Patents by Inventor Andrzej Malek

Andrzej Malek has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20230062065
    Abstract: A process for preparing C2 to C4 olefins includes introducing a feed stream of hydrogen gas and a carbon-containing gas into a reaction zone of a reactor and converting the feed stream into a product stream including C2 to C4 olefins in the reaction zone in the presence of a hybrid catalyst and in a non-oxidative atmosphere. The hybrid catalyst includes a metal oxide catalyst component comprising gallium oxide and zirconia, and a microporous catalyst component having an 8 membered ring structure. The process also includes periodically introducing an oxidative atmosphere into the reaction zone.
    Type: Application
    Filed: December 14, 2020
    Publication date: March 2, 2023
    Applicant: Dow Global Technologies LLC
    Inventors: Joseph F. DEWILDE, Adam CHOJECKI, Alexey KIRILIN, Ewa A. TOCHA-BIELAK, David F. Yancey, Glenn Pollefeyt, Davy L.S. NIESKENS, Andrzej MALEK
  • Publication number: 20230052682
    Abstract: A process for preparing C2 to C4 hydrocarbons includes introducing a feed stream into a reaction zone of a reactor, the feed stream comprising hydrogen gas and carbon monoxide. An additional stream is introduced into the reaction zone of the reactor, the additional stream comprising carbon dioxide. A combined stream that includes the feed stream and the additional stream is converted into a product stream comprising C2 to C4 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a mixed metal oxide catalyst component, and a microporous catalyst component. The process operates at a gas hourly space velocity in excess of 2500 hr-1 and effectively yields a net carbon dioxide selectivity of less than 5.0% and a productivity of C2-C4 hydrocarbons greater than 75 g hydrocarbons per kilogram of catalyst per hour.
    Type: Application
    Filed: December 2, 2020
    Publication date: February 16, 2023
    Applicant: Dow Global Technologies LLC
    Inventors: Glenn Pollefeyt, Davy L.S. Nieskens, Alexey Kirilin, Adam Chojecki, Joseph F. Dewilde, Barry B. Fish, Andrzej Malek
  • Patent number: 11572321
    Abstract: A process for preparing C2 to C5 paraffins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C2 to C5 paraffins in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component and a microporous catalyst component. The metal oxide catalyst component satisfies: an atomic ratio of Cu/Zn from 0.01 to 3.00; an atomic ratio of Cr/Zn from 0.01 to 1.50; and percentage of (Al+Cr) from greater than 0.0 at % to 50.0 at % based on a total amount of metal in the metal oxide catalyst component.
    Type: Grant
    Filed: November 22, 2021
    Date of Patent: February 7, 2023
    Assignee: Dow Global Technologies LLC
    Inventors: Davy L. S. Nieskens, Glenn Pollefeyt, Andrzej Malek, Edward M. Calverley, Peter E. Groenendijk, Aysegul Ciftci Sandikci
  • Patent number: 11555000
    Abstract: A process for preparing C2 to C5 hydrocarbons includes introducing a feed stream into a reaction zone of a reactor, the feed stream including hydrogen gas and carbon monoxide. An additional stream is introduced into the reaction zone of the reactor, the additional stream comprising water, carbon dioxide, or mixtures thereof. A combined stream that includes the feed stream and the additional stream is converted into a product stream comprising C2 to C5 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component, and a microporous catalyst component.
    Type: Grant
    Filed: May 9, 2019
    Date of Patent: January 17, 2023
    Assignee: Dow Global Technologies LLC
    Inventors: Davy L. S. Nieskens, Glenn Pollefeyt, Andrzej Malek
  • Patent number: 11548835
    Abstract: A process for preparing C2 to C5 olefins includes introducing a feed stream comprising hydrogen and at least one carbon-containing component selected from the group consisting of CO, CO2, and mixtures thereof into a reaction zone. The feed stream is contacted with a hybrid catalyst in the reaction zone, and a product stream is formed that exits the reaction zone and includes C2 to C5 olefins. The hybrid catalyst includes a methanol synthesis component and a solid microporous acid component that is selected from molecular sieves having 8-MR access and having a framework type selected from the group consisting of CHA, AEI, AFX, ERI, LTA, UFI, RTH, and combinations thereof. The methanol synthesis component comprises a metal oxide support and a metal catalyst. The metal oxide support includes titania, zirconia, hafnia or mixtures thereof, and the metal catalyst includes zinc.
