Abstract: The invention involves a process for converting an oxygenate-containing feed into an olefin-containing product comprising: (a) providing a co-catalyst oxide of a metal from Groups 2-4 of the Periodic Table of Elements, Lanthanides, Actinides, and combinations thereof, (b) contacting the metal oxide with nitromethane under conditions sufficient for the nitromethane to adsorb onto the metal oxide; (c) analyzing the nitromethane-adsorbed metal oxide using NMR to determine a basic site density of the metal oxide; (d) providing a catalyst system comprising a primary catalyst comprising aluminosilicates, aluminophosphates, silicoaluminophosphates, and metal-containing derivatives and combinations thereof, and the co-catalyst metal oxide whose basic site density is ?0.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90+% CHA framework-type character, a reaction mixture is prepared comprising sources of water, silicon, aluminum, and phosphorus, as well as an organic template. In one aspect, the reaction mixture is heated at more than 10° C./hour to a crystallization temperature and is retained at the crystallization temperature or within the crystallization temperature range for a crystallization time from 16 hours to 350 hours to produce the silicoaluminophosphate molecular sieve. In another aspect, the reaction mixture is heated at less than 10° C./hour to a crystallization temperature from about 150° C. to about 225° C. and is then retained there for less than 10 hours to produce the silicoaluminophosphate molecular sieve. The molecular sieve can then be recovered from the reaction mixture and, preferably, used in a hydrocarbon conversion process, such as oxygenates to olefins.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90+% CHA framework-type character, a reaction mixture is prepared comprising sources of water, silicon, aluminum, and phosphorus, as well as an organic template. In one aspect, the reaction mixture is heated at more than 10° C./hour to a crystallization temperature and is retained at the crystallization temperature or within the crystallization temperature range for a crystallization time from 16 hours to 350 hours to produce the silicoaluminophosphate molecular sieve. In another aspect, the reaction mixture is heated at less than 10° C./hour to a crystallization temperature from about 150° C. to about 225° C. and is then retained there for less than 10 hours to produce the silicoaluminophosphate molecular sieve. The molecular sieve can then be recovered from the reaction mixture and, preferably, used in a hydrocarbon conversion process, such as oxygenates to olefins.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90%+CHA framework type character, a reaction mixture is prepared comprising first combining a reactive source of aluminum with a reactive source of phosphorus to form a primary mixture that is aged. A reactive source of silicon and a template for directing the formation of the molecular sieve can then be added to form a synthesis mixture. Crystallization is then induced in the synthesis mixture. Advantageously, (i) the source of silicon comprises an organosilicate, (ii) the source of phosphorus optionally comprises an organophosphate, and (iii) the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 ?m. The molecular sieve can then preferably be used in a hydrocarbon (oxygenates-to-olefins) conversion process.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90+% CHA framework-type character, a reaction mixture is prepared comprising sources of water, silicon, aluminum, and phosphorus, as well as an organic template. In one aspect, the reaction mixture is heated at more than 10° C./hour to a crystallization temperature and is retained at the crystallization temperature or within the crystallization temperature range for a crystallization time from 16 hours to 350 hours to produce the silicoaluminophosphate molecular sieve. In another aspect, the reaction mixture is heated at less than 10° C./hour to a crystallization temperature from about 150° C. to about 225° C. and is then retained there for less than 10 hours to produce the silicoaluminophosphate molecular sieve. The molecular sieve can then be recovered from the reaction mixture and, preferably, used in a hydrocarbon conversion process, such as oxygenates to olefins.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90%+CHA framework type character, a reaction mixture is prepared comprising first combining a reactive source of aluminum with a reactive source of phosphorus to form a primary mixture that is aged. A reactive source of silicon and a template for directing the formation of the molecular sieve can then be added to form a synthesis mixture. Crystallization is then induced in the synthesis mixture. Advantageously, (i) the source of silicon comprises an organosilicate, (ii) the source of phosphorus optionally comprises an organophosphate, and (iii) the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 ?m. The molecular sieve can then preferably be used in a hydrocarbon (oxygenates-to-olefins) conversion process.

