Green fluid catalytic cracking process

Abstract

A process and apparatus for co-processing a hydrocarbon feedstock and a renewable biomass feedstock are described. Solid particles of biomass are introduced into the riser reactor zone and mixed with catalyst. The hydrocarbon feed stock is also introduced into the riser reactor zone. The solid particles of biomass react in the presence of the catalyst and are converted into oxygenated hydrocarbons, while the hydrocarbon reacts in the presence of the catalyst to form hydrocarbon products having a lower boiling point than the feedstock.

What is claimed is: 
     
         1 . A process for co-processing a hydrocarbon feedstock and a renewable biomass feedstock comprising:
 introducing a lift gas into a fluid catalytic cracking riser reactor zone;   introducing a catalyst into the riser reactor zone at a point downstream of where the lift gas is introduced;   injecting solid particles of the biomass feedstock into the riser reactor zone;   introducing the hydrocarbon feedstock into the riser reactor zone;   mixing the solid particles of the biomass feedstock with the catalyst, the solid particles of the biomass feedstock reacting in the presence of the catalyst to form biomass products comprising gas, vapor, and char, and the gas and vapor biomass products further reacting in the presence of the catalyst to form oxygenated hydrocarbon products;   mixing the hydrocarbon feedstock with the catalyst, the hydrocarbon feedstock reacting in the presence of the catalyst to form hydrocarbon products having a lower boiling point than a boiling point of the hydrocarbon feedstock; and   recovering the oxygenated hydrocarbon products, the hydrocarbon products, or both;   wherein the solid particles of biomass feedstock are injected into the riser reactor zone at a point upstream of where the hydrocarbon feedstock is introduced and at or downstream of the point where the catalyst is introduced, or at a point downstream of where the hydrocarbon feedstock and the catalyst are introduced.   
     
     
         2 . The process of  claim 1  wherein the solid particles of biomass feedstock are injected using a pressurized auger. 
     
     
         3 . The process of  claim 1  wherein introducing the catalyst into the riser reactor zone comprises introducing regenerated catalyst from a regeneration zone into the riser reactor zone. 
     
     
         4 . The process of  claim 3  further comprising:
 separating the catalyst from the oxygenated hydrocarbon products and the hydrocarbon products in a separation zone of the riser reactor zone; and 
 regenerating at least a portion of the separated catalyst in the regeneration zone to form the regenerated catalyst. 
 
     
     
         5 . The process of  claim 1  wherein a ratio of an amount of the biomass feedstock to an amount of the hydrocarbon feedstock is less than about 20%. 
     
     
         6 . The process of  claim 1  wherein a ratio of an amount of catalyst to an amount of total feedstock is at least about 4 to 1. 
     
     
         7 . The process of  claim 1  wherein a temperature in the riser reactor zone is in a range of about 470° C. to about 600° C. 
     
     
         8 . The process of  claim 1  wherein mixing the solid particles of the biomass feedstock with the catalyst comprises mixing the solid particles of the biomass feedstock with the catalyst in a chamber, the chamber having a catalyst inlet and a biomass inlet. 
     
     
         9 . The process of  claim 8  wherein the chamber further comprises a baffle for mixing the solid particles of the biomass feedstock with the catalyst. 
     
     
         10 . The process of  claim 1 , wherein the solid particles of the biomass feedstock have a particle size of about 6 mm. 
     
     
         11 . The process of  claim 1 , wherein the catalyst comprises a zeolitic catalyst. 
     
     
         12 . The process of  claim 1 , further comprising drying the biomass feedstock to a moisture content of less than about 20% before injecting the solid particles of the biomass feedstock into the riser reactor zone. 
     
     
         13 . A process for co-processing a hydrocarbon feedstock and a renewable biomass feedstock comprising:
 introducing a lift gas into a chamber in a fluid catalytic cracking riser reactor zone;   introducing a catalyst into the chamber at a point downstream of where the lift gas is introduced;   injecting solid particles of the biomass feedstock into the chamber;   mixing the solid particles of the biomass feedstock with the catalyst, the solid particles of the biomass feedstock reacting in the presence of the catalyst to form biomass products comprising gas, vapor, and char, and the gas and vapor biomass products further reacting in the presence of the catalyst to form oxygenated hydrocarbon products;   introducing the hydrocarbon feedstock into the riser reactor zone downstream of the chamber;   mixing the hydrocarbon feedstock with the catalyst, the hydrocarbon feedstock reacting in the presence of the catalyst to form hydrocarbon products having a lower boiling point than a boiling point of the hydrocarbon feedstock; and   recovering the oxygenated hydrocarbon products, the hydrocarbon products, or both.   
     
     
         14 . The process of  claim 13  wherein the solid particles of biomass feedstock are injected using a pressurized auger. 
     
     
         15 . The process of  claim 13  further comprising:
 separating the catalyst from the oxygenated hydrocarbon products and the hydrocarbon products in a separation zone of the riser reactor zone; and 
 regenerating at least a portion of the separated catalyst in a regeneration zone; and 
 wherein introducing the catalyst into the chamber comprises introducing the regenerated catalyst into the chamber. 
 
     
     
         16 . The process of  claim 13  wherein a ratio of an amount of catalyst to an amount of total feedstock is at least about  4  to  1 . 
     
     
         17 . The process of  claim 13  wherein a temperature in the riser reactor zone is in a range of about 470° C. to about 600° C. 
     
     
         18 . The process of  claim 13  wherein the chamber has at least one catalyst inlet and at least one biomass inlet. 
     
     
         19 . The process of  claim 18  wherein the mixing chamber further comprises a baffle for mixing the solid particles of the biomass feedstock with the catalyst. 
     
     
         20 . A riser reactor zone comprising:
 a riser reactor;   a chamber at one end of the riser reactor, the chamber having at least one lift gas inlet, at least one biomass inlet, and at least one catalyst inlet;   a hydrocarbon inlet in the riser reactor, the hydrocarbon inlet being downstream of the chamber.