Gravity-based separation system of slurry catalyst in a petroleum-based liquid carrier

Abstract

A process includes passing a first slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier through one or more gravity-based separation processes to obtain a solid-rich stream comprising the solid catalyst particles and a solid-free lean stream comprising the petroleum-based oil liquid carrier, and mixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the solid-rich stream comprising the solid catalyst particles to obtain a second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.

Description

T-l 1897A-WO01 (538-366 PCT)GRAVITY-BASED SEPARATION SYSTEM OF SLURRY CATALYSTIN A PETROLEUM-BASED LIQUID CARRIERPRIORITY CLAIM

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 773,791, entitled “Gravity-Based Separation System of Slurry Catalyst in a Petroleum-Based Liquid Carrier,” filed March 18, 2025, the content of which is incorporated by reference herein in its entirety.BACKGROUND

[0002] Slurry hydroconversion processes such as slurry hydrocracking processes have been used for the upgrading of heavy hydrocarbon feedstocks to produce distillate products. In slurry hydrocracking processes, these feedstocks are converted in the presence of hydrogen and slurry catalyst containing solid catalyst particles. The slurry catalyst can be used with a liquid carrier to assist in transporting it in the slurry hydrocracking processes. The liquid carriers used can be petroleum-based oil liquid carriers such as heavy oils produced during the slurry hydrocracking processes.

[0003] Due to environmental regulations, governmental regulations and incentives, and an increasing worldwide demand for energy, there is an increasing emphasis on replacing petroleumbased feedstocks with renewable-based feedstocks. Currently, refineries are interested in processing renewable-based feedstocks such as liquid, sugar and lignocellulose. In addition, refineries are processing renewable-based feedstocks in existing refinery units to minimize the installation and operational cost and reduce the revamp requirement.SUMMARY

[0004] In accordance with an aspect of the present discloure, a process comprises:

[0005] passing a first slurry catalyst comprising solid catalyst particles and a petroleumbased oil liquid carrier through one or more gravity-based separation processes to obtain a solidrich stream comprising the solid catalyst particles and a solid-free lean stream comprising the petroleum-based oil liquid carrier, andT-l 1897A-WO01 (538-366 PCT)

[0006] mixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the solid-rich stream comprising the solid catalyst particles to obtain a second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.BRIEF DESCRIPTION OF THE DRAWING

[0007] In combination with the accompanying drawing and with reference to the following detailed description, the features, advantages, and other aspects of the implementations of the present disclosure will become more apparent, and several implementations of the present disclosure are illustrated herein by way of example but not limitation. The principles illustrated in the example embodiments of the drawing can be applied to alternate processes and apparatus. Additionally, the elements and features shown in the drawing are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Certain dimensions or positions may be exaggerated to help visually convey such principles. In the accompanying drawing:

[0008] FIG. 1 illustrates a schematic diagram of a system and process for converting a slurry catalyst comprising solid particles and a petroleum-based oil liquid carrier to a slurry catalyst and one of a renewable-based liquid carrier or a circular-based liquid carrier using a gravity-based separation unit, according to an illustrative embodiment.DETAILED DESCRIPTION

[0009] Various illustrative embodiments described herein are directed to systems and processes for converting a slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid catalyst particles and one of a renewablebased liquid carrier or a circular-based liquid carrier using a gravity-based separation unit. The conversion of a slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid catalyst particles and one of a renewable-based liquid carrier or a circular-based liquid carrier offers one alternative to crude.

[0010] DEFINITIONST-l 1897A-WO01 (538-366 PCT)

[0011] To define more clearly the terms used herein, the following definitions are provided. Unless otherwise indicated, the following definitions are applicable to this disclosure. If a term is used in this disclosure but is not specifically defined herein, the definition from the IUPAC Compendium of Chemical Terminology can be applied, as long as that definition does not conflict with any other disclosure or definition applied herein or render indefinite or non-enabled any claim to which that definition is applied. To the extent that any definition or usage provided by any document incorporated herein by reference conflicts with the definition or usage provided herein, the definition or usage provided herein controls.

[0012] While systems and processes are described in terms of “comprising” various components or steps, the systems and processes can also “consist essentially of’ or “consist of’ the various components or steps, unless stated otherwise.

[0013] The terms “a,” “an,” and “the” are intended to include plural alternatives, e.g., at least one. The terms “including,” “with,” and “having,” as used herein, are defined as comprising (i.e., open language), unless specified otherwise.

[0014] Various numerical ranges are disclosed herein. When Applicant discloses or claims a range of any type, Applicant’s intent is to disclose or claim individually each possible number that such a range could reasonably encompass, including end points of the range as well as any sub-ranges and combinations of sub-ranges encompassed therein, unless otherwise specified. For example, all numerical end points of ranges disclosed herein are approximate, unless excluded by proviso.

[0015] Values or ranges may be expressed herein as “about,” from “about” one particular value, and / or to “about” another particular value. When such values or ranges are expressed, other embodiments disclosed include the specific value recited, from the one particular value, and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that there are a number of values disclosed therein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. In another aspect, use of the term “about” means ±20% of the stated value, ±15% of the stated value, ±10% of the stated value, ±5% of the stated value, ±3% of the stated value, or ±1% of the stated value.T-l 1897A-WO01 (538-366 PCT)

[0016] Applicant reserves the right to proviso out or exclude any individual members of any such group of values or ranges, including any sub-ranges or combinations of sub-ranges within the group, that can be claimed according to a range or in any similar manner, if for any reason Applicant chooses to claim less than the full measure of the disclosure, for example, to account for a reference that Applicant may be unaware of at the time of the filing of the application. Further, Applicant reserves the right to proviso out or exclude any members of a claimed group.

[0017] The term “hydroconverting” or “hydroconversion,” as used herein refers to any process in which hydrocarbons are processed or treated in the presence of a hydrogen stream and a catalyst. Representative examples of hydroconverting include hydrocracking, hydrotreating, hydrogenation, deoxygenation, desulfurization, denitrogenation, demetallization, dechlorination, decarboxylation, decarbonylation, dearomatization or a combination thereof.

[0018] The term “hydrocracking,” as used herein refers to a process in which hydrocarbons crack in the presence of a hydrogen stream and a hydrocracking catalyst to lower molecular weight hydrocarbons. Hydrocracking also includes slurry hydrocracking in which a feed is mixed with a slurry catalyst and hydrogen to make a slurry and cracked to lower boiling products.

[0019] The term “continuous” as used herein shall be understood to mean a system that operates without interruption or cessation for a period of time, such as where reactant(s) and catalyst(s) are continually fed into a reaction zone and products are continually or regularly withdrawn without stopping the reaction in the reaction zone.

[0020] The term “fresh catalyst” as used herein denotes a catalyst which has not previously been used in a catalytic process.

