Abstract: The disclosed invention relates to a process for converting ethylbenzene to styrene, comprising: flowing a feed composition comprising ethylbenzene in at least one process microchannel in contact with at least one catalyst to dehydrogenate the ethylbenzene and form a product comprising styrene; exchanging heat between the process microchannel and at least one heat exchange channel in thermal contact with the process microchannel; and removing product from the process microchannel. Also disclosed is an apparatus comprising a process microchannel, a heat exchange channel, and a heat transfer wall positioned between the process microchannel and heat exchange channel wherein the heat transfer wall comprises a thermal resistance layer.

Abstract: The present invention provides a new monomer and methods of using the monomer to fabricate robust polymer surface coatings with controlled thicknesses between 1 and 5 nanometers. The coatings are composed of a new material containing polymerized monomers of 4-vinylbenzenepropanethiol. The polymer surface coating may be applied to metal and silicon. The method includes exposing a metal substrate to a solution of the monomer in hexanes in order to deposit a monolayer of the monomer onto the metal surface. The substrate is then irradiated with ultraviolet radiation in order to graft a thin polymer coating onto the surface. The procedure can be repeated in order to control the thickness of the coating between about 1 nm and 5 nm. Alternatively, thermally initiated polymerization or deposition of partially oligomerized monomers onto the surface provides nanothin coatings with identical performance.

Abstract: A method and system for providing heat to a chemical conversion process is advantageously employed in the production of olefin by the catalytic dehydrogenation of a corresponding hydrocarbon. The catalytic dehydrogenation process employs diluent steam operating at a steam to oil ratio which can be 1.0 or below and relatively low steam superheater furnace temperature. The process and system are advantageously employed for the production of styrene by the catalytic dehydrogenation of ethylbenzene.

Abstract: The present invention relates to catalysts comprising at least one support and at least one layer applied to said support, said layer containing a) 20 to 95% by weight of at least one aluminum, silicon, titanium or magnesium oxide compound or a silicon carbide or a carbon support or mixtures thereof, and b) 5 to 50% by weight of at least one nanocarbon. The catalysts can be used to produce unsaturated hydrocarbons by means of the oxidative dehydrogenation of alkylaromatics, alkenes and alkanes in the gas phase.

Abstract: Catalysts and methods are described for the dehydrogenation of ethylbenzene in the presence of an oxidant gas, such as oxygen or carbon dioxide, using a mixed metal oxide (MMO) catalyst or lithium-promoted sulfated zirconia catalyst to prepare styrene monomer. Ethylbenzene, steam or other inert gas, and an oxidant gas are fed to an oxydehydrogenation unit containing a MMO catalyst or lithium-promoted sulfated zirconia catalyst to produce a dehydrogenated product mixture. The dehydrogenated product mixture is cooled, off gases and condensate are separated from the mixture, and the dehydrogenated product mixture is fed to a distillation unit. Styrene monomer is distilled from the dehydrogenated product mixture.

Abstract: The invention relates to a process of oxydehydrogenating an alkyl-substituted aromatic hydrocarbon starting compound into the corresponding alkenyl-substituted aromatic hydrocarbon product, respectively, which process comprises a step of contacting the starting compound and an oxidant at dehydrogenating conditions, in the presence of a boria-alumina catalyst, characterized in that the boria-alumina catalyst has been prepared by a co-precipitation method. The co-precipitation method comprises the steps of preparing a solution of aluminium salt in an organic medium, followed by adding to this solution a boron compound and then adding ammonia gas to the mixture obtained in previous step to form a precipitate and/or a gel. This process enables oxydehydrogenation of ethyl-benzene to styrene with high selectivity.

Abstract: High temperature treatment of graphite nanofibers to increase their catalytic activity. The heat treated graphite nanofiber catalysts are suitable for catalyzing chemical reactions such as oxidation, hydrogenation, oxidative-dehydrogenation, and dehydrogenation.

Abstract: Process for the production of vinyl-aromatic monomers which comprises: a) feeding an aromatic stream and an olefinic stream to alkylation; b) feeding the reaction product coming from the alkylation section to a first separation section; c) recovering the mono-alkylated aromatic hydrocarbon from the first separation section; d) feeding the mono-alkylated aromatic product to a dehydrogenation section; e) cooling and condensing the reaction gases in the shell of one or more heat exchangers; f) feeding the reaction product coming from the dehydrogenation section to a second separation section; g) recovering the stream of vinyl-aromatic monomer.

Abstract: Methods and processes for reducing alkylation catalyst poisoning are described herein.

