# US 2025/0145892 A1 · Process for Hydroprocessing of Non-Petroleum Feedstocks with Hydrogen Production > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2025/0145892 A1 - Document ID: US20250145892A1 - Status: Published application - Kind: A1 - Application number: 19/012,317 - Filed: 2025-01-07 - Published: 2025-05-08 - Earliest claimed: 2012-01-19 - Assignees: Duke Technologies, LLC - Applicants: Duke Technologies, LLC - Inventors: Michael D. Ackerson; Michael Stevan Byars - Web page: https://patentgrep.com/patent/US20250145892A1 ## CPC - C10G 3/42: {Catalytic treatment} - C10G 3/50: {in the presence of hydrogen, hydrogen donors or hydrogen generating compounds} - C10G 49/00: Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 - C07C 1/0485: {Set-up of reactors or accessories; Multi-step processes} - C10G 2300/1014: of vegetal origin - C10G 2300/1018: of animal origin - C10G 2300/202: Heteroatoms content, i.e. S, N, O, P - C10G 2300/4081: Recycling aspects - C10G 2300/802: Diluents - Y02P 30/20: using bio-feedstock - C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES - C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of hydroprocessing is performed wherein non-petroleum feedstocks are treated in a first reaction zone to provide reaction products. The process involves introducing the feedstock along with diluents or a recycle and hydrogen in a first reaction zone and allowing the feed and hydrogen to react in a liquid phase within the first reaction zone to produce reaction products, at least some of the reaction products being in a liquid phase. Gases are separated from the liquid phase reaction products. At least a portion of the gases comprising at least one of C1 or greater hydrocarbons are reformed to form hydrogen gas, which may be used as hydrogen gas for the hydroprocessing process or elsewhere. ## Claims ### Claim 1 A method of hydroprocessing comprising: (a) introducing a non-petroleum feed to be treated along with a diluent and hydrogen into a first reaction zone containing a hydroprocessing catalyst, the amount of diluent combined with the non-petroleum feed being selected to at least one of (A) dissolve a preselected amount of hydrogen in the combined non-petroleum/diluent feed; (B) maintain the temperature within the reactor below a preselected temperature; and (C) adjust the capacity of the liquid phase to dissolve or carry water and/or hydrogen; (b) allowing the feed and hydrogen to react in a liquid phase within the first reaction zone to produce reaction products, at least some of the reaction products remaining in the liquid phase; (c) separating any gases from the liquid phase reaction products; and (d) reforming at least a portion of the separated gases from (c) comprising at least one of C1 or greater hydrocarbons to form hydrogen gas. ### Claim 2 (depends on 1) The method of claim 1, wherein: at least a portion of the hydrogen formed in (d) is used as at least a portion of the hydrogen in (a). ### Claim 3 (depends on 1) The method of claim 1, wherein: the produced reaction products of (b) are cooled prior to the separating any gases in (c). ### Claim 4 (depends on 3) The method of claim 3, further comprising: (e) separating water from the cooled reaction products as an aqueous phase to provide a separated reaction product that is free from the separated water; (f) introducing at least a portion of the separated reaction product as a feed along with hydrogen into a second reaction zone containing a hydroprocessing catalyst; and (g) allowing the separated reaction product feed and hydrogen to react in a liquid phase within the second reaction zone to produce a second-reaction-zone reaction product. ### Claim 5 (depends on 4) The method of claim 4, wherein: at least a portion of the hydrogen gas formed in (d) is used as at least a portion of the hydrogen in (f). ### Claim 6 (depends on 4) The method of claim 4, further comprising: (h) separating gases from the second-reaction-zone reaction product; and (i) reforming at least a portion of the separated gases from (h) comprising at least one of C1 or greater hydrocarbons to form hydrogen gas. ### Claim 7 (depends on 4) The method of claim 4, wherein: the diluent is provided by at least one of (1) a further portion of the separated reaction product of (e) and (2) at least a portion of the second-reaction-zone reaction product of (g). ### Claim 8 (depends on 1) The method of claim 1, wherein: the at least a portion of the separated gases from (c) are purified to remove undesirable compounds prior to reforming. ### Claim 9 (depends on 1) The method of claim 1, wherein: the non-petroleum feed is comprised of at least one of pyrolysis oils, pyrolysis oils derived from at least one of cellulosic biomass materials and coal, plant-derived materials, animal-derived materials, cellulosic materials, vegetable oil, and animal oil. ### Claim 10 (depends on 1) The method of claim 1, wherein: the non-petroleum feed is introduced in the first reaction zone under conditions so that substantially all the feed and hydrogen are in a continuous liquid phase within the first reaction zone. ### Claim 11 (depends on 1) The method of claim 1, wherein: the non-petroleum feed contains from about 10% or more oxygen by weight. ### Claim 12 A method of hydroprocessing comprising: (a) introducing a non-petroleum feed to be treated along with a diluent and hydrogen into a first reaction zone containing a hydroprocessing catalyst, the amount of diluent combined with the non-petroleum feed being selected to at least one of (A) dissolve a preselected amount of hydrogen in the combined non-petroleum/diluent feed; (B) maintain the temperature within the reactor below a preselected temperature; and (C) adjust the capacity of the liquid phase to dissolve or carry water and/or hydrogen; (b) allowing the feed and hydrogen to react in a liquid phase within the first reaction zone to produce reaction products, at least some of the reaction products remaining in the liquid phase; (c) separating any gases from the liquid phase reaction products; and (d) reforming at least a portion of the separated gases from (c) comprising at least one of C1 or greater hydrocarbons to form hydrogen gas. ### Claim 13 (depends on 12) The method of claim 12, wherein: at least a portion of the hydrogen formed in (d) is used as at least a portion of the hydrogen in (a). ### Claim 14 (depends on 12) The method of claim 12, wherein: the produced reaction products of (b) are cooled prior to the separating any gases in (c). ### Claim 15 (depends on 14) The method of claim 14, further comprising: (e) separating water from the cooled reaction products as an aqueous phase to provide a separated reaction product that is free from the separated water; (f) introducing at least a portion of the separated reaction product as a feed along with hydrogen into a second reaction zone containing a hydroprocessing catalyst; and (g) allowing the separated reaction product feed and hydrogen to react in a liquid phase within the second reaction zone to produce a second-reaction-zone reaction product. ### Claim 16 (depends on 15) The method of claim 15, wherein: at least a portion of the hydrogen gas formed in (d) is used as at least a portion of the hydrogen in (f). ### Claim 17 (depends on 15) The method of claim 15, further comprising: (h) separating gases from the second-reaction-zone reaction product; and (i) reforming at least a portion of the separated gases from (h) comprising at least one of C1 or greater hydrocarbons to form hydrogen gas. ### Claim 18 (depends on 15) The method of claim 15, wherein: the diluent is provided by at least one of (1) a further portion of the separated reaction product of (e) and (2) at least a portion of the second-reaction-zone reaction product of (g). ### Claim 19 (depends on 12) The method of claim 12, wherein: the non-petroleum feed is comprised of at least one of pyrolysis oils, pyrolysis oils derived from at least one of cellulosic biomass materials and coal, plant-derived materials, animal-derived materials, cellulosic materials, vegetable oil, and animal oil. ### Claim 20 (depends on 12) The method of claim 12, wherein: the at least a portion of the separated gases from (c) are purified to remove undesirable compounds prior to reforming.