[0021] The term “spent catalyst” as used herein denotes a catalyst that has less activity at the same reaction conditions (e.g., temperature, pressure, inlet flows) than the catalyst had when it was originally exposed to the process. This can be due to a number of reasons, several nonlimiting examples of causes of catalyst deactivation are coking or carbonaceous material sorption or accumulation, steam or hydrothermal deactivation, metals (and ash) sorption or accumulation, attrition, morphological changes including changes in pore sizes, cation or anion substitution, and / or chemical or compositional changes.

[0022] The term “regenerated catalyst” as used herein denotes a catalyst that had become spent, as defined above, and was then subjected to a process that increased its activity to a levelT-l 1897A-WO01 (538-366 PCT)greater than it had as a spent catalyst. This may involve, for example, reversing transformations or removing contaminants outlined above as possible causes of reduced activity. The regenerated catalyst typically has an activity that is equal to or less than the fresh catalyst activity.

[0023] The term “renewable source” as used herein refers to a material originating from a renewable resource (e.g., plants) and non-geologically derived. The term “geologically derived” means originating from, for example, crude oil, natural gas, or coal. “Geologically derived” materials cannot be easily replenished or regrown (e.g., in contrast to plant- or algae-produced oils).

[0024] The term “circular source” as used herein refers to a material at a point in time of a user or a supply chain considered as a waste / processing residue that has not been landfilled or energetically used, but instead it is reused as is, further used or recycled in a loop without being removed from the economy. In non-limiting illustrative embodiments, a circular source can refer to a municipal solid waste or an industrial solid waste.

[0025] The term “municipal solid waste” as used herein refers to nonliquid waste that comes from homes, institutions, and small businesses.

[0026] The term “industrial solid waste” as used herein refers to waste that comes from the production of consumer goods which do not normally reach a consumer.

[0027] The term “recycled waste” is used herein to indicate a material recovered from both post-consumer waste and industrial waste, as opposed to virgin polymers.

[0028] The term “post-consumer waste” as used herein refers to objects having completed at least a first use cycle (or life cycle), i.e., having already served their first purpose.

[0029] The term “virgin” as used herein denotes the newly produced materials and / or objects prior to their first use, which have not already been recycled.

[0030] The term “biofuels” as used herein refers to liquid fuels obtained from a renewable source (e.g., of a biological origin).

[0031] The term “effluent” as used herein refers to a stream that is passed out of a reactor, a reaction zone, a mixing unit or a separator following a particular reaction, combination or separation. Generally, an effluent has a different composition than the stream that entered the reactor, reaction zone, or separator. It should be understood that when an effluent is passed to another component or system, only a portion of that effluent may be passed. For example, aT-l 1897A-WO01 (538-366 PCT)slipstream may carry some of the effluent away, meaning that only a portion of the effluent may enter the downstream component or system.

[0032] As discussed above, hydroconversion processes such as slurry hydrocracking processes have been used for the upgrading of heavy hydrocarbon feedstocks to produce distillate products. In slurry hydrocracking processes, these heavy hydrocarbon feedstocks are converted in the presence of hydrogen and a slurry catalyst comprising solid catalyst particles. The slurry catalyst comprising solid catalyst particles can be used with a liquid carrier to assist in transporting it in the slurry hydrocracking processes. The liquid carriers used have been petroleum-based oil liquid carriers such as heavy oils produced during the slurry hydrocracking processes. For example, a slurry catalyst from, for example, a slurry hydroconversion process, is prepared in a fossil-based liquid carrier, e.g., a petroleum-based oil such as a vacuum gas oil. However, since refineries are becoming more interested in processing renewable-based feedstocks rather than petroleum-based feedstocks, it can be critical to eliminate petroleum-based feedstocks, including petroleum-based oil liquid carriers from the slurry catalyst.

[0033] The non-limiting illustrative embodiments described herein overcome the drawbacks discussed above by providing systems and processes for converting a slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid catalyst particles and one of a renewable-based liquid carrier or a circular-based liquid carrier using a gravity-based separation unit. The slurry catalyst in one of a renewablebased liquid carrier or a circular-based liquid carrier can then be used in a slurry system and process using a renewable feedstock to produce renewable fuels such as biofuels without any contamination from a petroleum product such as a petroleum-based oil liquid carrier. In addition, the renewable fuels such as biofuels will have a lower carbon footprint than a corresponding than a hydrocarbon product produced from one of a petroleum-based process or a slurry catalyst in a petroleum-based oil liquid carrier. Therefore, the carbon emission of the entire process will be much lower.

[0034] The systems and processes according to the non-limiting illustrative embodiments described herein convert a slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid catalyst particles and one of a renewablebased liquid carrier or a circular-based liquid carrier using a gravity -based separation unit to formT-l 1897A-WO01 (538-366 PCT)a solid-rich stream (i.e., a concentrate) comprising the solid catalyst particles and then mixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the solid-rich stream comprising the solid catalyst particles to obtain the slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.

[0035] The non-limiting illustrative embodiments of the present disclosure will now be specifically described below with reference to the accompanying drawing. For the purpose of clarity, some steps leading up to the production of a slurry catalyst comprising solid particles and one of a renewable-based liquid carrier or a circular-based liquid carrier as illustrated in FIG. 1 may be omitted. In other words, one or more well-known processing steps which are not illustrated but are well-known to those of ordinary skill in the art have not been included in the figure. This is not intended to be interpreted as a limitation of any particular embodiment, or illustration, or scope of the claims.

[0036] Referring now to the drawing in more detail, FIG. 1 illustrates a system 100 for converting a slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid catalyst particles and one of a renewable-based liquid carrier or a circular-based liquid carrier, according to illustrative embodiments of the invention. System 100 includes at least a gravity -based separation unit 102, a mixing unit 108 and a retrofit renewable slurry reactor 116 according to the non-limiting illustrative embodiments of the present disclosure. It is to be understood that system 100 including gravity -based separation unit 102, mixing unit 108 and retrofit renewable slurry reactor 116 is not limited to the configuration of the embodiments shown in FIG. 1, and other configurations are contemplated herein.

[0037] In this particular non-limiting illustrative embodiment, a slurry catalyst stream 101 comprising solid catalyst particles and a petroleum-based oil liquid carrier is sent to gravity-based separation unit 102. In some embodiments, slurry catalyst stream 101 can be received from a separation unit (not shown) following a slurry hydroconversion process in a slurry hydroconversion reactor including at least a petroleum feedstock, or directly from a slurry hydroconversion reactor. In some embodiments, slurry catalyst stream 101 can be received from a fresh catalyst slurry synthesis unit (not shown).