    Type: Grant
    Filed: October 11, 2018
    Date of Patent: January 10, 2023
    Assignee: Dow Global Technologies
    Inventors: Alexey Kirilin, Adam Chojecki, Kyle C. Andrews, Vera P. Santos Castro, Aysegul Ciftci Sandikci, Davy L. S. Nieskens, Peter E. Groenendijk, Andrzej Malek
  • Patent number: 11446642
    Abstract: A hybrid catalyst including a metal oxide catalyst component comprising chromium, zinc, and at least one additional metal selected from the group consisting of iron and manganese, and a microporous catalyst component that is a molecular sieve having 8-MR pore openings. The at least one additional metal is present in an amount from 5.0 at % to 20.0 at %.
    Type: Grant
    Filed: June 20, 2019
    Date of Patent: September 20, 2022
    Assignee: Dow Global Technologies LLC
    Inventors: Glenn Pollefeyt, Davy L. S. Nieskens, Vera P. Santos Castro, Alexey Kirilin, Adam Chojecki, David Yancey, Andrzej Malek
  • Publication number: 20220289647
    Abstract: A method for separating CO2 from C2 to C5 alkanes includes introducing a first stream including C2 to C5 alkanes and CO2 into a first separation zone, the first separation zone including a hydrocarbon solvent, and separating the first stream into a recycle stream and a second stream in the first separation zone. The recycle stream including CO2 and one or more of CO, H2, and CH4, and the second stream including C2 to C5 alkanes. The method further includes introducing the second stream into a second separation zone, and separating the second stream into a third stream and a fourth stream, wherein the third stream includes C2 alkanes and the fourth stream includes C3 to C5 alkanes.
    Type: Application
    Filed: June 1, 2022
    Publication date: September 15, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Barry Brent Fish, Peter E. Groenendijk, Andrzej Malek, Davy L.S. Nieskens, Brien A. Stears
  • Publication number: 20220251005
    Abstract: A method for operating an acetylene hydrogenation unit of a steam cracking system that integrates a fluidized catalytic dehydrogenation (FCDh) effluent from a fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from the steam cracking system into at least a hydrogenation feed comprising at least acetylene, CO, and hydrogen, introducing the FCDh effluent to the separation system, combining the FCDh effluent with the cracked gas upstream of the separation system, or both. The method may include hydrogenating acetylene in the hydrogenation feed. Elevated CO concentration in the hydrogenation feed due to the FCDh effluent may reduce a reaction rate of acetylene hydrogenation. The acetylene hydrogenation unit may operate at an elevated temperature relative to normal operating temperatures when the portion of the FCDh effluent is not integrated, such that a concentration of acetylene in the hydrogenated effluent is less than a threshold acetylene concentration.
    Type: Application
    Filed: June 8, 2020
    Publication date: August 11, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Hangyao Wang, Lin Luo, Yu Liu, Matthew T. Pretz, Andrzej Malek
  • Publication number: 20220227687
    Abstract: A method for operating an acetylene hydrogenation unit in an integrated steam cracking-fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from a steam cracking system and an FCDh effluent from an FCDh system into a hydrogenation feed and an acetylene-depleted stream, the hydrogenation feed comprising at least hydrogen, CO, and acetylene. During normal operating conditions, at least 20% of the CO in the hydrogenation feed is from the cracked gas. The method may include contacting the hydrogenation feed with an acetylene hydrogenation catalyst to hydrogenate at least a portion of the acetylene in the hydrogenation feed to produce a hydrogenated effluent. The steam cracking is operated under conditions that increase CO production such that a concentration of CO in the cracked gas is great enough that when a flowrate of the FCDh effluent is zero, a CO concentration in the hydrogenation feed is at least 100 ppmv.
    Type: Application
    Filed: June 8, 2020
    Publication date: July 21, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Lin Luo, Hangyao Wang, Yu Liu, Matthew T. Pretz, Andrzej Malek
  • Publication number: 20220220044
    Abstract: A method for preparing C2 to C5 paraffins including introducing a feed stream of hydrogen gas and a carbon-containing gas selected from carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor. Converting the feed stream into a product stream that includes C2 to C5 paraffins in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst including a microporous catalyst component; and a metal oxide catalyst component. The metal oxide catalyst component including a metal component present on a metal oxide support material. The metal oxide support material includes at least one oxide of a metal selected from Group 4 of the IUPAC periodic table of elements. The product stream has a C3/C2 carbon molar ratio greater than or equal to 4.0.
