Process for producing diesel fuel and aviation fuel from renewable feedstocks having improving yields

1. A process for producing both a diesel range product and an aviation range product from a renewable feedstock comprising:

hydrogenating and deoxygenating the renewable feedstock by contacting the renewable feedstock and hydrogen with a hydrogenation and deoxygenation catalyst in a hydrogenation and deoxygenation zone at hydrogenating and deoxygenating conditions to provide a hydrogenation and deoxygenation zone effluent comprising paraffins, hydrogen, water, and carbon oxides;

separating at least the paraffins from the hydrogenation and deoxygenation zone effluent;

separating the paraffins into at least a diesel boiling range fraction and an aviation boiling range fraction in a first fractionation zone;

isomerizing and selectively hydrocracking the diesel boiling range fraction and the aviation boiling range fraction by alternately:

contacting the diesel boiling range fraction with an isomerization and selective hydrocracking catalyst in the presence of hydrogen in an isomerization and selective hydrocracking zone at first isomerization and selective hydrocracking conditions for the diesel boiling range fraction and generating a first effluent comprising at least first normal and branched paraffins in the diesel boiling point range, first normal and branched paraffins in the aviation boiling point range, first unreacted hydrogen, first naphtha, and first LPG;

separating the first effluent into a first gaseous component and a first liquid component wherein the first liquid component comprises the first normal and branched paraffins in the diesel boiling point range, the first normal and branched paraffins in the aviation boiling point range, the first naphtha, and the first LPG; and

separating the first liquid component into at least a diesel range product comprising the first normal and branched paraffins in the diesel boiling point range in a second fractionation zone;

or:

contacting the aviation boiling range fraction with the isomerization and selective hydrocracking catalyst in the presence of hydrogen in the isomerization and selective hydrocracking zone at second isomerization and selective hydrocracking conditions for the aviation boiling range fraction and generating a second effluent comprising at least second normal and branched paraffins in the aviation boiling point range, second hydrogen, second naphtha, and second LPG;

separating the second effluent into a second gaseous component and a second liquid component wherein the second liquid component comprises the second normal and branched paraffins in the aviation boiling point range, the second naphtha, and the second LPG; and

separating the second liquid component into at least an aviation range product comprising the second normal and branched paraffins in the aviation boiling point range in the second fractionation zone.

2. The method of claim 1 wherein separating the second liquid component into at least the aviation range product in the second fractionation zone comprises separating the second liquid component into at least the aviation range product; further comprising:

recycling at least a portion of the first diesel range product to the second fractionation zone.

3. The method of claim 1 wherein:

separating the first liquid component into at least the first diesel range product in the second fractionation zone comprises separating the first liquid component into at least the first diesel range product, a first aviation range product comprising the first normal and branched paraffins in the aviation boiling point range, a first naphtha product comprising the first naphtha, and a first LPG product comprising the first LPG;

or

separating the second liquid component into at least the second aviation range product in the second fractionation zone comprises separating the second liquid component into at least the second aviation range product, a second naphtha product comprising the second naphtha, and a second LPG product comprising the second LPG;

or both.

4. The method of claim 1 further comprising:

storing the diesel boiling range fraction in an intermediate diesel storage tank and storing the aviation boiling range fraction in an intermediate aviation storage tank; and

alternately feeding the diesel boiling range fraction from the intermediate diesel storage tank to the isomerization and selective hydrocracking zone and feeding the aviation boiling range fraction from the intermediate aviation storage tank to the isomerization and selective hydrocracking zone.

5. The method of claim 1 wherein at least one of the first or second isomerization and selective hydrocracking conditions include a temperature of about 150° C. to about 360° C. and a pressure of about 1724 kPa absolute (250 psia) to about 4825 kPa absolute (700 psia).

6. The method of claim 1 wherein hydrogenating and deoxygenating conditions include a temperature of about 200° C. to about 400° C. and a pressure of about 1379 kPa absolute (200 psia) to about 6895 kPa absolute (1000 psia).

7. The method of claim 1 wherein the diesel boiling range fraction comprises paraffins having 16 or more carbon atoms and wherein the aviation boiling range fraction comprises paraffins having 8 to 15 carbon atoms.

8. The method of claim 1 wherein the renewable feedstock comprises a vegetable oil or an animal oil.

9. The method of claim 1 wherein the renewable feedstock comprises at least one component selected from the group consisting of canola oil, corn oil, soy 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, palm kernel oil, babassu oil, mustard oil, cottonseed oil, inedible tallow, yellow and brown greases, lard, train oil, fats in milk, fish oil, algal oil, sewage sludge, pyrolysis oil, liquids derived from the gasification of coal, liquids derived from depolymerization, synthetic oils, microbial oils, modified vegetable oils, and mixtures thereof.

