Process for making a distillate product and/or c2-c4 olefins

Abstract

A process for making a distillate product and one or more C2-C4 olefins from a FCC feedstock containing a cellulosic material and a hydrocarbon co-feed is provided.

We claim: 
     
         1 . A process for making a distillate product and one or more C2-C4 olefins comprising:
 a) contacting a FCC feedstock with a FCC catalyst at a temperature of at least 400° C. in a main reactor to produce a distillate product and a spent FCC catalyst, wherein the FCC feedstock comprises a solid cellulosic material and a hydrocarbon co-feed, said solid cellulosic material is supplied to the main reactor at a location upstream of the location where the hydrocarbon co-feed is supplied to the main reactor wherein the solid cellulosic material undergoes in-situ pyrolysis in the main reactor;   b) separating at least a portion of the distillate product from the spent FCC catalyst;   c) regenerating the spent FCC catalyst to produce a regenerated FCC catalyst;   d) contacting an intermediate reactor feedstock with at least a portion of the regenerated FCC catalyst at a temperature of at least 500° C. in an intermediate reactor to produce one or more C2-C4 olefins and a used regenerated FCC catalyst;   e) separating at least a portion of the one or more C2-C4 olefins from the used regenerated catalyst; and   f) providing at least a portion of the used regenerated FCC catalyst as FCC catalyst in step a).   
     
     
         2 . The process of  claim 1  wherein at least one lift gas is supplied to the main reactor upstream of the solid cellulosic material. 
     
     
         3 . The process of  claim 2  wherein the lift gas is steam, light hydrocarbon gases, vaporized oil and/or oil fractions, and/or any mixtures thereof. 
     
     
         4 . The process of  claim 1  wherein the main reactor is a fast fluidized bed reactor or riser reactor. 
     
     
         5 . The process of  claim 4  wherein the main reactor is a riser reactor. 
     
     
         6 . The process of  claim 1  wherein the solid cellulosic material has a particle size distribution with a mean particle size in the range from equal to or more than 5 micrometer to equal to or less than 5000 micrometer particle size distribution. 
     
     
         7 . The process of  claim 1  wherein the hydrocarbon co-feed comprises at least 8 wt % elemental hydrogen, based on the total weight of the hydrocarbon co-feed on a dry basis. 
     
     
         8 . The process of  claim 1  wherein the hydrocarbon co-feed comprises in the range from at least 20 wt % to at most 100 wt % of at least one paraffin, based on the total weight of the hydrocarbon co-feed. 
     
     
         9 . The process of  claim 1  wherein the combination of the cellulosic material and the hydrocarbon co-feed has an overall molar ratio of hydrogen to carbon (H/C) of equal to or more than 1.1 (1.1/1). 
     
     
         10 . The process of  claim 1  where at least one lift gas is provided to the intermediate reactor. 
     
     
         11 . The process of  claim 10  wherein the lift gas is steam, light hydrocarbon gases, vaporized oil and/or oil fractions, and/or any mixtures thereof. 
     
     
         12 . The process of  claim 1  wherein the FCC catalyst comprises zeolite Y or ultrastable zeolite Y (USY) in combination with an MFI type zeolite. 
     
     
         13 . The process of  claim 1  wherein step a) comprises contacting a FCC feedstock with a FCC catalyst at a temperature of at least 400° C. in a main reactor to produce a gasoline-containing-product, a distillate product and a spent FCC catalyst; and
 wherein at least a portion of the gasoline-containing-product is provided as an intermediate reactor feedstock in step d). 
 
     
     
         14 . The process of  claim 1  wherein the intermediate reactor feedstock in step d) comprises in the range from at least 20 wt % to at most 65 wt % of one or more olefins, based on the total weight of intermediate reactor feedstock. 
     
     
         15 . The process of  claim 14  wherein the one or more olefins are one or more C5 + -olefins. 
     
     
         16 . The process of  claim 1  wherein the intermediate reactor feedstock in step d) comprises one or more hydrocarbon compounds, and at least 80 wt % of said one or more hydrocarbon compounds has a boiling temperature at 0.1 MPa in the range from at least 30° C. to less than 221° C. 
     
     
         17 . The process of  claim 1  wherein the temperature in step d) is higher than the temperature in step a). 
     
     
         18 . The process of  claim 1  wherein the intermediate reactor feedstock comprise further biological feed components. 
     
     
         19 . The process of  claim 1  for the comprising;
 g) blending at least a portion of the distillate product and/or at least a portion of the one or more C2-C4 olefins with one or more other components to produce a biofuel and/or a biochemical. 
 
     
     
         20 . The process of  claim 19  wherein at least one lift gas is supplied to the main reactor upstream of the solid cellulosic material. 
     
     
         21 . The process of  claim 20  wherein the lift gas is steam, light hydrocarbon gases, vaporized oil and/or oil fractions, and/or any mixtures thereof. 
     
     
         22 . The process of  claim 1  wherein the solid cellulosic material is a torrefied solid cellulosic material. 
     
     
         23 . A process for the preparation of a biofuel and/or a biochemical, comprising
 a) contacting a FCC feedstock with a FCC catalyst at a temperature of at least 400° C. in a main reactor to produce a distillate product and a spent FCC catalyst, wherein the FCC feedstock comprises a solid cellulosic material and a hydrocarbon co-feed, said solid cellulosic material is supplied to the main reactor at a location upstream of the location where the hydrocarbon co-feed is supplied to the main reactor wherein the solid cellulosic material undergoes in-situ pyrolysis in the main reactor;   b) separating at least a portion of the distillate product from the spent FCC catalyst;   c) regenerating the spent FCC catalyst to produce a regenerated FCC catalyst;   d) contacting an intermediate reactor feedstock with at least a portion of the regenerated FCC catalyst at a temperature of at least 500° C. in an intermediate reactor to produce a used regenerated FCC catalyst, one or more C2-C4 olefins and a gasoline-containing-product, said gasoline-containing-product comprises one or more hydrocarbon compounds, wherein at least 80 wt % of such one or more hydrocarbon compounds has a boiling temperature at 0.1 MPa in the range from equal to or more than 30° C. to less than 221° C.;   e) separating at least a portion of the gasoline-containing-product and at least a portion of the one or more C2-C4 olefins from the used regenerated catalyst;   f) providing at least a portion of the used regenerated FCC catalyst as FCC catalyst in step a); and   g) blending at least a portion of the distillate product and/or at least a portion of the gasoline-containing-product with one or more other components to produce a biofuel and/or a biochemical.   
     
     
         24 . The process of  claim 23  wherein at least one lift gas is supplied to the main reactor upstream of the solid cellulosic material. 
     
     
         25 . The process of  claim 24  wherein the lift gas is steam, light hydrocarbon gases, vaporized oil and/or oil fractions, and/or any mixtures thereof. 
     
     
         26 . The process of  claim 23  wherein the temperature in step d) is higher than the temperature in step a). 
     
     
         27 . The process of  claim 23  wherein the intermediate reactor feedstock in step d) comprises in the range from at least 20 wt % to at most 65 wt % of one or more olefins, based on the total weight of intermediate reactor feedstock. 
     
     
         28 . The process of  claim 23  wherein the solid cellulosic material is a torrefied solid cellulosic material. 
     
     
         29 . The process of  claim 23  wherein the main reactor is a fast fluidized bed reactor or riser reactor. 
     
     
         30 . The process of  claim 23  wherein the solid cellulosic material has a particle size distribution with a mean particle size in the range from equal to or more than 5 micrometer to equal to or less than 5000 micrometer particle size distribution.