Abstract: The invention provides a method of making ethylene, propylene, and butylene by contacting a molecular sieve catalyst with an oxygenate to convert a portion of the oxygenate to a product containing olefin; separating the catalyst from the olefin product and directing a portion of the separated catalyst to a regenerator; contacting, in an alcohol contact zone, the regenerated catalyst with an alcohol selected from methanol, ethanol, 1-propanol, 1-butanol, or mixtures thereof; and directing the catalyst from the alcohol contact zone to an oxygenate conversion zone. The relative amounts of ethylene, proplyene, and butylene produced by the process is in part dependant upon the composition of the alcohol used to contact the regenerated catalyst.

Abstract: A process for increasing the ethylene selectivity of a silicoaluminophosphate molecular sieve catalyst by using acetone in an oxygenate conversion process. Acetone can be added with the oxygenate feed at a concentration from about 1% to about 15% by weight, preferably about 1% to about 8% by weight, more preferably about 2% to about 5% by weight. Alternatively, acetone can be added as a pre-feed to the molecular sieve catalyst, particularly regenerated and fresh catalyst, in an contact zone. The pre-feed contacted catalyst is then directed to an oxygenate conversion zone. The acetone concentration in the pre-feed is from about 1 % to about 99% by weight, preferably about 30% to about 70% by weight.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: The invention provides a method of making ethylene, propylene, and butylene by contacting a molecular sieve catalyst with an oxygenate to convert a portion of the oxygenate to a product containing olefin; separating the catalyst from the olefin product and directing a portion of the separated catalyst to a regenerator; contacting, in an alcohol contact zone, the regenerated catalyst with an alcohol selected from methanol, ethanol, 1-propanol, 1-butanol, or mixtures thereof; and directing the catalyst from the alcohol contact zone to an oxygenate conversion zone. The relative amounts of ethylene, prtoplyene, and butylene produced by the process is in part dependant upon the composition of the alcohol used to contact the regenerated catalyst.

Abstract: Disclosed is a method for making olefin product from an oxygenate-containing feedstock. In the method, a silicoaluminophosphate molecular sieve catalyst is contacted with the oxygenate-containing feedstock in a reactor at an average catalyst feedstock exposure index of at least 1.0. The method produces lower coke yield and provides an olefin product which is low in C1-C4 paraffin content. The invention is particularly effective in producing an olefin product having a very low propane content.

Abstract: Disclosed is a method of heat treating a molecular sieve. The method comprises providing a template-containing molecular sieve, heating the molecular sieve under conditions effective to remove a portion of the template from the molecular sieve, and cooling the heated molecular sieve to leave an amount of template effective to cover catalytic sites within the molecular sieve. A catalyst composition is also provided which comprises a molecular sieve having a microporous structure and a binder, wherein between 10 and 90 vol % of the microporous structure is occupied by a material, the material comprising a template or a carbonaceous residue of a template, and the catalyst composition exhibits a Davison Index of not greater than 30.

Abstract: Disclosed is a method of heat treating a molecular sieve. The method comprises providing a template-containing molecular sieve, heating the molecular sieve under conditions effective to remove a portion of the template from the molecular sieve, and cooling the heated molecular sieve to leave an amount of template effective to cover catalytic sites within the molecular sieve. A catalyst composition is also provided which comprises a molecular sieve having a microporous structure and a binder, wherein between 10 and 90 vol % of the microporous structure is occupied by a material, the material comprising a template or a carbonaceous residue of a template, and the catalyst composition exhibits a Davison Index of not greater than 30.

Abstract: A method for converting oxygenates to light olefins.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: A process for producing propylene from a catalytically cracked or thermally cracked naphtha stream is disclosed herein. The naphtha stream is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500° C. to 650° C. and a hydrocarbon partial pressure from about 10 to 40 psia. A separate stream containing aromatics may be co-fed with the naphtha stream.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: A process for producing polymers from C2-C4 olefins selectively produced from a catalytically-cracked or thermally-cracked naphtha stream is disclosed herein. A mixture of the naphtha stream and a stream of steam is feed into a reaction zone where it is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions that include temperatures from about 500° C. to 650° C. and a hydrocarbon partial pressure from about 10 to 40 psia.