[0038] In some embodiments, slurry catalyst stream 101 can contain from about 50 wt. % to about 99 wt. % petroleum-based oil liquid carrier, or from about 70 wt. % to about 97 wt. %T-l 1897A-WO01 (538-366 PCT)petroleum-based oil liquid carrier, or from about 80 wt. % to about 95 wt. % petroleum-based oil liquid carrier, and from about 1 wt. % to about 50 wt. % catalyst, or from about 3 wt. % to about 30 wt. % catalyst, or from about 5 wt. % to about 20 wt. % catalyst (as solids, in the form of a slurry catalyst in one or more of spent catalyst, regenerated catalyst or fresh catalyst).

[0039] In some embodiments, a light solvent can be added to dilute slurry catalyst stream 101 to assist in accelerating the settling rate or improve the separation efficiency in gravity -based separation unit 102. In some embodiments, a light solvent can be, for example, a light solvent derived from a fossil source or a non-fossil source. In some embodiments, a light solvent derived from a fossil source includes, for example, naphtha, jet, diesel, aromatic solvents such as toluene, aliphatic hydrocarbons such as heptane. In some embodiments, a light solvent derived from a nonfossil source includes, for example, a Ci-Ce alcohol such as methanol, ethanol and the like, heterocyclic solvents such as tetrahydrofuran and the like. In some embodiments, from about 20 vol. % to about 200 vol. % light solvent can be added slurry catalyst stream 101. In some embodiments, from about 50 vol. % to about 100 vol. % light solvent can be added slurry catalyst stream 101.

[0040] Slurry Catalyst

[0041] In some embodiments, slurry hydroconversion processes use a dispersed catalyst which is continuously doped into the feed. The slurry catalyst can correspond to one or more catalytically active metals in particulate form and / or supported on particles. Catalytically active metals for use in the slurry hydroconversion processes can include those from Groups 4-12 of the IUPAC Periodic Table of Elements. Suitable metals include, for example, iron, nickel, molybdenum, zinc, vanadium, tungsten, cobalt, ruthenium, and any combination thereof. The catalytically active metal may be present as a solid particulate in elemental form or as an organic compound or an inorganic compound such as a sulfide or other ionic compound. Metal or metal compound nanoaggregates may also be used to form the solid particulates.

[0042] In some embodiments, the slurry catalyst may have an average particle size of at least about 0.1 micron to about 300 microns. In some embodiments, the slurry catalyst may have an average particle size of at least about 0.1 micron to about 200 microns. In some embodiments, the slurry catalyst may have an average particle size of at least about 0.1 micron to about 100 microns, e.g., from about 1 micron to about 10 microns. In some embodiments, the slurry catalystT-l 1897A-WO01 (538-366 PCT)comprises a metal sulfide comprising one or more metals selected from the group consisting of molybdenum, nickel, cobalt, tungsten, iron and zine, and the slurry catalyst comprises particles having an average particle size of about 0.1 micron to about 200 microns.

[0043] In some embodiments, the slurry catalyst includes sulfided catalytically active metals. Examples of suitable catalytically active metals include, without limitation, sulfided nickel, sulfided cobalt, sulfided molybdenum, sulfided tungsten, sulfided CoMo, sulfided NiMo, sulfided MoW, sulfided NiW, and combinations thereof.

[0044] A slurry catalyst in the form of a solid particulate is generally a compound of a catalytically active metal, or a metal in elemental form, either alone or supported on a refractory material such as an inorganic metal oxide (e.g., alumina, silica, titania, zirconia, and any combination thereof). Other suitable refractory materials can include carbon, coal, and clays. Zeolites and non-zeolitic molecular sieves are also useful as solid supports. In some embodiments, a supported slurry catalyst can have from about 0.01 to about 30 wt. % of the catalytic active metal based on the total weight of the slurry catalyst.

[0045] In some embodiments, it can be desirable to form the slurry catalyst in situ, such as forming a slurry catalyst from a metal sulfate (e.g., iron sulfate monohydrate) catalyst precursor or another type of catalyst precursor that decomposes or reacts in a hydroconversion reaction zone environment, or in a pretreatment step, to form a desired, well-dispersed and catalytically active solid particulate (e.g., as iron sulfide). Precursors also include oil-soluble organometallic compounds containing the catalytically active metal of interest, such as iron naphthenate, Mo octoate, Ni naphthenate, which can thermally decompose to form the solid particulate (e.g., iron sulfide, molybdenum sulfide, nickel sulfide) having catalytic activity. Other suitable precursors include metal oxides that may be converted to catalytically active (or more catalytically active) compounds such as metal sulfides. In a particular embodiment, a metal oxide containing mineral may be used as a precursor of a solid particulate comprising the catalytically active metal (e.g., iron sulfide) on an inorganic refractory metal oxide support (e.g., alumina).

[0046] In some embodiments, the slurry catalyst comprises one or more of molybdenum sulfide, iron sulfide, nickel sulfide, zinc sulfide, and iron zinc.T-l 1897A-WO01 (538-366 PCT)

[0047] In some embodiments, suitable catalyst slurry concentrations can range from about 0.005% to about 15% on a metal basis (e.g., about 0.02% to about 1% on a metal basis, or about 1% to about 10% on a metal basis.

[0048] The slurry catalyst described above is merely illustrative and any known slurry catalyst or later developed slurry catalyst is contemplated in the illustrative embodiments described herein.

[0049] Petroleum-Based Oil Liquid Carrier

[0050] The slurry catalyst further includes a petroleum-based oil liquid carrier and cocatalyst particles. The co-catalyst particles may be in admixture with the petroleum-based oil liquid carrier. In some embodiments, the petroleum-based oil liquid carrier may have a boiling range greater than 500°F (260°C), e.g., greater than 500°F (260°C) and up to about 1500°F (815°C), or from about 55O°F (288°C) to about 1200°F (689°C), or from about 550°F (288°C) to about 950°F (510°C). In some embodiments, at least about 20% or at least about 30%, or at least about 40%, or at least about 50%, or at least about 60%, or at least about 70%, or at least about 80%, or at least about 90% or at least about 95% of the petroleum-based oil liquid carrier may have a boiling range greater than 500°F (260°C), e.g., greater than 500°F (260°C) and up to about 1500°F (815°C), or from about 55O°F (288°C) to about 1200°F (689°C), or from about 55O°F (288°C) to about 950°F (510°C).

[0051] Suitable petroleum-based oil liquid carriers include, for example, vacuum gas oil, light vacuum gas oil, heavy vacuum gas oil, lube oil base stock, heavy diesel, deasphalted oil, FCC main column bottoms (MCB), heavy cycle oil (HCO), decant oil (DCO), medium cycle oil, and combinations thereof.

