Approach

Field of the Invention:

In general, this specification relates to a processes for manufacturing fuels from plant and/or animal fats, oils, and/or greases (“FOG”). In particular, the specification relates to processes using hydrogenation, decarboxylation, decarbonylation, and/or

hydrodeoxygenation in a reaction zone where a liquid recycle stream is used before the first reactor and/or bed where partial conversion takes palace.

Description of the Related Art:

• US Patent Number 8,022,258 B2 states that the formation of high molecular weight compounds can be significantly reduced by having a recycle ratio of at least 5: 1 renewable feed stocks containing more than 5% free fatty acids when using a mild hydrotreating temperature of 280 - 340 °C. US Patent Number 8,022,258 B2 also states that there is significant formation of high molecular weight compounds during hydrotreating for renewable feedstocks containing more than 5% FFAs. In US Patent Number 8,022,258 B2 they found that“Due to the free fatty acids contained in bio oils and fats, the formation of heavy molecular weight compounds is significantly increased compared to triglyceridic bio feeds, which have only low amount of free fatty acids (<1%)”

• US Patent Number 7,982,076 B2 purports to disclose a process for the production of renewable diesel from renewable feedstock using a recycle ration of 2: 1 to 8: 1.

Summary

Brief Description of the Drawings

Fig. 1 is a schematic view of a plant operating a process in accordance with the present invention.

Figs. 2-3 are plots of data from a pilot plant built according to Fig. 1. Detailed Description

The disclosure relates to a process to reduce the formation of high molecular weight compounds and catalyst coking in the production of renewable diesel. Renewable diesel is produced using hydrogenation, decarboxylation, decarbonylation, and/or

hydrodeoxygenation of renewable feedstocks such as animal and/or plant fats, oils, and/or greases (“FOG”). By first reacting the most reactive species in the FOG in an initial reaction zone prior to the main reaction zone, maximum reaction temperatures and side reactions that lead to the formation of high molecular weight compounds are reduced. This reduces catalyst coking (extends catalyst life) and improves product quality.

Figure l is a schematic view of a pilot plant constructed to carry out the methods disclosed.

Some characteristics of the first reactor and/or bed

• Low activity catalyst

• High liquid hourly space velocity (Total LHSV > 10 hr ¹ )

• Reduced inlet temperature

• Partial conversion

Example 1

Tests were performed on a 3 million gallon per year plant in Garnett, KS. The results of the test are shown in Table 1. Partial reduction of free fatty acids (“FFA”) was performed in a first stage reactor. The reactor was designed to be able to replace the catalyst online and to protect the primary reactor(s) from catalyst deactivation. Overall total liquid flow to fresh feed ratio for the reactor system was ~ 10 to 1. The total liquid flow to feed ratio for the first stage reactor varied from 2.11 to 4.25. First stage reactor inlet temperature ranged from 575 to 648 °F and initial FFA ranged from 4.96 to 9.98 percent. Percent decrease in FFA did not appear to be significantly affected by inlet temperature or initial percent FFA. Decrease percent of FFA was primarily dependent on the residence time (LHSV). The longer the residence time (lower LHSV) the greater the reduction of FFA (Figure 2).

Using a low activity catalyst at reduced temperature to reduce FFA in the first stage reactor limits side reactions and reduces the formation of heavy molecules while allowing the primary reactor(s) to operate at higher temperatures due to the reduced FFA. Patent US 8,002,258 B2 shows in Example 6 that operating below 626 °F significantly reduces side reactions. Plant data agreed with this showing that the reactor effluent cloud was reduced as the I ^st stage reactor inlet temperature decreased, where higher cloud is an indication of the formation of heavy molecules (Figure 3). Patent US 8,002,258 B2 shows in Table 3 that side reactions and the formation of heavy molecules is significantly reduced with the reduction of FFA. The first stage reactor operates using a lower recycle rate than the primary reactor(s) to increase the residence time (lower LHSV) in the first stage reactor and allows for a smaller first stage reactor. The heat generated in the first stage reactor reduces the heat requirement for the primary reactor(s). The recycle rate is increased for the primary reactor(s) to limit the exotherm in the primary reactor(s).

Table 1

Other Exemplary Embodiments

1. A process that involves the hydrogenation, decarboxylation, decarbonylation, and/or hydrodeoxygenation of animal and/or plant fats, oils and/or greases (FOG) in a reaction zone to form paraffins where the reaction zone is separated into two or more reactors and/or beds where a liquid recycle stream is added before the first reactor and/or bed where the animal and/or plant FOG is partially reacted in the first reactor and/or bed where a liquid recycle stream is added in between two reactors and/or beds in at least one place in a series of two or more reactors and/or beds.

