2-16, wherein the renewable feedstock is a biofeedstock containing only renewable biocomponents; or wherein a fossil feedstock is not used as a component of the renewable feedstock; or wherein an added sulfur component is not added to the process to maintain the catalyst activity.

18. The process of claims 1-16, wherein the feedstock comprises a fossil feedstock.

19. The process of claim 18, wherein the fossil feedstock comprises gas oil; vacuum gas oil; long residue; vacuum residue; atmospheric distillate; heavy fuel; oil; wax and paraffin; used oil; deasphalted residue or crude; charges resulting from thermal or catalytic conversion processes; shale oil; cycle oil; animal and vegetable derived fats, oils and waxes; petroleum and slack wax; or a combination thereof.

20. The process of claims 1-19, wherein the process is carried out in a single or multiple stage reactor system.

21. The process of claims 1-20, wherein the process is carried out in a single stage reactor system, e.g., in a single reactor.

22. The process of claims 1-21, wherein the process is carried out in two or more reactors, reactor sections, or reactor layers connected in a flow-through sequence, preferably with the second reactor, reactor section, or reactor layer comprising the hydrodeoxygenation catalyst.

23. The process according to claims 1-22, wherein the hydrodeoxygenation and / or hydroisomerization catalytic conditions comprise:a temperature in the range of about 400°F (204°C), or 450°F (232°C) to about 730°F (388°C), or 800°F (439°C);a pressure in the range of about 0 to about 3000 psig (0 to 20.68 MPa), or 0 to 2700 psig (0 to 18.62 MPa), or 0 to 2200 psig (0 to 15.17 MPa), or 0 to 1800 psig (0 to 12.41 MPa), or 0 to 1300 psig (0 to 8.96 MPa).

24. The process according to claims 1-23, wherein the process provides an overall renewable diesel yield for the noble metal catalyst system that is greater than a base metal catalyst system, or is at least 5%, or 10% or 20% greater than the base metal catalyst system.

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