[0052] Turning back to FIG. 1, gravity -based separation unit 102 separates slurry catalyst stream 101 including solid catalyst particles and a petroleum-based oil liquid carrier utilizing one or more gravity -based processes to provide a solid-rich stream 104 and a solid-free lean stream 106. In some embodiments, gravity -based separation unit 102 includes one or more gravity-based separators. Suitable gravity-based separators include, for example, a centrifuge, a gravity settler separation unit (e.g., a static settler), and the like. In some embodiments, gravity-based separation unit 102 includes a series of gravity -based separators. In another embodiment, gravity -based separation unit 102 include at least two to eight gravity -based separators.T-l 1897A-WO01 (538-366 PCT)

[0053] In some embodiments, a continuous process includes injecting slurry catalyst stream 101 including solid catalyst particles and a petroleum-based oil liquid carrier into a middle portion of one or more gravity -based separators of gravity -based separation unit 102. Separation of the solid catalyst particles and the petroleum-based oil liquid carrier occurs by centrifugal force or by static settlement separation by gravity. In some embodiment, a series of gravity-based separators are used in which slurry catalyst stream 101 is injected into a first gravity-based separator, thereby producing a first solid-free lean stream exiting a top portion of the first gravitybased separator and a first solid-rich stream exiting a bottom portion of the first gravity-based separator. The first solid-rich stream exits the first gravity -based separator in a concentrated form having a solid content greater than the initial solid content in slurry catalyst stream 101. The first solid-rich stream can then be injected into a second gravity -based separator to further concentrate the first solid-rich stream, thereby producing a second solid-free lean stream exiting a top portion of the second gravity-based separator and a second solid-rich stream exiting a bottom portion of the second gravity -based separator. In this manner, each solid-rich stream exiting from a bottom portion of the respective gravity-based separator is in a further concentrated form having a solid content greater than the solid content of the incoming solid-rich stream.

[0054] In some embodiments, a light solvent can be added to first solid-rich stream prior to, during or after being injected into the second gravity -based separator to assist in accelerating the settling rate or improve the separation efficiency in the second gravity-based separator of gravity -based separation unit 102. In some embodiments, a light solvent can be, for example, derived from a fossil source or a non-fossil source as discussed above. In some embodiments, a light solvent can be derived from a renewable source or a circular source as discussed below. For example, a solvent prepared from renewable sources such as agricultural crops or biomass, called bio-derived or bio-based natural sources that can be used for the production of bio-solvents include waste materials (agricultural, wood, and urban wastes, crop residues), forest products (wood, logging residues, trees, shrubs), energy crops (starch crops such as corn, wheat, and barley, sugar crops and grasses) and, aquatic biomass (Algae, water weed and water hyacinth). As a further example, a solvent prepared from circular sources include, for example, municipal solid waste, industrial solid waste and combinations thereof.T-l 1897A-WO01 (538-366 PCT)

[0055] In one embodiment, gravity -based separation unit 102, used in the illustrative embodiments described herein concentrates the solid content from an initial concentration of about 1 wt. % to about 50 wt. % of slurry catalyst stream 101, up to about 20 wt. % to about 95 wt. % , or from about 25 wt. % to about 95 wt. %, or from about 30 wt. % to about 95 wt. %, or from about 50 wt. % to about 95 wt. %, or from about 70 wt. % to about 95 wt. % of solid-rich stream 104 as the outlet stream while obtaining solid-free lean stream 106 as an outlet cleaned stream containing relatively little to no solid content.

[0056] In some embodiments, solid-free lean stream 106 will contain at least about 80% of the petroleum -based oil liquid carrier relative to slurry catalyst stream 101. In some embodiments, solid-free lean stream 106 will contain at least about 85% of the petroleum-based oil liquid carrier relative to slurry catalyst stream 101. In some embodiments, solid-free lean stream 106 will contain at least about 90% of the petroleum -based oil liquid carrier relative to slurry catalyst stream 101. In some embodiments, solid-free lean stream 106 will contain at least about 95% of the petroleum-based oil liquid carrier relative to slurry catalyst stream 101. In some embodiments, solid-free lean stream 106 will contain at least about 99% of the petroleum -based oil liquid carrier relative to slurry catalyst stream 101. In some embodiments, solid-free lean stream 106 can be recycled back to a slurry reactor (not shown) to form a new slurry catalyst for hydroconversion of a petroleum-based feedstock.

[0057] In some embodiments, the operating temperature for gravity-based separation unit 102 can be the temperature of the stream entering the gravity -based separation unit as well as the pressure. In some embodiments, the operating temperature can be operated from ambient temperature to about 932°F (500°C), or from about 122°F (50°C) to about 752°F (400°C), or from about 122°F (50°C) to about 572°F (300°C), or from about 122°F (50°C) to about 392°F (200°C). The operating pressure can be operated from atmospheric pressure to about 3000 psig, or from atmospheric pressure to about 2000 psig, or from atmospheric pressure to about 1000 psig, or from atmospheric pressure to about 500 psig, or from atmospheric pressure to about 200 psig or from atmospheric pressure to about 100 psig.

[0058] System 100 further includes mixing unit 108 for receiving solid-rich stream 104 and one of a renewable-based liquid carrier 110 or a circular-based liquid carrier 112. In some embodiments, mixing unit 108 can include a first inlet for receiving solid-rich stream 104, a secondT-l 1897A-WO01 (538-366 PCT)inlet for receiving renewable-based liquid carrier 110 and a third inlet for receiving circular-based liquid carrier 112. However, it is also contemplated that receiving solid-rich stream 104 and one of renewable-based liquid carrier 110 or circular-based liquid carrier 112 can be co-fed to mixing unit 108. Mixing unit 108 can be any conventional mixing unit known in the art for combining solid-rich stream 104 and one of renewable-based liquid carrier 110 or circular-based liquid carrier 112 to form a slurry catalyst effluent 114.

[0059] Mixing unit 108 further includes an outlet for releasing slurry catalyst effluent 114 comprising solid catalyst particles and one of a renewable-based liquid carrier or a circular-based liquid carrier. In some embodiments, slurry catalyst effluent 114 will have less than about 10 wt. % of petroleum-based oil liquid carrier. In some embodiments, slurry catalyst effluent 114 will have less than about 5 wt. % of petroleum-based oil liquid carrier.

[0060] In some embodiments, slurry catalyst effluent 114 can contain from about 50 wt. % to about 99 wt. % of one of renewable-based liquid carrier 110 or circular-based liquid carrier 112, or from about 70 wt. % to about 97 wt. % of one of renewable-based liquid carrier 110 or circular-based liquid carrier 112, or from about 80 wt. % to about 95 wt. % of one of renewablebased liquid carrier 110 or circular-based liquid carrier 112, and from about 1 wt. % to about 50 wt. % solid catalyst particles, or from about 3 wt. % to about 30 wt. % solid catalyst particles, or from about 5 wt. % to about 20 wt. % solid catalyst particles.