2. The process according to embodiment 1, wherein the LHSV to the first reactor and/or bed is more than 10 hr ¹ on a total feed basis

3. The process according to embodiment 1, wherein the LHSV to the first series of reactors and/or beds is more than 10 hr ^'1 on a total feed basis.

4. The process according to embodiment 1, wherein the LHSV to the first reactor and/or bed is more than 20 hr ^'1 on a total feed basis.

5. The process according to embodiment 1, wherein the LHSV to the first series of reactors and/or beds is more than 20 hr ¹ on a total feed basis. The process according to embodiment 1, wherein it the first reactor and/or bed outlet temperature is more than the second reactor and/or bed inlet temperature. The process according to embodiment 1, wherein the free fatty acid concentration is reduced in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein the free fatty acid concentration is reduced in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein the free fatty acid concentration is reduced in the reaction zone of the first reactor and/or bed below 5 wt% on a fresh feed basis. The process according to embodiment 1, wherein the free fatty acid concentration is reduced in the reaction zone of the first series of reactors and/or beds below 5 wt% on a fresh feed basis. The process according to embodiment 1, wherein FOG saturation is more than 25% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG saturation is more than 25% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein FOG saturation is more than 50% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG saturation is more than 50% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein FOG saturation is more than 75% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG saturation is more than 75% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 1, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 1, wherein it will be further processed in an isomerization step. The process according to embodiment 1, wherein it will be further processed in an isomerization and/or cracking step to produce a lighter boiling point range product. The process according to embodiment 1, wherein it will be further processed in an isomerization and/or cracking step to produce a jet/kerosene boiling range product. The process according to embodiment 1, wherein it will be further processed in an isomerization and/or cracking step to produce a naphtha/gasoline boiling range product. The process according to embodiment 1, wherein it will be further processed in an isomerization and/or cracking step to produce a fuel gas boiling range product. A process that involves the hydrogenation, decarboxylation, decarbonylation, and/or hydrodeoxygenation of animal and/or plant fats, oils and/or greases (FOG) in a reaction zone to form paraffins where the reaction zone is separated into two or more reactors and/or beds where a liquid recycle stream is added before the first reactor and/or bed at a recycle to fresh feed ratio of less than 5: 1 where the animal and/or plant FOG is partially reacted in the first reactor and/or bed where a liquid recycle stream is added in between two reactors and/or beds in at least one place in a series of two or more reactors and/or beds. The process according to embodiment 28, wherein the LHSV to the first reactor and/or bed is more than 10 hr ^'1 on a total feed basis. The process according to embodiment 28, wherein the LHSV to the first series of reactors and/or beds is more than 10 hr ¹ on a total feed basis. The process according to embodiment 28, wherein the LHSV to the first reactor and/or bed is more than 20 hr ¹ on a total feed basis. The process according to embodiment 28, wherein the LHSV to the first series of reactors and/or beds is more than 20 hr ¹ on a total feed basis. The process according to embodiment 28, wherein it the first reactor and/or bed outlet temperature is more than the second reactor and/or bed inlet temperature. The process according to embodiment 28, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed below 5 wt% on a fresh feed basis. The process according to embodiment 28, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds below 5 wt% on a fresh feed basis. The process according to embodiment 28, wherein FOG saturation is more than 25% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG saturation is more than 25% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein FOG saturation is more than 50% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG saturation is more than 50% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein FOG saturation is more than 75% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG saturation is more than 75% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 28, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 28, wherein it will be further processed in an isomerization step. The process according to embodiment 28, wherein it will be further processed in an isomerization and/or cracking step to produce a lighter boiling point range product.. The process according to embodiment 28, wherein it will be further processed in an isomerization and/or cracking step to produce a jet/kerosene boiling range product. The process according to embodiment 28, wherein it will be further processed in an isomerization and/or cracking step to produce a naphtha/gasoline boiling range product. The process according to embodiment 28, wherein it will be further processed in an isomerization and/or cracking step to produce a fuel gas boiling range product. A process that involves the hydrogenation, decarboxylation, decarbonylation, and/or hydrodeoxygenation of animal and/or plant fats, oils and/or greases (FOG) in a reaction zone to form paraffins where the reaction zone is separated into two or more reactors and/or beds where a liquid recycle stream is added before the first reactor and/or bed where the animal and/or plant FOG is partially reacted in the first reactor and/or bed where