Abstract: A process for reacting feed in and an apparatus comprising a radial flow reactor including a first catalyst bed disposed between an outer wall and a centerpipe of the vessel and a second catalyst bed disposed within a centerpipe. Also disclosed is a method of loading catalyst into the radial flow reactor.

Abstract: An improved dehydrogenation process that comprises the dehydrogenation of dehydrogenatable hydrocarbons by the utilization of an iron oxide based dehydrogenation catalyst composition having a low titanium content under low steam-to-oil process conditions.

Abstract: Improved methods and related apparatus are disclosed for efficiently recovering the heat of condensation from overhead vapor produced during separation of various components of dehydrogenation reaction effluent, particularly in ethylbenzene-to-styrene operations, by the use of at least a compressor to facilitate azeotropic vaporization of an ethylbenzene and water mixture within a preferred range of pressure/temperature conditions so as to minimize undesired polymerization reactions.

Abstract: The invention relates to a method of improving a dehydrogenation process comprising: removing a volume of a first dehydrogenation catalyst from a radial dehydrogenation reactor; loading the reactor with a volume of a second dehydrogenation catalyst that has a lower decline rate than the first dehydrogenation catalyst; and passing a dehydrogenatable hydrocarbon through the reactor wherein the volume of the second catalyst is at most 90% of the volume of the removed catalyst.

Abstract: This invention relates to a process for the production of styrene monomer by the dehydrogenation or oxidative dehydrogenation of ethylbenzene in the presence of recycle gas and more particularly to a method of reducing the boiling point of liquid ethylbenzene feed in the production of styrene monomer. The process comprises the step of catalytically dehydrogenating or oxydehydrogenating ethylbenzene in the presence of a mixture, wherein the mixture substantially comprises carbon dioxide, thereby catalytically producing styrene monomer.

Abstract: Processes are provided for the production of styrene monomer by oxidative dehydrogenation of EB using CO2 as a soft oxidant. Carbon dioxide is used as the reaction diluent in one or more dehydrogenation reactors and to supply the heat required for the endothermic reaction of EB to styrene monomer. In the dehydrogenation reactors, two parallel reactions for styrene monomer formation occur simultaneously: (1) direct EB dehydrogenation to styrene monomer over a catalyst using heat provided by the carbon dioxide, and (2) oxidative dehydrogenation of EB with carbon dioxide to form styrene monomer.

Abstract: Methods and processes for increasing the efficiency and/or expanding the capacity of a dehydrogenation unit by use of at least one direct heating unit are described.

Abstract: Methods and systems for extending the life of a dehydrogenation catalyst are described herein. For example, one embodiment includes providing a reaction vessel loaded with a dehydrogenation catalyst with a feedstream via a conduit in operable communication with the reaction vessel. The feedstream may include an alkyl aromatic hydrocarbon and the dehydrogenation catalyst may be adapted to convert the alkyl aromatic hydrocarbon to a vinyl aromatic hydrocarbon. The feedstream may be contacted with an aqueous catalyst life extender, wherein the aqueous catalyst life extender enters the conduit at a linear velocity sufficient to prevent vaporization of the catalyst life extender in the conduit prior to contact with the feedstream.

Abstract: An alkylaromatic dehydrogenation system is described. In addition, a method is described for monitoring an alkylaromatic dehydrogenation process comprising: drawing a sample from the process at a first sample point; passing the sample through an analyzer; and measuring the amount of at least one component present in the sample wherein the sample is at least partially uncondensed. An apparatus is also described for monitoring an ethylbenzene dehydrogenation process comprising a plurality of sample lines that are heat-traced sufficiently to inhibit condensation in the sample lines; and a Fourier Transform Infrared Spectrometer comprising two sample cells wherein the ratio of the length of a first sample cell to the length of the second sample cell is from about 1:1000 to about 1:1.

Abstract: Dehydrogenation of a reactor system of one or more vertically oriented flow reactors equipped with a system for introducing a catalyst extender into the inlet of the reactor. A vertically oriented radial flow reactor comprises inner and outer reactor tubes having perforated wall members extending longitudily of the reactor and defining an annulus containing a dehydrogenation catalyst. A supply line to the reactor is equipped with a rotation vane. An injection nozzle comprising a coaxial flow tube extends into the supply line downstream of the vane. The coaxial flow tube has an interior chamber and an annular chamber surrounding the interior chamber and extending into the supply line along with the interior chamber. The interior chamber is connected to a catalyst extender source and the annular chamber is connected to a source of a carrier gas which is effective to disperse the extender within feedstock flowing into the reactor.