[0061] Renewable-Based Liquid Carrier

[0062] In some embodiments, renewable-based liquid carrier 110 may originate from any renewable or biological source or sources, and is meant to include herein feedstocks other than those obtained from, for example, mineral oil, shale oil or coal.

[0063] In an illustrative embodiment, renewable-based liquid carrier 110 may originate from any renewable source or sources such as, for example, from any type of plant, animal, microorganism such as algae (e.g., algae oil, algae biomass, algae cultivation), fish and microbiological process.

[0064] In some embodiments, renewable-based liquid carrier 110 may originate from any renewable source or sources such as, for example, plant-based oils and / or animal-based fats and oils.T-l 1897A-WO01 (538-366 PCT)

[0065] Many different renewable sources derived from plants can be used. In non-limiting illustrative embodiments, plant-based oils can include, for example, rapeseed oil, soybean oil (including degummed soybean oil), canola oil, cottonseed oil, grape seed oil, mustard seed oil, corn oil, linseed oil, safflower oil, sunflower oil, poppy-seed oil, pecan oil, walnut oil, oat oil, peanut oil, rice bran oil, camellia oil, castor oil, and olive oil, palm oil, coconut oil, rice oil, algae oil, seaweed oil, and Chinese Tallow tree oil. In non-limiting illustrative embodiments, plantbased sources can be obtained from, for example, argan, avocado, babassu palm, balanites, borneo tallow nut, brazil nut, calendula, camelina, caryocar, cashew nut, Chinese vegetable tallow, cocoa, coffee, cohune palm, coriander, cucurbitaceae, euphorbia, hemp, illipe, jatropha, jojoba, kenaf, kusum, macadamia nuts, mango seed, noog abyssinia, nutmeg, opium poppy, perilla, pili nut, pumpkin seed, rice bran, sacha inche, seje, sesame, shea nut, teasel, allanblackia, almond, chaulmoogra, cuphea, jatropa curgas, karanja seed, neem, papaya, tonka bean, tung, and ucuuba, cajuput, clausena anisata, davana, galbanum natural oleoresin, German chamomile, hexastylis, high-geraniol monarda, juniapa-hinojo sabalero, lupine, melissa officinalis, milfoil, ninde, patchouli, tarragon, and wormwood.

[0066] Many different renewable sources derived from animals can also be used. In nonlimiting illustrative embodiments, animal-based sources can include, for example, choice white grease, lard (pork fat), tallow (beef fat), fish oil, and poultry fat.

[0067] Many different renewable sources derived from microorganisms (e.g., Eukaryotes, Eubacteria and Archaea) can also be used. In non-limiting illustrative embodiments, microbebased sources include, for example, the L-glycerol lipids of Archaea and algae and diatom oils. In some embodiments, renewable sources derived from microorganisms can include bacteria, protozoa, algae, and fungi.

[0068] In some embodiments, renewable sources derived from both plant and animal sources can be used such as, for example, yellow grease, white grease, and brown grease. In nonlimiting illustrative embodiments, yellow, white or brown grease can include frying oils from deep fryers and can thus include fats of both plant and animal origin. In some embodiments, renewable sources can specifically include used cooking oil.

[0069] In an illustrative embodiment, renewable-based liquid carrier 110 may originate from any renewable source or sources such as, for example, a biological raw material componentT-l 1897A-WO01 (538-366 PCT)such as a vegetable oil, animal fat, and algae oil. The common feature of these sources is that they are composed of glycerides and free fatty acids (FFAs). Both of these classes of compounds contain aliphatic carbon chains having from about 8 to about 24 carbon atoms. The aliphatic carbon chains in the glycerides or FFAs can be saturated or mono-, di- or poly-unsaturated aliphatic carbon atoms.

[0070] Accordingly, in an illustrative embodiment, renewable-based liquid carrier 110 that can be used herein includes any of those which comprise glycerides and FFAs. In some embodiments, the glycerides will contain a majority of triglycerides; however, monoglycerides and diglycerides may be present and processed as well. In an illustrative embodiment, renewablebased liquid carrier 110 can contain at least about 10 wt. % triglycerides. In an illustrative embodiment, renewable-based liquid carrier 110 can contain at least about 25 wt. % triglycerides. In an illustrative embodiment, renewable-based liquid carrier 110 can contain at least about 50 wt. % triglycerides. In an illustrative embodiment, renewable-based liquid carrier 110 can contain at least about 75 wt. % triglycerides. In an illustrative embodiment, renewable-based liquid carrier 110 can contain at least about 90 wt. % triglycerides. In an illustrative embodiment, renewablebased liquid carrier 110 can contain 100 wt. % triglycerides.

[0071] Suitable vegetable oils include, for example, castor oil, canola oil, coconut oil, corn oil, cottonseed oil, jatropha oil, linseed oil, mustard oil, olive oil, palm oil, palm kernel oil, peanut oil, rapeseed oil, safflower oil, sesame oil, soybean oil, and sunflower oil. Suitable vegetable oils can also include processed vegetable oil materials such as the fatty acids and fatty acid (Ci to Cs) alkyl esters derived from vegetable oils.

[0072] Representative examples of animal fats include beef fat (tallow), hog fat (lard), poultry fat, and fish oil. Suitable animal fats can also include processed animal fat materials such as the fatty acids and fatty acid (Ci to Cs) alkyl esters derived from animal fats.

[0001] In some embodiments, renewable-based liquid carrier 110 can include one or more biocrudes such as, for example, tall oil products, renewable liquid products from other liquefaction processes such as pyrolysis oil from biomass, hydrothermal liquefaction product from biomass, distiller corn oil and the like. Suitable tall oil products include, for example, crude tall oil, tall oil fatty acid, distilled tall oil, rosin acid and tall oil pitch (TOP).T-l 1897A-WO01 (538-366 PCT)

[0073] The term “tall oil pitch (TOP)” refers to residual bottom residual bottom fraction from tall oil distillation processes. In some embodiments, tall oil pitch comprises from about 34 to about 51 wt. % free acids, from about 23 to about 37 wt. % esterified acids, and from about 25 to about 34 wt. % unsaponifiable neutral compounds of the total weight of the tall oil pitch. The free acids include, for example, dehydroabietic acid, abietic and other resin acids. The esterified acids include, for example, oleic and linoleic acids. The unsaponifiable neutral compounds include, for example, diterpene sterols, fatty alcohols, sterols, and dehydrated sterols.

[0074] The term “crude fatty acid (CFA)” refers to fatty acid-containing materials obtainable by purification (e.g., distillation under reduced pressure, extraction, and / or crystallization) of crude tall oil (CTO).

[0075] The term “tall oil fatty acid (TOFA)” refers to fatty acid rich fraction of crude tall oil (CTO) distillation processes. TOFA comprises mainly fatty acids, such as at least about 80 wt. % of the total weight of the TOFA. In some embodiments, TOFA comprises less than about 10 wt. % rosin acids.