Abstract: In a method of synthesizing a silicoaluminophosphate molecular sieve having 90%+CHA framework type character, a reaction mixture is prepared comprising first combining a reactive source of aluminum with a reactive source of phosphorus to form a primary mixture that is aged. A reactive source of silicon and a template for directing the formation of the molecular sieve can then be added to form a synthesis mixture. Crystallization is then induced in the synthesis mixture. Advantageously, (i) the source of silicon comprises an organosilicate, (ii) the source of phosphorus optionally comprises an organophosphate, and (iii) the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 ?m. The molecular sieve can then preferably be used in a hydrocarbon (oxygenates-to-olefins) conversion process.

Abstract: Disclosed herein is a method of recovery of the activity of a molecular sieve catalyst following use of the catalyst in an OTO conversion process. This is achieved by a regeneration apparatus and a method of regenerating a molecular sieve catalyst, comprising two stages. In a pretreatment stage, the catalyst is pretreated under pretreatment conditions by heating the catalyst to a temperature of between 320° C. to 700° C. in an oxygen depleted medium for a residence time of between 1 minute to two hours; and, in a regeneration stage, the catalyst is regenerated under regeneration conditions by heating the catalyst at a temperature of between 200° C. to 700° C. in an oxidizing medium for a residence time of between 1 to 60 minutes.

Abstract: The invention relates to a method for forming olefins from an oxygenate-containing feedstock, comprising contacting the at least partially vaporized feed comprising oxygenates with a first catalyst upstream of an OTO reactor, the first catalyst consisting of a reactive guard bed of metal oxides comprising one or more metals from Groups 2, 3, and 4 of the Periodic Table and/or one or more metals in the Lanthanide and Actinide series, then contacting the feedstock in the OTO reactor with a second catalyst under conditions effective to form an effluent comprising the olefins.

Abstract: This invention, in one embodiment, is drawn to a process for forming olefin product by contacting an oxygenate with an olefin-forming catalyst under supercritical conditions to form an olefin product. This invention also relates to methods for activating molecular sieve catalyst, regenerating molecular sieve catalyst, and forming and/or disposing a co-catalyst within a molecular sieve catalyst, each under supercritical conditions.

Abstract: This invention provides a process for manufacturing a catalyst with a desired attrition index, comprising the steps of selecting at least one molecular sieve having a morphology and size index (MSI) of from 1 to about 1000 to secure said desired attrition index of said catalyst.

Abstract: Disclosed herein is a method of recovery of the activity of a molecular sieve catalyst following use of the catalyst in an OTO conversion process. This is achieved by a regeneration apparatus and a method of regenerating a molecular sieve catalyst, comprising two stages. In a pretreatment stage, the catalyst is pretreated under pretreatment conditions by heating the catalyst to a temperature of between 320° C. to 700° C. in an oxygen depleted medium for a residence time of between 1 minute to two hours; and, in a regeneration stage, the catalyst is regenerated under regeneration conditions by heating the catalyst at a temperature of between 200° C. to 700° C. in an oxidizing medium for a residence time of between 1 to 60 minutes.

Abstract: The present invention relates to a method for converting a feed including an oxygenate to a product including a light olefin. In particular, this invention relates to converting an oxygenate feedstock with a silicoaluminophosphate catalyst to a product including a light olefin in a reaction apparatus. More particularly, this invention provides a means by which an optimum level of coke can be determined and utilized to generate an optimum or near-optimum yield of light olefins such as ethylene and propylene in a oxygenates to olefins system.

