Integrated catalytic cracking with ethanol conversion to fuel

Abstract

Processes relating to the conversion of ethanol in a stripper unit of a fluidized catalytic cracking system. An ethanol stream comprising at least 4 volume percent water mixes with a catalyst in the stripper unit under conditions of temperature that favor conversion of the ethanol to hydrocarbons, thereby increasing incorporation of ethanol into liquid transportation fuels without exceeding regulatory limits on fuel vapor pressure. Certain embodiments additionally combine the ethanol stream with a hydrocarbon stream in the stripper and react in the presence of a catalyst to produce hydrocarbons that may have an increased boiling point, increased octane rating, decreased vapor pressure, decreased benzene content, or combinations of these properties.

We claim: 
     
         1 . A process for converting ethanol to liquid transportation fuels, the process comprising mixing and reacting a catalyst with an ethanol stream and a hydrocarbon stream within a conversion unit to produce a mixed product stream comprising hydrocarbons having an increased average molecular weight, wherein the mixed product stream is next conveyed to a fluidized catalytic cracking unit. 
     
     
         2 . The process according to  claim 1 , wherein the hydrocarbon stream comprises at least one of cracked hydrocarbons, light olefins or benzene. 
     
     
         3 . The process according to  claim 1 , wherein the reacting comprises alkylation, oligomerization, condensation or combinations thereof. 
     
     
         4 . The process according to  claim 1 , wherein the reacting decreases the Reid vapor pressure, the total benzene content, or both, of the mixed product stream. 
     
     
         5 . The process according to  claim 1 , wherein the reacting increases at least one of the molecular weight, the alkylaromatics content and the octane of the mixed product stream. 
     
     
         6 . The process according to  claim 1 , wherein the catalyst is used to replenish the catalyst within the fluidized catalytic cracking unit. 
     
     
         7 . The process according to  claim 1 , wherein the ethanol stream is derived from biomass and comprises at least 4 weight percent of water. 
     
     
         8 . The process according to  claim 6 , wherein the water in the ethanol stream is converted to steam either prior to, or upon entering the conversion unit to prevent contact between the liquid water and the catalyst. 
     
     
         9 . The process according to  claim 1 , wherein the hydrocarbon stream comprises cracked hydrocarbons produced by the fluidized catalytic cracking unit. 
     
     
         10 . The process according to  claim 1 , wherein the hydrocarbon stream is a fraction obtained from a fractionator located immediately downstream from the fluidized catalytic cracking unit.