[0076] The term “distilled tall oil (DTO)” refers to resin acid rich fraction of crude tall oil (CTO) distillation processes. DTO comprises mainly fatty acids, such as from about 55 to about 90 wt. %, and resin acids, such as from about 10 to about 40 wt. % resin acids, of the total weight of the DTO. In some embodiments, DTO comprises less than about 10 wt. % unsaponifiable neutral compounds of the total weight of the distilled tall oil.

[0077] In some embodiments, renewable-based liquid carrier 110 can include any renewable products produced from a renewable source such as, for example, bio-derived products by a thermochemical process including, for example, a catalytic pyrolysis process, such as a fluid catalytic cracking (FCC) process, a hydrothermolysis (HTL) process, or a torrefaction process, or a hydroconversion process, or a hydrocracking process. Such processes are known in the art, as are processes for producing bio-oils, bio-residue oil or heavy products from biomass feedstocks (e g., algal oils produced from algae) by these processes, and, therefore, are not described in detail herein. For example, a bio-oil may be further processed into useful renewable hydrocarbons, including bio-diesel, renewable diesel, renewable jet fuel, renewable gasoline, and other renewable transportation fuels, bio-base oil, etc.T-l 1897A-WO01 (538-366 PCT)

[0078] In some embodiments, renewable-based liquid carrier 110 can include one or more of a plant, an animal and a microorganism based renewable feedstock.

[0079] In some embodiments, renewable-based liquid carrier 110 can include one or more of a crude tall oil, a tall oil pitch, a bio-residual oil and a heavy product derived from a biomass hydroprocessing product.

[0080] Circular-Based Liquid Carrier

[0081] In some embodiments, circular-based liquid carrier 112 may originate from any circular source or sources. In non-limiting illustrative embodiments, suitable circular sources include, for example, municipal solid waste, industrial solid waste and combinations thereof. Representative examples of municipal solid waste include, but are not limited to, domestic household waste, sewage sludge, medical or hospital waste, textiles, plastics, rubber, cartons and the like. Representative examples of industrial solid waste include, but are not limited to, industrial sludge, paper pulp sludge, waste paper, waste paperboard, textiles, plastics, rubber, cartons, and the like.

[0082] In non-limiting illustrative embodiments, suitable circular sources include, for example, one or more of a waste plastic feedstock, a pyrolysis-derived product of a waste plastic feedstock and combinations thereof. In illustrative embodiments, a “waste plastic” as used herein includes high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), polystyrene (PS) and mixed plastics, e.g., a mixture of polyethylene (PE), polypropylene (PP), and polystyrene (PS) or a mixture of LDPE, HDPE and PP. The waste plastic can be co-fed by dissolving in other feedstocks or through a dedicated solid feeding system e.g., a screw feeder. In non-limiting illustrative embodiments, a pyrolysis-derived product of a waste plastic feedstock includes a plastic pyrolysis residue, a plastic pyrolysis oil, and combinations thereof. For example, a pyrolysis-derived product of a waste plastic can be derived by pyrolyzing waste plastic into various desirable end products such as plastic pyrolysis oil. In a non-limiting illustrative embodiment, a plastic pyrolysis oil is produced from thermal degradation of different types of waste plastics which include high density polyethene (HDPE), low density polyethene (LDPE), polypropylene (PP), polystyrene (PS), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and mixed plastics, e.g., a mixture of polyethylene (PE), polypropylene (PP), and polystyrene (PS) or a mixture of LDPE, HDPE and PP. If desired, the plastic pyrolysis oil can be further refined toT-l 1897A-WO01 (538-366 PCT)remove unwanted impurities such as chlorine, nitrogen, and metal contained in the plastic pyrolysis oil as known in the art.

[0083] In an illustrative embodiment, the waste plastic feedstock and the pyrolysis-derived product of a waste plastic feedstock are low carbon-intensity feedstocks. For example, in an illustrative embodiment, the waste plastic feedstock and the pyrolysis-derived product of a waste plastic feedstock are low carbon footprint feedstocks to assist in achieving carbon neutrality.

[0084] In non-limiting illustrative embodiments, suitable circular sources include, for example, a recycled material, which is recovered from a waste plastic material derived from postconsumer and / or post-industrial waste. In an illustrative embodiment, suitable circular sources include, for example, a recycled material such as recycled plastic. The plastic can be any of the plastic material described above.

[0085] Turning back to FIG. 1, system 100 further includes retrofit renewable slurry reactor 116 for receiving slurry catalyst effluent 114 comprising solid catalyst particles and one of renewable-based liquid carrier 110 or circular-based liquid carrier 112, and one or more renewable feedstocks 118 for hydroconversion of one or more renewable feedstocks 118 under hydroconversion conditions to produce a hydroconversion product stream 120.

[0002] The process is capable of processing a wide range of renewable feedstocks. In some embodiments, one or more renewable feedstocks 118 can be any type of biologically derived liquid feedstock that can be usefully processed in retrofit renewable slurry reactor 116. Examples of such biologically derived liquid feedstocks include lipids (e.g., fats, oils, grease).

[0086] In some embodiments, one or more renewable feedstocks 118 are solid biomass feedstocks. Suitable solid biomass feedstocks for one or more renewable feedstocks 118 include, for example, (1) agricultural residues, such as com stalks, straw, seed hulls, sugarcane leavings, bagasse, nutshells, and manure from cattle, poultry, and hogs; (2) wood materials, such as wood or bark, sawdust, timber slash, and mill scrap; (3) municipal waste, such as waste paper and yard clippings; (4) algae-derived biomass, including carbohydrates and lipids from microalgae (e.g., Botryococcus braunii, Chlorella, Dunaliella tertiolecta, Gracilaria, Pleurochyrsis carlerae. and Sargassum) and macroalgae (e.g., seaweed); and (5) energy crops, such as poplars, willows, switch grass, miscanthus, sorghum, alfalfa, prairie bluestream, corn, soybean, and the like.T-l 1897A-WO01 (538-366 PCT)

[0087] In some embodiments, one or more renewable feedstocks 118 may include a solid biomass feedstock containing lignocellulosic material. Lignocellulosic material includes three main components, namely, cellulose, hemicellulose and lignin. In some embodiments, cellulose is the primary structural component of lignocellulose and provides rigidity and forms the framework of plant cell walls. Cellulose can consist of a beta (l-4)-linked chain of glucose molecules. Hydrogen bonds between different layers of cellulose contribute to its resistance to degradation. In some embodiments, hemicellulose is usually the second most abundant component in lignocellulose and contributes to the overall structure and flexibility of the plant cell wall. Hemicelluloses are polysaccharides made up of various sugars. For example, hemicellulose can be composed of various 5- and 6-carbon sugars, including arabinose, galactose, glucose, mannose and xylose. In some embodiments, lignin is the most complex constituent and provides additional strength, protection, and resistance to decay. Lignin is a polymer structure of three major phenolic components, including p-coumaryl alcohol (H), coniferyl alcohol (G) and sinapyl alcohol (S).