Abstract: The invention relates to a process for the preparation of styrene comprising the gas phase dehydration of 1-phenylethanol at elevated temperature in the presence of a dehydration catalyst in which the dehydration catalyst is a shaped alumina catalyst particles having a surface area (BET) of from 80 to 140 m2/g and a pore volume (Hg) of more than 0.65 ml/g.

Abstract: Methods and systems for extending the life of a dehydrogenation catalyst are described herein. For example, one embodiment includes providing a reaction vessel loaded with a dehydrogenation catalyst with a feedstream via a conduit in operable communication with the reaction vessel. The feedstream may include an alkyl aromatic hydrocarbon and the dehydrogenation catalyst may be adapted to convert the alkyl aromatic hydrocarbon to a vinyl aromatic hydrocarbon. The feedstream may be contacted with an aqueous catalyst life extender, wherein the aqueous catalyst life extender enters the conduit at a linear velocity sufficient to prevent vaporization of the catalyst life extender in the conduit prior to contact with the feedstream.

Abstract: High temperature treatment of graphite nanofibers to increase their catalytic activity. The heat treated graphite nanofiber catalysts are suitable for catalyzing chemical reactions such as oxidation, hydrogenation, oxidative-dehydrogenation, and dehydrogenation.

Abstract: Device for injecting fluid in successive layers into a rotating fluidized bed and methods for catalytic polymerization, drying or other treatments of solid particles or for catalytic conversion of fluids, in which a succession of injectors (12), distributed around the fixed circular wall (2) of a circular reaction chamber, inject along this wall, in successive layers, one or more fluids (13), which entrain the solid particles (17), passing through this chamber, in a movement of rapid rotation whereof the centrifugal force concentrates these particles along this wall, thereby forming a fluidized bed rotating around a central duct (3), through which the fluids are removed.

Abstract: Described are a reactor for carrying out a chemical conversion process in a catalytic bed with mechanism for supplying heat integrated into the reactor, and with a very compact reaction zone, combined with efficient use of the catalyst, and a process for converting a feed, such as a hydrocarbon feed, undergoing an endothermic reaction using the disclosed reactor.

Abstract: A process for producing cumene, which comprises supplying cumyl alcohol and hydrogen to a dehydration catalyst to obtain a mixture containing ?-methyl styrene and water produced and hydrogen, and supplying the mixture to a hydrogenation catalyst.

Abstract: Described is a method for operating and shutting down a dehydrogenation reactor that contains a volume of dehydrogenation catalyst. After termination of the introduction of a dehydrogenation feed into the dehydrogenation reactor that is operated under dehydrogenation reaction conditions, a first cooling fluid comprising steam is introduced into the reactor for a first time period sufficient to cool the dehydrogenation catalyst contained in the dehydrogenation reactor to a second temperature. The introduction of the first cooling fluid is terminated followed by the introduction of a second cooling fluid for a second time period sufficient to cool the dehydrogenation catalyst contained in the dehydrogenation reactor to a third temperature that allows for the handling and removal of the dehydrogenation catalyst from the dehydrogenation reactor.

Abstract: A styrene process is disclosed that uses a dehydrogenation reactor and a transalkylation reactor and in which a significant portion of the benzene, the inhibitors, or both, recovered from the dehydrogenation reactor passes to the transalkylation reactor. The process disclosed herein can also use an alkylation reactor and can increase the run length of the alkylation catalyst.

Abstract: The overall efficiency of a regenerative bed reverse flow reactor system is increased where the location of the exothermic reaction used for regeneration is suitably controlled. The present invention provides a method and apparatus for controlling the combustion to improve the thermal efficiency of bed regeneration in a cyclic reaction/regeneration processes. The process for thermal regeneration of a regenerative reactor bed entails (a) supplying the first reactant through a first channel means in a first regenerative bed and supplying at least a second reactant through a second channel means in the first regenerative bed, (b) combining said first and second reactants by a gas mixing means situated at an exit of the first regenerative bed and reacting the combined gas to produce a heated reaction product, (c) passing the heated reaction product through a second regenerative bed thereby transferring heat from the reaction product to the second regenerative bed.

Abstract: An apparatus for converting a gaseous and/or liquid feed fluid to gaseous and/or liquid products using a solid catalyst comprises a reactor, a liquid phase disposed within the reactor volume, a fixed catalyst at least partially disposed in the liquid phase, a cooling system having a cooling element in thermal contact with the liquid phase, a feed inlet positioned to feed the feed fluid into the reactor volume, and a fluid outlet in fluid communication with the liquid phase. The catalyst is contained in a catalyst container and the container may be adjacent to said cooling element, extend through said cooling element, or may surround the catalyst container. The catalyst may be a Fischer-Tropsch catalyst.