Abstract: A process for selectively producing C.sub.2 -C.sub.4 olefins from a catalytically cracked or thermally cracked naphtha stream is disclosed. A mixture of the naphtha stream and a stream of steam is feed into a reaction zone where it is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500 to 650.degree. C. and a hydrocarbon partial pressure from about 10 to 40 psia.

Abstract: The present invention is directed toward improved processes for the regeneration of noble metal-containing catalysts wherein iron contamination of the catalyst during regeneration is significantly diminished. It has been found that maintenance of any iron present in contact with the catalyst in the oxidized state (e.g., as Fe.sub.2 O.sub.3 or Fe.sub.3 O.sub.4) during contact of the catalyst with a source of halogen in the regeneration haliding step results in a marked decrease in the degree of catalyst contamination by iron species.

Abstract: The present invention is directed toward improved processes for the regeneration of noble metal-containing catalysts wherein iron contamination of the catalyst during regeneration is significantly diminished. It has been found that maintenance of any iron present in contact with the catalyst in the oxidized state (e.g., as Fe.sub.2 O.sub.3 or Fe.sub.3 O.sub.4) during contact of the catalyst with a source of halogen in the regeneration haliding step results in a marked decrease in the degree of catalyst contamination by iron species.

Abstract: A deactivated reforming catalyst comprising a type L zeolite containing a Group VIII noble metal may be regenerated and have enhanced dispersion by a method involving contacting the catalyst with oxygen and water at elevated temperatures, contacting the catalyst at elevated temperatures with a source of chlorine such as HCl or Cl.sub.2, and preferably oxygen and water, contacting the catalyst at elevated temperatures with oxygen and optionally water, and contacting the catalyst at elevated temperatures with hydrogen and optionally water to reduce the catalyst. Preferably the noble metal is platinum.

Abstract: A deactivated reforming catalyst comprising a type L zeolite containing a Group VIII noble metal may be regenerated and have enhanced dispersion by a method involving contacting the catalyst with oxygen and water at elevated temperatures, contacting the catalyst at elevated temperatures with a source of chlorine such as HCl or Cl.sub.2, and preferably oxygen and water, contacting the catalyst at elevated temperatures with oxygen and optionally water, and contacting the catalyst at elevated temperatures with hydrogen and optionally water to reduce the catalyst. Preferably the noble metal is platinum.

Abstract: A deactivated reforming catalyst comprising a type L zeolite containing a Group VIII noble metal may be regenerated and have enhanced dispersion by a method involving contacting the catalyst with oxygen and water at elevated temperatures, contacting the catalyst at elevated temperatures with a source of chlorine such as HCl or Cl.sub.2, and preferably oxygen and water, contacting the catalyst at elevated temperatures with oxygen and optionally water, and contacting the catalyst at elevated temperatures with hydrogen and optionally water to reduce the catalyst. Preferably the noble metal is platinum.

Abstract: A deactivated reforming catalyst comprising a type L zeolite containing a Group VIII noble metal may be regenerated and have enhanced dispersion by a method involving contacting the catalyst with oxygen and water at elevated temperatures, contacting the catalyst at elevated temperatures with a source of chlorine such as HCl or Cl.sub.2, and preferably oxygen and water, contacting the catalyst at elevated temperatures with oxygen and optionally water, and contacting the catalyst at elevated temperatures with hydrogen and optionally water to reduce the catalyst. Preferably the noble metal is platinum.

Abstract: A method for regenerating a Group VIII noble metal catalyst which has been contaminated with coke during a reforming process. The method comprises (a) burning off the coke from the catalyst, redispersing the noble metal on the surface of the catalyst support by contacting the catalyst with halogen gas and carbon dioxide, and (c) chemically reducing the catalyst. The presence of carbon dioxide in the redispersing step improves the activity of the regenerated catalyst.