[0088] Lignocellulosic material may include a mixture of lignin, cellulose and hemicelluloses in any proportion. Such material can be more difficult to convert into fungible liquid hydrocarbon products than cellulosic and hemicellulosic material. Suitable lignocellulosecontaining biomass includes woody biomass and agricultural and forestry products and residues (e g., whole harvest energy crops, round wood, forest slash, bamboo, sawdust, bagasse, sugarcane tops and trash, cotton stalks, com stover, com cobs, castor stalks, Jatropha whole harvest, Jatropha trimmings, de-oiled cakes of palm, castor and Jatropha, coconut shells, residues derived from edible nut production and mixtures thereof), and municipal solid wastes containing lignocellulosic material. The municipal solid waste may include, for example, any combination of lignocellulosic material (yard trimmings, pressure- treated wood such as fence posts, plywood), discarded paper and cardboard and waste plastics, along with refractories such as glass, and metal.

[0089] In some embodiments, a solid form of the solid biomass feedstock for one or more renewable feedstocks 118 includes, for example, particles, pellets, shavings, fibers, needles and / or other geometries. The solid form does not necessarily have to have a homogeneous configuration. Instead, the configuration may be regular or irregular. For example, in the case of the solid form comprising particles, the particles can be, for example, virtually spherical particles, and likewise particles having an irregular and / or angular outward shape. In addition, the surface of the particlesT-l 1897A-WO01 (538-366 PCT)may be smooth, but it is also possible that the surface of the material is rough and / or has unevenness and / or depressions and / or elevations. In an illustrative embodiment, a solid form can contain particles of the solid biomass feedstock having a particle size of about 1 millimeter (mm) to about 3.5 mm.

[0090] The solid biomass material may be washed, dried, roasted, torrefied and / or reduced in particle size before it is used as a feedstock in retrofit renewable slurry reactor 116.

[0091] In some embodiments, suitable slurry reactors for retrofit renewable slurry reactor 116 of system 100 include continuous stirred tank reactors, fluidized bed reactors, spouted bed reactors, spray reactors, bubble column reactors, liquid recirculation reactors, slurry recirculation reactors, and combinations thereof. One or more slurry reactors may be utilized in parallel or in series. Thus, the slurry reactor for hydroconversion of one or more renewable feedstocks 118 would be a retrofit of a slurry reactor for hydroconversion of a petroleum-based feedstock.

[0092] Reaction conditions for the hydroconversion of one or more renewable feedstocks 118 are within the purview of one skilled in the art. In some embodiments, the processed one or more renewable feedstocks which have been subjected to hydroconversion conditions provide a product with a lower carbon footprint than a corresponding hydrocarbon product produced from a petroleum-based feedstock.

[0093] In some cases, the conversion of one or more renewable feedstocks 118 using slurry catalyst effluent 114 into clean fuels takes less energy than production of fuels from a virgin petroleum feedstock. As the collection and processing of the renewable feedstocks improves, as is happening now, the gain in energy efficiencies will further improve. In those cases, fuels produced from one or more renewable feedstocks 118 using slurry catalyst effluent 114 can have lower carbon footprints than the corresponding fuels made from pure petroleum-based feedstocks. The process according to the non-limiting illustrative embodiments disclosed herein can produce clean gasoline, jet fuel and diesel with recycled contents and lower CO2 (lower carbon) footprints than a hydrocarbon product produced from one of a petroleum-based process or a slurry catalyst in a petroleum-based oil liquid carrier.

[0094] Hydroconversion product stream 120, comprising cracked renewable hydrocarbons, may be separated into one or more hydrocarbon fractions using, for example, a fractionator (not shown). For example, hydroconversion product stream 120 can have a variety ofT-l 1897A-WOOI (538-366 PCT)cracked hydrocarbon products that may be separated into two or more constituent streams by conventional means. In non-limiting illustrative embodiments, constituent streams may include a renewable naphtha, jet, diesel, etc.

[0095] According to an aspect of the present disclosure, a process comprises:

[0096] passing a first slurry catalyst comprising solid catalyst particles and a petroleumbased oil liquid carrier through one or more gravity-based separation processes to obtain a solidrich stream comprising the solid catalyst particles and a solid-free lean stream comprising the petroleum-based oil liquid carrier, and

[0097] mixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the solid-rich stream comprising the solid catalyst particles to obtain a second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.

[0098] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the first slurry catalyst comprises from about 1 wt. % to about 50 wt. % of the solid catalyst particles and from about 50 wt. % to about 99 wt. % of the petroleum-based oil liquid carrier.

[0099] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the first slurry catalyst comprises from about 2 wt. % to about 30 wt. % of the solid catalyst particles.

[0100] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the first slurry catalyst comprises from about 3 wt. % to about 20 wt. % of the solid catalyst particles.

[0101] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, at least about 90% of the petroleum-based oil liquid carrier has a boiling point greater than 500°F (260°C).

[0102] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the process further comprises adding a light solvent to the first slurry catalyst prior to passing the first slurry catalyst through one or more gravity-based separation processes.T-l 1897A-WO01 (538-366 PCT)

[0103] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the one or more gravity-based separation processes are carried out in a gravity-based separation unit.

[0104] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the gravity-based separation unit comprises from two to eight gravity-based separators.

[0105] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the gravity-based separation unit comprises a first gravity-based separator and a second gravity-based separator.

[0106] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the first gravity-based separator and the second gravity-based separator comprise one of a gravity settler separation unit or a centrifugation unit.

[0107] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the process comprises:

[0108] passing the first slurry catalyst comprising solid catalyst particles and the petroleum-based oil liquid carrier through a first gravity-based separation process in a first gravitybased separator to obtain a first solid-rich stream comprising the solid catalyst particles and a first solid-free lean stream comprising the petroleum-based oil liquid carrier,

[0109] adding a light solvent to the first solid-rich stream comprising the solid catalyst particles to form a diluted solid-rich stream comprising the solid catalyst particles and the light solvent,

[0110] passing the diluted solid-rich stream comprising the solid catalyst particles and the light solvent through a second gravity -based separation process in a second gravity -based separator to obtain a second solid-rich stream comprising the solid catalyst particles and a second solid-free lean stream comprising the petroleum-based oil liquid carrier, and

[0111] mixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the second solid-rich stream comprising the solid catalyst particles to obtain the second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.T-l 1897A-WO01 (538-366 PCT)

[0112] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the renewable-based liquid carrier comprises one or more of a plant, an animal and a microorganism based renewable feedstock.