Abstract: This invention provides a method of making a molecular sieve catalyst composition comprising the steps of: a) combining molecular sieve crystals with binder and liquid to form a binder-sieve mixture; b) combining the binder-sieve mixture with matrix material to form a binder-sieve-matrix mixture; c) mixing the binder-sieve-matrix mixture under conditions sufficient to form a slurry having a solids content of at least 40 wt %, based on total weight of the slurry; d) progressing the mixing until slurry viscosity decreases without significant additional dilution of the slurry, so that the slurry solids content does not significantly decrease; and e) drying the decreased viscosity slurry to produce a dried molecular sieve catalyst composition having an attrition rate index of not greater than 1 wt %/hr. The aforementioned catalyst compositions can be used in processes for making olefin product from oxygenate feedstock, which olefin products can be further used for making (co)polymer products.

Abstract: A gas-solids reaction system is provided for improving product recovery in a multiple reactor reaction system. An oxygenate feedstock, desirably of high concentration in oxygenate, is reacted with a catalyst having a low to modest acidity and a Si/Al2 ratio of from 0.10 to 0.32. The reaction occurs in a reaction zone of a fluidized bed reactor at an oxygenate partial pressure of at least 45 psia and a reactor gas superficial velocity of at least 10 ft/s, conveying catalyst through the reaction zone to a circulation zone. The catalyst undergoes displacement with an inert gas in the circulation zone at a displacement gas superficial velocity of at least 0.03 m/s, after which at least a portion, preferably a large portion is returned to the reaction zone. The catalyst has a residence time in the circulation zone of at least twice that of the residence time of catalyst in the reaction zone.

Abstract: The invention involves a process for converting an oxygenate-containing feed into an olefin-containing product comprising: (a) providing a co-catalyst oxide of a metal from Groups 2-4 of the Periodic Table of Elements, Lanthanides, Actinides, and combinations thereof, (b) contacting the metal oxide with nitromethane under conditions sufficient for the nitromethane to adsorb onto the metal oxide; (c) analyzing the nitromethane-adsorbed metal oxide using NMR to determine a basic site density of the metal oxide; (d) providing a catalyst system comprising a primary catalyst comprising aluminosilicates, aluminophosphates, silicoaluminophosphates, and metal-containing derivatives and combinations thereof, and the co-catalyst metal oxide whose basic site density is ?0.

Abstract: The invention relates to a feed vaporization and introduction system for an OTO reactor. The invention includes: means for vaporizing at least a portion of the feed; means for contacting the at least partially vaporized feed with a first catalyst comprising one or more metals from Groups 2, 3, and 4 of the Periodic Table and/or one or more metals in the Lanthanide and Actinide series.

Abstract: One aspect of the invention relates to a method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50° C. to about 250° C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26% and a first micropore surface area; (c) aging the thermally treated synthesized molecular sieve for at least one year; (d) analyzing the aged, thermally treated molecular sieve to determine a second micropore surface area, wherein the second micropore surface area is 3% or less lower than the first micropore surface area; and (e) combining the aged, thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an aged, formulated molecular sieve catalyst composition.

Abstract: A crystalline microporous silicoaluminophosphate (SAPO) molecular sieve is prepared by: (a) providing a reaction mixture having a molar composition within the following ranges: P:Al from 0.75 to 1.25, Si:Al2 from 0.01 to 0.32, H2O:Al2 from 25 to 50, and R:Al2 from 1 to 3, where R designates a structure directing agent (template), and wherein the molar ratios for the aluminum, phosphorus, and silicon sources are calculated based on the oxide forms; (b) heating the mixture to a crystallization temperature of between 150° C. to 250° C. to form the crystalline molecular sieve within the reaction mixture; and (c) following crystallization in step (b), aging the crystalline molecular sieve in an alkaline liquid at a temperature below the crystallization temperature from 0.5 hour for up to 120 hours. Aging can affect both catalyst life and catalyst activity.

Abstract: This invention is directed to methods of converting oxygenates to olefin products. The methods provided include steps for protecting against deactivation of active molecular sieve catalysts during the conversion process. In particular, the invention provides for methods of regenerating coked catalyst to minimize catalyst deactivation due to contact with moisture.