Hydroprocessing of pyrolysis oil and its use as a fuel

Abstract

This invention provides low sulfur fuels, particularly low sulfur bunker fuels, comprising hydroprocessed pyrolysis oil. The hydroprocessed pyrolysis oil can be produced using a catalyst suited to processing pyrolysis oils that may be relatively high in water content and under relatively low severity conditions to limit water formation, while making the hydroprocessed pyrolysis oil more stable than prior to hydroprocessing. The pyrolysis oil can be converted to a more stable hydroprocessed product, e.g., by converting at least a majority of the aldehydes, ketones, and/or carboxylic acids in the pyrolysis oil to more highly stable compounds, such as alcohols. The hydroprocessed product can be particularly suited as a blend component for producing a variety of reduced sulfur fuels.

1 . A process for producing a reduced sulfur fuel, comprising:
 hydroprocessing pyrolysis oil in the presence of a non-aluminum-containing support catalyst and hydrogen at a hydrogen to pyrolysis oil ratio of not greater than about 1000 SCF/bbl (about 170 Nm 3 /m 3 ) to produce a hydroprocessed product; and   combining at least a portion of the hydroprocessed product with a base fuel in which the base fuel has a sulfur content in excess of that of the hydroprocessed product to produce the reduced sulfur fuel.   
     
     
         2 . The process of  claim 1 , wherein the hydrocarbon feedstock comprises biomass. 
     
     
         3 . The process of  claim 1 , wherein the non-aluminum-containing support catalyst includes at least one metal from Groups 8-10 of the Periodic Table of Elements. 
     
     
         4 . The process of  claim 1 , wherein the non-aluminum-containing support comprises a carbon support or a silica support. 
     
     
         5 . The process of  claim 4 , wherein the non-aluminum-containing support catalyst comprises at least one of palladium and platinum. 
     
     
         6 . The process of  claim 1 , wherein the pyrolysis oil is comprised of one or more of aldehydes, ketones, and carboxylic acids. 
     
     
         7 . The process of  claim 1 , wherein the base fuel includes at least one gas oil, heavy fuel oil, or resid oil component. 
     
     
         8 . The process of  claim 1 , wherein the hydroprocessed product comprises at least 10 wt % non-aromatic alcohols, based on total weight of the hydroprocessed product. 
     
     
         9 . The process of  claim 1 , wherein the reduced sulfur fuel comprises a diesel fuel, a home heating oil, an industrial heater or boiler fuel, a marine fuel, or a combination thereof. 
     
     
         10 . The process of  claim 1 , wherein the pyrolysis oil is a liquid fraction of a pyrolysis product. 
     
     
         11 . A process for producing a reduced sulfur fuel, comprising:
 pyrolyzing a hydrocarbon feedstock to produce a pyrolysis oil;   hydroprocessing the pyrolysis oil in the presence of a non-aluminum-containing support catalyst and hydrogen at a hydrogen to pyrolysis oil ratio of not greater than about 1000 SCF/bbl (about 170 Nm 3 /m 3 ) to produce a hydroprocessed product; and   combining at least a portion of the hydroprocessed product with a base fuel in which the base fuel has a sulfur content in excess of that of the hydroprocessed product to produce the reduced sulfur fuel.   
     
     
         12 . The process of  claim 11 , wherein the hydrocarbon feedstock comprises biomass. 
     
     
         13 . The process of  claim 11 , wherein the non-aluminum-containing support catalyst includes at least one metal from Groups 8-10 of the Periodic Table of Elements. 
     
     
         14 . The process of  claim 11 , wherein the non-aluminum-containing support comprises a carbon support or a silica support. 
     
     
         15 . The process of  claim 14 , wherein the non-aluminum-containing support catalyst comprises at least one of palladium and platinum. 
     
     
         16 . The process of  claim 11 , wherein the pyrolysis oil is comprised of one or more of aldehydes, ketones, and carboxylic acids. 
     
     
         17 . The process of  claim 11 , wherein the base fuel includes at least one gas oil, heavy fuel oil, or resid oil component. 
     
     
         18 . The process of  claim 11 , wherein the hydroprocessed product comprises at least 10 wt % non-aromatic alcohols, based on total weight of the hydroprocessed product. 
     
     
         19 . The process of  claim 11 , wherein the reduced sulfur fuel comprises a diesel fuel, a home heating oil, an industrial heater or boiler fuel, a marine fuel, or a combination thereof. 
     
     
         20 . The process of  claim 11 , wherein the pyrolysis oil is a liquid fraction of a pyrolysis product.