Production of fuel from co-processing multiple renewable feedstocks
A process for producing a fuel or fuel blending component from co-processing at least two different classes of renewable feedstocks, is presented. One feedstock comprises glycerides and free fatty acids in feedstocks such as plant and animal oils while the other feedstock comprises biomass derived pyrolysis oil. The source of the animal or plant oil and the biomass may be the same renewable source.
1. A process for producing a fuel comprising:
a) treating a first renewable feedstock comprising at least glycerides and a second renewable feedstock comprising at least whole pyrolysis oil concurrently in a first reaction zone by catalytically hydrogenating and catalytically deoxygenating the glycerides and components of the whole pyrolysis oil using at least one catalyst at reaction conditions in the presence of hydrogen to provide an effluent stream comprising hydrogen, water, carbon oxides, and hydrocarbons; and
b) separating at least hydrogen, carbon dioxide, and water, from the effluent stream and collecting at least a portion of the remainder for use as a fuel or fuel blending component.
2. The process of claim 1 further comprising separating the remainder into a gasoline boiling point range component, an aviation boiling point range component, and a diesel boiling point range component.
3. The process of claim 1 further comprising introducing at least a portion of the hydrocarbons generated in the first reaction zone to a second reaction zone to contact an isomerization and selective hydrocracking catalyst at isomerization and selective hydrocracking conditions to selectively hydrocrack at least a portion of the hydrocarbons and to isomerize at least a portion of the hydrocarbons, to generate the effluent stream.
4. The process of claim 3 further comprising selectively separating, in a hot high pressure hydrogen stripper, a gaseous stream comprising at least a portion of the hydrogen, water, and carbon oxides from the hydrocarbons to generate the hydrocarbons passed to the second reaction zone.
5. The process of claim 4 further comprising recycling, to a rectification zone in the hot high pressure hydrogen stripper, a portion of the remainder.
6. The process of claim 4 wherein the second reaction zone effluent further comprises hydrogen and at least a portion of the hydrogen is separated from the effluent stream and recycled to the hot high pressure hydrogen stripper.
7. The process of claim 1 wherein the remainder comprises hydrocarbons in the diesel, gasoline, and aviation boiling point ranges.
8. The process of claim 1 wherein the first and second renewable feedstocks are derived from a single renewable source.
9. The process of claim 1 further comprising recycling a portion of the hydrocarbons from the first reaction zone back to the first reaction zone at a volume ratio of recycle to renewable feedstock in the range of about 2:1 to about 8:1.
10. The process of claim 3 further comprising recycling at least a portion of the remainder to the second reaction zone.
11. The process of claim 1 further comprising pre-treating the first renewable feedstock, the second renewable feedstock, or both in one or more pretreatment zones at pretreatment conditions to remove at least a portion of contaminants in the feedstocks.
12. The process of claim 3 wherein the first and second reaction zones are operated at conditions including a temperature of about 40° C. to about 400° C. and a pressure of about 689 kPa absolute (100 psia) to about 13,790 kPa absolute (2000 psia);
13. The process of claim 4 wherein the hot high pressure hydrogen stripper is operated at a temperature of about 40° C. to about 300° C. and a pressure of about 689 kPa absolute (100 psia) to about 13,790 kPa absolute (2000 psia).
14. The process of claim 4 wherein the hot high pressure hydrogen stripper is operated at a pressure that is within 1034 kPa absolute (150 psia) that of the first reaction zone and the second reaction zone is operated at a pressure at least about 345 kPa absolute (50 psia) greater than that of the first reaction zone.
15. The process of claim 1 further comprising a third feedstock treated concurrently with the first and second feedstocks wherein the third feedstock comprises a petroleum hydrocarbon feedstock.
16. A diesel boiling point range fuel, an aviation boiling point range fuel, and a gasoline boiling point range fuel as produced by the process of claim 1 .
17. The process of claim 1 further comprising mixing one or more additives to at least a portion of the remainder.
18. The process of claim 1 wherein the treating of the first and the second renewable feedstocks, concurrently, in the first reaction zone by hydrogenating and deoxygenating the glycerides and components of the whole pyrolysis oil comprises:
a) treating the first and second renewable feedstocks by partially deoxygenating the glycerides and components of the whole pyrolysis oil in a partial deoxygenation zone of the first reaction zone by contacting the first and second feedstocks concurrently with a first deoxygenation and hydrogenation catalyst in the presence of hydrogen at deoxygenation conditions to produce a partially deoxygenated stream comprising water, gasses, light ends, and hydrocarbons;
b) passing the partially deoxygenated stream to a separation zone to separate a water, gases, and light ends stream from a hydrocarbon stream; and
c) passing the hydrocarbon stream to a full deoxygenation zone of the first reaction zone and deoxygenating the hydrocarbon stream by contacting with a second deoxygenation catalyst under deoxygenation conditions, to generate the effluent stream.
19. The process of claim 18 wherein the partial deoxygenation zone is operated at a pressure in the range from 3.4 MPa a (500 psia) to about 20.6 MPa a (3000 psia) and a temperature in the range of about 100° C. to about 400° C.; and the full deoxygenation zone is operated at a pressure between about 689 kPa (100 psia) to about 13.8 MPa a (2000 psia) and at a temperature of about 300° C. to about 500° C.
20. The process of claim 18 further comprising recycling a portion of the remainder to the partial deoxygenation zone, the full deoxygenation zone, or both wherein the volume ratio of recycle to feed to the partial or full deoxygenation zone is in the range of about 2:1 to about 8:1.