Abstract: Iron oxides are upgraded by calcining at from 700 to 1200° C.

Abstract: A process for the dehydrogenation of a C2 or C3 alkyl aromatic compound to a corresponding vinyl aromatic compound in a tubular reactor incorporating a spiral flow path. Preferred embodiments of the invention provide processes for the production of styrene or divinylbenzene by the catalytic dehydrogenation of ethylbenzene or diethylbenzene, respectively. A feedstock containing a C2 or C3 alkyl aromatic and steam is supplied into the inlet of a tubular reactor containing a dehydrogenation catalyst and comprising a hydrogen permeable outer wall. The alkyl aromatic compound is dehydrogenated to a corresponding vinyl aromatic compound with the attendant production of hydrogen. The feedstock and products of the dehydrogenation reactor are flowed along a longitudinal spiral flow path providing for an outward radial flow of hydrogen to provide a pressure gradient through the hydrogen permeable outer wall of the reactor with the flow of hydrogen therethrough. Hydrogen is removed from the outer wall of the reactor.

Abstract: Quinone methide derivatives such as 4-benzylidene-2,6-di-tert-butyl-cyclohexa-2,5 dienone are used to inhibit styrene monomer polymerization in the dehydrogenator portion of a styrene monomer production system. The inhibitor contacts the dehydrogenation effluent and does not partition in substantial amounts to the aqueous phase that is separated in the phase separator.

Abstract: A styrene process is disclosed that uses a dehydrogenation reactor and a transalkylation reactor and in which a significant portion of the benzene, the inhibitors, or both, recovered from the dehydrogenation reactor passes to the transalkylation reactor. The process disclosed herein can also use an alkylation reactor and can increase the run length of the alkylation catalyst.

Abstract: C2–C30-alkanes are dehydrogenated in a process in which (i) ethylbenzene is dehydrogenated to styrene in a first part process to give a hydrogen-containing offgas stream, and (ii) one or more C2–C30-alkanes are dehydrogenated in the presence of a heterogeneous catalyst in one or more reaction zones in a second part process to give the corresponding olefins, with a hydrogen-containing gas stream being mixed into the reaction gas mixture of the dehydrogenation in at least one reaction zone, wherein at least part of the hydrogen-containing offgas stream obtained in the dehydrogenation of ethylbenzene is mixed into the reaction gas mixture of the alkane dehydrogenation.

Abstract: An integrated process of preparing a C2-5 alkenyl-substituted aromatic compound using a C6-12 aromatic compound and a C2-5 alkane as raw materials.

Abstract: A process is disclosed for producing ?-methylstyrene, acetone, and phenol wherein the amount of ?-methylstyrene produced may be controlled by selectively converting a portion of the cumene hydroperoxide to dimethyl phenyl carbinol, the hydrated form of ?-methylstyrene. The dimethyl phenyl carbinol thus produced will lead to increased production of ?-methylstyrene upon dehydration in the acid cleavage unit of the phenol plant. By controlling the fraction of the cumene hydroperoxide reduced to dimethyl phenyl carbinol, the amount of ?-methylstyrene produced in the plant can be continuously set to meet the demand of the market for ?-methylstyrene. Also disclosed is a non-acidic catalyst for reduction of cumene hydroperoxide.

Abstract: Disclosed is a method for extending the life of dehydrogenation catalysts used to prepare vinyl aromatic hydrocarbons. The catalysts, which typically include both iron oxide and potassium containing catalysis promoter, are exposed to additional potassium delivered using a potassium carboxylate. The potassium carboxylates are desirably free of halogens and other catalysts poisons or groups that could result in the undesirable properties in vinyl aromatic hydrocarbons produced therewith. The present invention is particularly useful with the production of styrene and methyl styrene.

Abstract: A catalyst for the selective oxidation of hydrogen has been developed. It comprises an inert core such as cordierite and an outer layer comprising a lithium aluminate support. The support has dispersed thereon a platinum group metal and a promoter metal, e.g. platinum and tin respectively. This catalyst is particularly effective in the selective oxidation of hydrogen in a dehydrogenation process.

Abstract: A process is described for the dehydrogenation of ethylbenzene to styrene in a fluid-bed reactor-regenerator system, which uses a catalyst based on iron oxide supported on a modified alumina and promoted with further metal oxides.

