Methods and apparatuses for co-processing pyrolysis oil

Abstract

Methods for co-processing pyrolysis oil streams and fuel processing apparatuses are provided. In one example, a method for co-processing a pyrolysis oil stream and a hydrocarbon stream is provided. The method includes mixing the pyrolysis oil stream and the hydrocarbon stream with a surfactant to form an emulsion. The method introduces the emulsion to a reaction zone in an fluid catalytic cracking (FCC) unit. The method includes contacting the emulsion with a catalyst in the reaction zone to form an FCC product stream.

What is claimed is: 
     
         1 . A method for co-processing a pyrolysis oil stream and a hydrocarbon stream, the method comprising the steps of:
 mixing the pyrolysis oil stream and the hydrocarbon stream with a surfactant to form an emulsion;   introducing the emulsion to a reaction zone in an fluid catalytic cracking (FCC) unit; and   contacting the emulsion with a catalyst in the reaction zone to form an FCC product stream.   
     
     
         2 . The method of  claim 1  wherein the pyrolysis oil stream comprises from about 15 vol % water to about 35 vol % water. 
     
     
         3 . The method of  claim 1  further comprising dissolving the surfactant in the hydrocarbon stream before mixing the pyrolysis oil stream and the hydrocarbon stream. 
     
     
         4 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion comprises mixing the pyrolysis oil stream and the hydrocarbon stream with a non-ionic surfactant. 
     
     
         5 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion comprises mixing the pyrolysis oil stream and the hydrocarbon stream with sorbitan esters of fatty acids, polyglycol esters of fatty acids, mono-glycerides, di-glycerides, a mixture of mono-glycerides and di-glycerides, esters of monofunctional fatty acids with poly-12-hydroxystearic acid, esters of monofunctional alcohols with poly-12-hydroxystearic acid, polymeric esters of difunctional fatty acids, polymeric esters of difunctional alcohols, esters of fatty acids with polyethylene glycol having up to five polyoxyethylene units, esters of hydroxyacids with polyethylene glycol having up to five polyoxyethylene units, succinic anhydride or succinimide-modified linear and branched polyalkylene compounds, or mixtures thereof. 
     
     
         6 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion comprises forming the emulsion with a content of from about 1 to about 55 vol % pyrolysis oil stream, from about 45 to about 50 vol % hydrocarbon stream, and about 0.5 to about 5 vol % surfactant. 
     
     
         7 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion comprises forming the emulsion with a content of from about 1 to about 8 vol % pyrolysis oil stream, from about 87 to about 99 vol % hydrocarbon stream, and about 0.5 to about 5 vol % surfactant. 
     
     
         8 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion comprises forming the emulsion with a content of from about 48 to about 52 vol % pyrolysis oil stream, from about 47 to about 48 vol % hydrocarbon stream, and about 2 to about 3 vol % surfactant. 
     
     
         9 . The method of  claim 1  wherein:
 the hydrocarbon stream is a diesel stream or an atmospheric gas oil stream; 
 mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant comprises mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion; 
 the method further comprises blending the emulsion with a vacuum gas oil (VGO) stream to form a blended stream; 
 introducing the emulsion to the reaction zone in the FCC unit comprises introducing the blended stream to the reaction zone in the FCC unit; and 
 contacting the emulsion with the catalyst in the reaction zone comprises contacting the blended stream with the catalyst in the reaction zone to form the FCC product stream. 
 
     
     
         10 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant comprises mixing the pyrolysis oil stream, the hydrocarbon stream and a lipid stream with the surfactant to form the emulsion. 
     
     
         11 . The method of  claim 1  wherein mixing the pyrolysis oil stream and the hydrocarbon stream with the surfactant to form the emulsion further comprises forming a dispersed phase. 
     
     
         12 . A method for co-processing a pyrolysis oil stream and a lipid stream, the method comprising the steps of:
 mixing the pyrolysis oil stream and the lipid stream with a surfactant to form a mixture;   introducing the mixture to a reaction zone in an fluid catalytic cracking (FCC) unit; and   contacting the mixture with a catalyst in the reaction zone to form an FCC product stream.   
     
     
         13 . The method of  claim 12  wherein the pyrolysis oil stream comprises from about 15 vol % water to about 35 vol % water. 
     
     
         14 . The method of  claim 12  further comprising dissolving the surfactant in the lipid stream before mixing the pyrolysis oil stream and the lipid stream. 
     
     
         15 . The method of  claim 12  wherein mixing the pyrolysis oil stream and the lipid stream with the surfactant comprises mixing the pyrolysis oil stream and the lipid stream with a non-ionic surfactant. 
     
     
         16 . The method of  claim 12  wherein mixing the pyrolysis oil stream and the lipid stream with the surfactant comprises mixing the pyrolysis oil stream and the lipid stream with sorbitan esters of fatty acids, polyglycol esters of fatty acids, mono-glycerides, di-glycerides, a mixture of mono-glycerides and di-glycerides, esters of monofunctional fatty acids with poly-12-hydroxystearic acid, esters of monofunctional alcohols with poly-12-hydroxystearic acid, polymeric esters of difunctional fatty acids, polymeric esters of difunctional alcohols, esters of fatty acids with polyethylene glycol having up to five polyoxyethylene units, esters of hydroxyacids with polyethylene glycol having up to five polyoxyethylene units, succinic anhydride or succinimide-modified linear and branched polyalkylene compounds, or mixtures thereof. 
     
     
         17 . The method of  claim 12  wherein mixing the pyrolysis oil stream and the lipid stream with the surfactant to form the mixture comprises forming the mixture with a content of from about 1 to about 55 vol % pyrolysis oil stream, from about 45 to about 50 vol % lipid stream, and about 0.5 to about 5 vol % surfactant. 
     
     
         18 . The method of  claim 12  wherein mixing the pyrolysis oil stream and the lipid stream with the surfactant to form the mixture comprises forming the mixture with a content of from about 1 to about 8 vol % pyrolysis oil stream, from about 87 to about 99 vol % lipid stream, and about 0.5 to about 5 vol % surfactant. 
     
     
         19 . A fuel processing apparatus comprising:
 a pyrolysis oil source;   a mixing unit in fluid communication with the pyrolysis oil source and configured to mix a pyrolysis oil, a hydrocarbon feedstock, and a surfactant to form an emulsion; and   a fluid catalytic cracking (FCC) unit in fluid communication with the mixing unit and including a reaction chamber suitable for contacting components of the emulsion with a catalyst to form an FCC product stream.   
     
     
         20 . The fuel processing apparatus of  claim 19  wherein the apparatus is configured to blend the emulsion with a gas oil stream to form a blended stream, wherein the blended stream is fed to the FCC unit.