10. The method of claim 1 wherein the isomerization and selective hydrocracking conditions include a temperature of about 280° C. to about 360° C. and a pressure of about 3102 kPa absolute (250 psia) to about 3792 kPa absolute (550 psia).

11. The method of claim 1 further comprising pre-treating the renewable feedstock in a pretreatment zone at pretreatment conditions to remove at least a portion of contaminants in the feedstock.

12. The method of claim 1 wherein the renewable feedstock is in a mixture or co-feed with a petroleum hydrocarbon feedstock.

13. A process for producing both a diesel range product and an aviation range product from a renewable feedstock comprising:

hydrogenating and deoxygenating the renewable feedstock by contacting the renewable feedstock and hydrogen with a hydrogenation and deoxygenation catalyst in a hydrogenation and deoxygenation zone at hydrogenating and deoxygenating conditions to provide a hydrogenation and deoxygenation zone effluent comprising paraffins, hydrogen, water, and carbon oxides;

separating at least the paraffins from the hydrogenation and deoxygenation zone effluent;

separating the paraffins into at least a diesel boiling range fraction and an aviation boiling range fraction in a first fractionation zone;

storing the diesel boiling range fraction in an intermediate diesel storage tank and storing the aviation boiling range fraction in an intermediate aviation storage tank;

isomerizing and selectively hydrocracking the diesel boiling range fraction and the aviation boiling range fraction by alternately:

contacting the diesel boiling range fraction from the intermediate diesel storage tank with an isomerization and selective hydrocracking catalyst in the presence of hydrogen in an isomerization and selective hydrocracking zone at first isomerization and selective hydrocracking conditions for the diesel boiling range fraction and generating a first effluent comprising at least first normal and branched paraffins in the diesel boiling point range, first normal and branched paraffins in the aviation boiling point range, first unreacted hydrogen, first naphtha, and first LPG;

separating the diesel range effluent into a first gaseous component and a first liquid component wherein the first liquid component comprises the first normal and branched paraffins in the diesel boiling point range, the first normal and branched paraffins in the aviation boiling point range, the first naphtha, and the first LPG; and

separating the first liquid component into at least a diesel product comprising the first normal and branched paraffins in the diesel boiling point range, a first aviation product comprising the first normal and branched paraffins in the aviation boiling point range, a first naphtha product comprising the first naphtha, and a first LPG product comprising the first LPG in a second fractionation zone;

or:

contacting the aviation boiling range fraction from the intermediate aviation storage tank with the isomerization and selective hydrocracking catalyst in the presence of hydrogen in the isomerization and selective hydrocracking zone at second isomerization and selective hydrocracking conditions for the aviation boiling range fraction and generating a second effluent comprising at least second normal and branched paraffins in the aviation boiling point range, second hydrogen, second naphtha, and second LPG;

separating the aviation range effluent into a second gaseous component and a second liquid component wherein the second liquid component comprises the second normal and branched paraffins in the aviation boiling point range, the second naphtha, and the second LPG; and

separating the second liquid component into at least a second aviation product comprising the second normal and branched paraffins in the aviation boiling point range, a second naphtha product comprising the second naphtha, and a second LPG product comprising the second LPG in the second fractionation zone.

14. The method of claim 13 further comprising recycling at least a portion of the first diesel range product to the second fractionation zone.

15. The method of claim 13 wherein the first isomerization and selective hydrocracking conditions include a temperature of about 150° C. to about 360° C. and a pressure of about 1724 kPa absolute (250 psia) to about 4825 kPa absolute (700 psia).

16. The method of claim 13 wherein hydrogenating and deoxygenating conditions include a temperature of about 200° C. to about 400° C. and a pressure of about 1379 kPa absolute (200 psia) to about 6895 kPa absolute (1000 psia).

17. The method of claim 13 wherein the diesel boiling range portion comprises paraffins having 16 or more carbon atoms and wherein the aviation boiling range portion comprises paraffins having 8 to 15 carbon atoms.

18. The method of claim 13 wherein the renewable feedstock comprises at least one component selected from the group consisting of canola oil, corn oil, soy 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, palm kernel oil, babassu oil, mustard oil, cottonseed oil, inedible tallow, yellow and brown greases, lard, train oil, fats in milk, fish oil, algal oil, sewage sludge, pyrolysis oil, liquids derived from the gasification of coal, liquids derived from depolymerization, synthetic oils, microbial oils, modified vegetable oils, and mixtures thereof.

19. The method of claim 13 wherein the isomerization and selective hydrocracking conditions include a temperature of about 280° C. to about 360° C. and a pressure of about 3102 kPa absolute (250 psia) to about 3792 kPa absolute (550 psia).

20. The method of claim 13 further comprising pre-treating the renewable feedstock in a pretreatment zone at pretreatment conditions to remove at least a portion of contaminants in the feedstock.