a liquid recycle stream is added in between two reactors and/or beds in at least one place in a series of two or more reactors and/or beds where the combination of all recycle streams to fresh feed ratio is greater than 8: 1. The process according to embodiment 55, wherein the LHSV to the first reactor and/or bed is more than 10 hr ¹ on a total feed basis. The process according to embodiment 55, wherein the LHSV to the first series of reactors and/or beds is more than 10 hr ¹ on a total feed basis. The process according to embodiment 55, wherein the LHSV to the first reactor and/or bed is more than 20 hr ^'1 on a total feed basis. The process according to embodiment 55, wherein the LHSV to the first series of reactors and/or beds is more than 20 hr ^'1 on a total feed basis. The process according to embodiment 55, wherein it the first reactor and/or bed outlet temperature is more than the second reactor and/or bed inlet temperature. The process according to embodiment 55, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed below 5 wt% on a fresh feed basis. The process according to embodiment 55, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds below 5 wt% on a fresh feed basis. The process according to embodiment 55, wherein FOG saturation is more than 25% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG saturation is more than 25% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein FOG saturation is more than 50% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG saturation is more than 50% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein FOG saturation is more than 75% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG saturation is more than 75% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 55, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 55, wherein it will be further processed in an isomerization step. The process according to embodiment 55, wherein it will be further processed in an isomerization and/or cracking step to produce a lighter boiling point range product. The process according to embodiment 55, wherein it will be further processed in an isomerization and/or cracking step to produce a jet/kerosene boiling range product. The process according to embodiment 55, wherein it will be further processed in an isomerization and/or cracking step to produce a naphtha/gasoline boiling range product. The process according to embodiment 55, wherein it will be further processed in an isomerization and/or cracking step to produce a fuel gas boiling range product. A process that involves the hydrogenation, decarboxylation, decarbonylation, and/or hydrodeoxygenation of animal and/or plant fats, oils and/or greases (FOG) in a reaction zone to form paraffins where the reaction zone is separated into two or more reactors and/or beds where a liquid recycle stream is added before the first reactor and/or bed at a recycle to fresh feed ratio of less than 5: 1 where the animal and/or plant FOG is partially reacted in the first reactor and/or bed where a liquid recycle stream is added in between two reactors and/or beds in at least one place in a series of two or more reactors and/or beds where the combination of all recycle streams to fresh feed ratio is greater than 8: 1. The process according to embodiment 82, wherein the LHSV to the first reactor and/or bed is more than 10 hr ¹ on a total feed basis. The process according to embodiment 82, wherein the LHSV to the first series of reactors and/or beds is more than 10 hr ¹ on a total feed basis. The process according to embodiment 82, wherein the LHSV to the first reactor and/or bed is more than 20 hr ^'1 on a total feed basis. The process according to embodiment 82, wherein the LHSV to the first series of reactors and/or beds is more than 20 hr ^'1 on a total feed basis. The process according to embodiment 82, wherein it the first reactor and/or bed outlet temperature is more than the second reactor and/or bed inlet temperature. The process according to embodiment 82, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein the free fatty acid

concentration is reduced in the reaction zone of the first reactor and/or bed below 5 wt% on a fresh feed basis. The process according to embodiment 82, wherein the free fatty acid

concentration is reduced in the reaction zone of the first series of reactors and/or beds below 5 wt% on a fresh feed basis. The process according to embodiment 82, wherein FOG saturation is more than 25% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG saturation is more than 25% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein FOG saturation is more than 50% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG saturation is more than 50% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein FOG saturation is more than 75% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG saturation is more than 75% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 50 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 25 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first reactor and/or bed. The process according to embodiment 82, wherein FOG conversion to paraffin is less than 10 wt% in the reaction zone of the first series of reactors and/or beds. The process according to embodiment 82, wherein it will be further processed in an isomerization step. The process according to embodiment 82, wherein it will be further processed in an isomerization and/or cracking step to produce a lighter boiling point range product. The process according to embodiment 82, wherein it will be further processed in an isomerization and/or cracking step to produce a jet/kerosene boiling range product. The process according to embodiment 82, wherein it will be further processed in an isomerization and/or cracking step to produce a naphtha/gasoline boiling range product. The process according to embodiment 82, wherein it will be further processed in an isomerization and/or cracking step to produce a fuel gas boiling range product.