Hydrocarbon upgrading process

1 . A process for upgrading a bio-oil stream comprising:

passing a catalyst stream to a reactor;

reacting a bio-oil stream with hydrogen in the presence of a metal sulfide catalyst from said catalyst stream in said reactor to produce an upgraded bio-oil stream; and

charging said upgraded bio-oil stream to an FCC unit, a hydroprocessing unit, or a reforming unit to produce an intermediate blend or a fuel stream; or

taking a fuel oil stream from said upgraded bio-oil stream.

2 . The process of claim 1 further comprising separating the catalyst from said upgraded bio-oil stream.

3 . The process of claim 1 , wherein said upgraded bio-oil stream is used directly as the intermediate blend or the fuel oil stream.

4 . The process of claim 1 , wherein the upgraded bio-oil comprises at least one or more of an aldehyde at a concentration of about 0 mol % H to about 4 mol % H, at least one of the group ketones and aldehydes at a concentration of about 0 mol % C to about 6 mol % C, at least one of the group carboxylic acids and esters at a concentration of about 0 mol % C to about 6 mol % C, at least one of the group ethers, alcohols, phenyl methoxy groups, and carbohydrates at a concentration of about 0 mol % C to about 11 mol % C.

5 . The process of claim 1 , wherein the upgraded bio-oil comprises a ratio of oxygenates of one or more of a (C—O)/C ratio from about 0 to about 0.7, a (C═O)/C ratio from about 0 to about 0.6, an OH/C ratio from about 0 to 3, and an O/C ratio from about 0 to 1.7.

6 . The process of claim 2 further comprising:

passing said upgraded bio-oil stream to a hot separator; and

separating the catalyst from said upgraded bio-oil stream in a hot bottoms stream of the hot separator to provide a hot overhead stream comprising said light upgraded bio-oil stream.

7 . The process of claim 6 further comprising:

passing said hot overhead stream to a cold separator to separate gaseous components and provide a bottoms light oil stream;

separating water from said bottoms light oil stream to produce said light upgraded bio-oil stream.

8 . The process of claim 6 further comprising:

taking a heavy oil stream and a recycle oil stream comprising the catalyst from said hot bottoms stream; and

recycling the recycle oil stream to the reactor to provide said upgraded bio-oil stream.

9 . The process of claim 8 further comprising:

separating catalyst from said heavy oil stream to provide a heavy oil product stream and a separated catalyst stream;

combining said separated catalyst stream with said recycle oil stream to provide a combined recycle oil stream; and

recycling said combined recycle oil stream to the reactor to provide said upgraded bio-oil stream.

10 . The process of claim 9 , wherein said heavy oil stream is passed to a filtration vessel, a vacuum distillation column, a wiped film evaporator, a centrifuge, or a combination thereof for separating the catalyst.

11 . The process of claim 1 further comprising operating said reactor at a temperature of about 300° C. to about 500° C.

12 . The process of claim 1 further comprising separating said upgraded bio-oil stream into several streams and charging at least one of said streams to said FCC unit, said hydroprocessing unit, or said reforming unit.

13 . The process of claim 1 , wherein the reactor is a once through reactor for producing said upgraded bio-oil stream.

14 . The process of claim 8 , wherein at least 50 wt % of said upgraded bio-oil stream is bio-derived.

15 . A process for upgrading a bio-oil stream, comprising:

reacting a bio-oil stream with hydrogen in the presence of a catalyst in a reactor to produce an upgraded bio-oil stream;

separating catalyst from said upgraded bio-oil stream to produce a light upgraded bio-oil stream;

recycling a recycle oil stream comprising the catalyst to the reactor; and

charging said light upgraded bio-oil stream to an FCC unit, a hydroprocessing unit, or a reforming unit to produce an intermediate blend or a fuel stream; or

taking a fuel oil stream from said upgraded bio-oil stream.

16 . The process of claim 15 further comprising:

passing said upgraded bio-oil stream to a hot separator;

separating the catalyst from said upgraded bio-oil stream in a hot bottoms stream in the hot separator to provide a hot overhead stream comprising said light upgraded bio-oil stream; and

separating water from said hot overhead stream to provide said light upgraded bio-oil stream.

17 . The process of claim 16 further comprising:

passing said hot overhead stream to a cold separator to separate gaseous components and provide a bottoms light oil stream; and

separating water from said bottoms light oil stream to produce said light upgraded bio-oil stream.

18 . The process of claim 16 further comprising:

taking said recycle oil stream comprising the catalyst from said hot bottoms stream; and

recycling the recycle oil stream to the reactor to provide said upgraded bio-oil stream.

19 . A process for upgrading a bio-oil stream comprising:

mixing a bio-oil stream and a petroleum stream at a mass ratio of said bio-oil stream and said petroleum stream of about 0:100 to about 80:20 at a start-up to provide a mixed stream;

reacting said mixed stream with hydrogen in the presence of a catalyst in a reactor to produce an upgraded bio-oil stream;

replacing the petroleum stream with a recycle oil stream taken from said upgraded bio-oil stream; and

charging said upgraded bio-oil stream to an FCC unit,

a hydroprocessing unit,

or a reforming unit to produce an intermediate blend or a fuel stream;

or

taking a fuel oil stream from said upgraded bio-oil stream.

20 . The process of claim 19 , wherein the mass ratio of said bio-oil stream and said petroleum stream is in the range of less than about 1 at the start-up.

21 . A process for upgrading a bio-oil stream comprising:

reacting a bio-oil stream with hydrogen in the presence of a metal sulfide catalyst in a reactor to produce an upgraded bio-oil stream;

passing said upgraded bio-oil stream to a hot separator; and

separating the catalyst from said upgraded bio-oil stream in a hot bottoms stream of the hot separator to provide a hot overhead stream comprising a light upgraded bio-oil stream; and

charging said light upgraded bio-oil stream to an FCC unit, a hydroprocessing unit, or a reforming unit to produce an intermediate blend or a fuel stream; or

taking a fuel oil stream from said light upgraded bio-oil stream.