One-step fixed-bed catalytic process for upgrading pyrolysis oil to lighter aromatic compounds

A system for upgrading a pyrolysis oil feed, the system comprising:

• a pyrolysis oil feed stream comprising:
• a heavy pyrolysis oil having greater than or equal to 30 wt. % multi-ring aromatic compounds having boiling point temperatures greater than or equal to 360° C.;
• and
• a diluent comprising a light pyrolysis oil having a density less than 0.98 grams per cubic centimeter;
• and
• a fixed-bed reactor comprising a hydrocracking catalyst, wherein:
• the hydrocracking catalyst comprises:
• a mixed metal oxide catalyst comprising a binder and a plurality of mixed metal oxide particles, each of the mixed metal oxide particles comprising iron oxide (Fe2O3), zirconium oxide (ZrO2), cerium oxide (CeO2), and alumina (Al2O3);
• or
• a supported metal oxide catalyst comprising molybdenum oxide and nickel oxide supported on a catalyst support material comprising a large-pore alumina having a total pore volume of from 0.8 centimeters cubed per gram to 1.1 centimeters cubed per gram;
• and
• the fixed-bed reactor is operable to contact the pyrolysis oil feed with hydrogen in the presence of the hydrocracking catalyst to produce a reactor effluent comprising a greater concentration of aromatic compounds having boiling point temperatures of from 50° C. to 360° C. compared to the pyrolysis oil feed;
• and
• a hydrocarbon gas steam cracking system upstream of the fixed-fixed bed reactor, the hydrocarbon gas steam cracking system comprising:
• a gas steam cracking unit operable to steam crack a hydrocarbon gas to produce a gas steam cracker effluent;
• and
• a gas steam cracker effluent separator operable to separate the gas steam cracker effluent to produce one or more steam cracking product streams and a light pyrolysis oil.

A method for upgrading pyrolysis oil, the method comprising:

• combining a heavy pyrolysis oil and a diluent to produce a pyrolysis oil feed, wherein:
• the heavy pyrolysis oil comprises greater than or equal to 30 wt. % multi-ring aromatic compounds having boiling point temperatures greater than or equal to 360° C.;
• and
• the diluent comprises a light pyrolysis oil having a density less than 0.98 grams per cubic centimeter;
• passing the pyrolysis oil feed to a fixed bed reactor comprising a hydrocracking catalyst comprising pellets having a particle size greater than or equal to 0.1 millimeter, wherein the hydrocracking catalyst comprises:
• a mixed metal oxide catalyst comprising a binder and a plurality of mixed metal oxide particles, each of the mixed metal oxide particles comprising iron oxide (Fe2O3), zirconium oxide (ZrO2), cerium oxide (CeO2), and alumina (Al2O3);
• or
• a supported metal oxide catalyst comprising molybdenum oxide and nickel oxide supported on a catalyst support material comprising a large-pore alumina having a total pore volume of from 0.8 centimeters cubed per gram to 1.1 centimeters cubed per gram;
• contacting the pyrolysis oil feed with the hydrogen in the presence of the hydrocracking catalyst at reaction conditions in the fixed bed reactor, wherein the contacting the pyrolysis oil feed with hydrogen in the presence of the hydrocracking catalyst causes at least a portion of the pyrolysis oil to react to form a reaction effluent comprising a concentration of aromatic compounds having boiling point temperatures of from 50° C. to 360° C. greater than the pyrolysis oil feed;
• steam cracking a naphtha stream in a steam cracking unit to produce a naphtha steam cracker effluent;
• separating the naphtha steam cracker effluent in a naphtha steam cracker effluent separator to produce one or more product streams and the heavy pyrolysis oil;
• and
• passing the heavy pyrolysis oil from the naphtha steam cracker effluent separator to the fixed-bed reactor as at least a portion of the pyrolysis oil feed.