Abstract: Process for the catalytic dehydrogenation of a C2 or C3 alkyl aromatic in which a feedstock containing the alkyl aromatic and steam is supplied into the inlet of a tubular reactor containing a dehydrogenation catalyst. Within the reactor, the feedstock flows through at least a portion of the reactor along a spiral flow path extending longitudinally of the reactor. The resulting vinyl aromatic product is then recovered from a downstream or outlet section of the reactor. The spiral flow path through which the feedstock is passed is located at least adjacent the inlet side of the reactor and at least a portion of the spiral flow path contains a particulate dehydrogenation catalyst. The spiral flow path may extend throughout a major portion of the elongated tubular reactor and may contain a particulate dehydrogenation catalyst in a substantial portion there.

Abstract: The present invention discloses a process and apparatus for improving the catalyst life and efficiency in a gas flow catalyst bed reactor assembly. The reactor comprises an outer reaction vessel, an inner displacement cylinder, and an annular catalyst bed surrounding the displacement cylinder having a top half and a bottom half. Fluid flow improvement is achieved by adding at least one baffle to the top half of the displacement cylinder to improve uniformity of fluid flow in the reaction vessel and across the catalyst bed. Also disclosed is a process for improving fluid flow uniformity in a gas phase reactor comprising an outer reaction vessel, an inner displacement vessel having a top half and a bottom half and a reaction outer surface and an inert inner space, and an annular catalyst bed. The process comprises conducting fluid flow simulations using actual reactor conditions. During simulation, baffles are added on the outer reaction surface of the displacement reactor to improve simulated fluid flow.

Abstract: A gel composition substantially contained within the pores of a solid material is disclosed for use as a catalyst or as a catalyst support in dehydrogenation and dehydrocyclization processes.

Abstract: A process for converting hydrocarbons in the presence of a catalyst is described that is carried out in a three-phase reactor in which the liquid Peclet number is in the range 0 (excluded) to about 10, with a superficial gas velocity Ug that is preferably less than 35 cm.s−1, to encourage gas transfer into the liquid phase and avoid too much attrition of the catalyst grains.

Abstract: Axial flow dehydrogenation reactors comprising multiple catalyst beds formed of honeycomb monoliths, the beds being separated from each other by heating stages to maintain reactant stream temperature, provide low pressure drop and improved conversion efficiency when used alone or in combination with other reactors, e.g., as reactor upgrades for series reactor systems incorporating radial flow reactor stages.

Abstract: The invention provides process and apparatus for conducting an endothermic reaction of an organic compound in the presence of molecular hydrogen and of multicomponent solids. The process comprises contacting the compound with a solid catalyst for the endothermic reaction and a hydrogen oxidizing solid reagent intermixed with the solid catalyst. Organic products of the endothermic reaction are produced, with evolution of molecular hydrogen. The solid catalyst becomes gradually deactivated by formation of carbonaceous deposits thereon. The evolved hydrogen undergoes an exothermic reaction with the hydrogen oxidizing solid reagent to form a reduction product which comprises deactivated hydrogen oxidizing solid reagent.

Abstract: An integrated process of preparing a C2-5 alkenyl-substituted aromatic compound using a C6-12 aromatic compound and a C2-5 alkane as raw materials.

Abstract: A radial reactor for utilization for catalytic reactions of gaseous or liquid feed streams including an annular catalyst bed, wherein the material contained within the catalyst bed includes an active catalyst material, contained within an outer ring-shaped layer of the catalyst bed, and a generally inert material, contained within an inner ring-shaped layer of the catalyst bed, wherein the generally inert material includes a potassium-containing compound, such as potassium oxide, hydroxide, carbonate or bicarbonate.

Abstract: A catalyst composition containing a zeolite and platinum, and a method of preparing such catalyst composition, are disclosed. The thus-obtained catalyst composition is employed in the conversion of a hydrocarbon to aromatics.

Abstract: Process for the catalytic dehydrogenation of a C2 or C3 alkyl aromatic in which a feedstock containing the alkyl aromatic and steam is supplied into the inlet of a tubular reactor containing a dehydrogenation catalyst. Within the reactor, the feedstock flows through at least a portion of the reactor along a spiral flow path extending longitudinally of the reactor. The resulting vinyl aromatic product is then recovered from a downstream or outlet section of the reactor. The spiral flow path through which the feedstock is passed is located at least adjacent the inlet side of the reactor and at least a portion of the spiral flow path contains a particulate dehydrogenation catalyst. The spiral flow path may extend throughout a major portion of the elongated tubular reactor and may contain a particulate dehydrogenation catalyst in a substantial portion there.

Abstract: A radial reactor for utilization for catalytic reactions of gaseous or liquid feed streams including a vertical, annular catalyst bed, wherein the material contained within the catalyst bed includes an active catalyst material, contained within an outer ring-shaped, vertical layer of the catalyst bed, and an inert material, contained within an inner ring-shaped, vertical layer of the catalyst bed.