[0113] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the renewable-based liquid carrier comprises one or more of a crude tall oil, a tall oil pitch, a bio-residual oil and a heavy product derived from a biomass hydroprocessing product.

[0114] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the circular-based liquid carrier comprises one or more of a pyrolysis-derived product of a waste plastic feedstock and combinations thereof.

[0115] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the second slurry catalyst comprises from about 1 wt. % to about 50 wt. % of the solid catalyst particles and from about 50 wt. % to about 99 wt. % of the one of the renewable-based liquid carrier or the circular-based liquid carrier.

[0116] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the second slurry catalyst comprises from about 2 wt. % to about 30 wt. % of the solid catalyst particles.

[0117] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the second slurry catalyst comprises less than about 10 wt. % of the petroleum-based oil liquid carrier.

[0118] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the process further comprises:

[0119] processing a renewable feedstock, in a retrofit renewable slurry reactor and under slurry hydroconversion conditions, in the presence of the second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier to produce one or more hydrocarbon products.

[0120] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the one or more hydrocarbon products have a lower carbon footprint than a hydrocarbon product produced from one of a petroleum-based process or a slurry catalyst in a petroleum-based oil liquid carrier.T-l 1897A-WO01 (538-366 PCT)

[0121] In one or more additional illustrative embodiments, as may be combined with the preceding paragraphs, the renewable feedstock comprises a solid biomass feedstock comprising one or more of a lignocellulosic material or a wood material.

[0122] Various features disclosed herein are, for brevity, described in the context of a single embodiment, but may also be provided separately or in any suitable sub-combination. All combinations of the embodiments are specifically embraced by the illustrative embodiments disclosed herein just as if each and every combination was individually and explicitly disclosed. In addition, all sub-combinations listed in the embodiments describing such variables are also specifically embraced by the present disclosure and are disclosed herein just as if each and every such sub-combination was individually and explicitly disclosed herein.

[0123] While the above description contains many specifics, these specifics should not be construed as limitations of the invention, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other embodiments within the scope and spirit of the invention as defined by the claims appended hereto.

Claims

T-l 1897A-WO01 (538-366 PCT)CLAIMS WHAT IS CLAIMED IS:

1. A process, comprising:passing a first slurry catalyst comprising solid catalyst particles and a petroleum-based oil liquid carrier through one or more gravity-based separation processes to obtain a solid-rich stream comprising the solid catalyst particles and a solid-free lean stream comprising the petroleum-based oil liquid carrier; andmixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the solid-rich stream comprising the solid catalyst particles to obtain a second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.

2. The process according to claim 1, wherein the first slurry catalyst comprises from about 1 wt. % to about 50 wt. % of the solid catalyst particles and from about 50 wt. % to about 99 wt. % of the petroleum-based oil liquid carrier.

3. The process according to claim 1, wherein the first slurry catalyst comprises from about 2 wt. % to about 30 wt. % of the solid catalyst particles.

4. The process according to claim 1, wherein the first slurry catalyst comprises from about 3 wt. % to about 20 wt. % of the solid catalyst particles.

5. The process according to any one of claims 1-4, wherein at least about 90% of the petroleum-based oil liquid carrier has a boiling point greater than 500°F (260°C).

6. The process according to any one of claims 1-5, further comprising adding a light solvent to the first slurry catalyst prior to passing the first slurry catalyst through one or more gravity-based separation processes.T-l 1897A-WO01 (538-366 PCT)7. The process according to any one of claims 1-6, wherein the one or more gravity -based separation processes are carried out in a gravity -based separation unit.

8. The process according to claim 7, wherein the gravity-based separation unit comprises from two to eight gravity -based separators.

9. The process according to claim 7, wherein the gravity-based separation unit comprises a first gravity-based separator and a second gravity-based separator.

10. The process according to claim 9, wherein the first gravity -based separator and the second gravity-based separator comprise one of a gravity settler separation unit or a centrifugation unit.

11. The process according to claim 1, comprising:passing the first slurry catalyst comprising solid catalyst particles and the petroleumbased oil liquid carrier through a first gravity-based separation process in a first gravity-based separator to obtain a first solid-rich stream comprising the solid catalyst particles and a first solid-free lean stream comprising the petroleum-based oil liquid carrier;adding a light solvent to the first solid-rich stream comprising the solid catalyst particles to form a diluted solid-rich stream comprising the solid catalyst particles and the light solvent;passing the diluted solid-rich stream comprising the solid catalyst particles and the light solvent through a second gravity-based separation process in a second gravity-based separator to obtain a second solid-rich stream comprising the solid catalyst particles and a second solid-free lean stream comprising the petroleum-based oil liquid carrier; andmixing one of a renewable-based liquid carrier or a circular-based liquid carrier with the second solid-rich stream comprising the solid catalyst particles to obtain the second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier.T-l 1897A-WO01 (538-366 PCT)12. The process according to any one of claims 1-11, wherein the renewable-based liquid carrier comprises one or more of a plant, an animal and a microorganism based renewable feedstock.

13. The process according to any one of claims 1-11, wherein the renewable-based liquid carrier comprises one or more of a crude tall oil, a tall oil pitch, a bio-residual oil and a heavy product derived from a biomass hydroprocessing product.

14. The process according to any one of claims 1-11, wherein the circular-based liquid carrier comprises one or more of a pyrolysis-derived product of a waste plastic feedstock and combinations thereof.

15. The process according to any one of claims 1-14, wherein the second slurry catalyst comprises from about 1 wt. % to about 50 wt. % of the solid catalyst particles and from about 50 wt. % to about 99 wt. % of the one of the renewable-based liquid carrier or the circular-based liquid carrier.

16. The process according to any one of claims 1-14, wherein the second slurry catalyst comprises from about 2 wt. % to about 30 wt. % of the solid catalyst particles.

17. The process according to any one of claims 1-16, wherein the second slurry catalyst comprises less than about 10 wt. % of the petroleum-based oil liquid carrier.

18. The process according to any one of claims 1-17, further comprising:processing a renewable feedstock, in a retrofit renewable slurry reactor and under slurry hydroconversion conditions, in the presence of the second slurry catalyst comprising the solid catalyst particles and the one of the renewable-based liquid carrier or the circular-based liquid carrier to produce one or more hydrocarbon products.T-l 1897A-WO01 (538-366 PCT)19. The process according to claim 18, wherein the one or more hydrocarbon products have a lower carbon footprint than a hydrocarbon product produced from one of a petroleum-based process or a slurry catalyst in a petroleum-based oil liquid carrier.

20. The process according to claim 18, wherein the renewable feedstock comprises a solid biomass feedstock comprising one or more of a lignocellulosic material or a wood material.

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