    Type: Application
    Filed: May 7, 2020
    Publication date: July 14, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Alexey Kirilin, Adam Chojecki, Joseph F. Dewilde, Glenn Pollefeyt, Davy L.S. Nieskens, Andrzej Malek
  • Patent number: 11377403
    Abstract: A method for separating CO2 from C2 to C5 alkanes includes introducing a first stream including C2 to C5 alkanes and CO2 into a first separation zone, the first separation zone including a hydrocarbon solvent, and separating the first stream into a recycle stream and a second stream in the first separation zone. The recycle stream including CO2 and one or more of CO, H2, and CH4, and the second stream including C2 to C5 alkanes. The method further includes introducing the second stream into a second separation zone, and separating the second stream into a third stream and a fourth stream, wherein the third stream includes C2 alkanes and the fourth stream includes C3 to C5 alkanes.
    Type: Grant
    Filed: April 25, 2018
    Date of Patent: July 5, 2022
    Assignee: Dow Global Technologies LLC
    Inventors: Barry Brent Fish, Peter E. Groenendijk, Andrzej Malek, Davy L. S. Nieskens, Brien A. Stears
  • Publication number: 20220135494
    Abstract: A process for preparing C2 to C5 paraffins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C2 to C5 paraffins in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component and a microporous catalyst component. The metal oxide catalyst component satisfies: an atomic ratio of Cu/Zn from 0.01 to 3.00; an atomic ratio of Cr/Zn from 0.01 to 1.50; and percentage of (Al+Cr) from greater than 0.0 at % to 50.0 at % based on a total amount of metal in the metal oxide catalyst component.
    Type: Application
    Filed: November 22, 2021
    Publication date: May 5, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Davy L.S. Nieskens, Glenn Pollefeyt, Andrzej Malek, Edward M. Calverley, Peter E. Groenendijk, Aysegul Ciftci Sandikci
  • Publication number: 20220088574
    Abstract: A method for preparing C2 to C5 paraffins includes introducing a feed stream including hydrogen gas and a carbon-containing gas selected from carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor. Converting the feed stream into a product stream including C2 to C5 paraffins in the presence of a hybrid catalyst. The hybrid catalyst includes a microporous catalyst component; and a metal oxide catalyst component selected from (A) a bulk material consisting of gallium oxide, (B) gallium oxide present on a titanium dioxide support material, and (C) a mixture of gallium oxide and at least one promoter present on a support material selected from Group 4 of the IUPAC periodic table of elements.
    Type: Application
    Filed: December 16, 2019
    Publication date: March 24, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Alexey Kirilin, Adam Chojecki, Glenn Pollefeyt, Davy L.S. Nieskens, Kyle C. Andrews, Vera P. Santos Castro, Joseph F. DeWilde, David F. Yancey, Andrzej Malek
  • Publication number: 20220080392
    Abstract: A process for preparing C2 to C4 olefins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas selected from carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor. The feed stream is converted into a product stream including C2 to C4 olefins in the reaction zone in the presence of the hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component comprising gallium oxide and phase pure zirconia, and a microporous catalyst component.
    Type: Application
    Filed: December 16, 2019
    Publication date: March 17, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Adam Chojecki, Alexey Kirilin, Andrzej Malek, Joseph F. DeWilde, Vera P. Santos Castro, David F. Yancey, Kyle C. Andrews
  • Publication number: 20220055968
    Abstract: A process for preparing C2 to C5 hydrocarbons includes introducing a feed stream into a reaction zone of a reactor, the feed stream including hydrogen gas and carbon monoxide. An additional stream is introduced into the reaction zone of the reactor, the additional stream comprising water, carbon dioxide, or mixtures thereof. A combined stream that includes the feed stream and the additional stream is converted into a product stream comprising C2 to C5 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component, and a microporous catalyst component.
    Type: Application
    Filed: May 9, 2019
    Publication date: February 24, 2022
    Applicant: Dow Global Technologies LLC
    Inventors: Davy L.S. Nieskens, Glenn Pollefeyt, Andrzej Malek
  • Patent number: 11220469
    Abstract: A process for converting a feed stream having carbon to C2 to C5 olefins, includes introducing a feed stream including methane and oxygen to a first reaction zone, reacting the methane and oxygen in the first reaction zone to form a first reaction zone product stream having a mixture of C2 to C5 alkanes, transporting the mixture of C2 to C5 alkanes to a second reaction zone, introducing a fresh stream of at least one of ethane and propane to the second reaction zone, converting the C2 to C5 alkanes to C2 to C5 olefins in the second reaction zone, producing one or more product streams in the second reaction zone, where a sum of the one or more product streams includes C2 to C5 olefins, and producing a recycle stream comprising hydrogen in the second reaction zone, where the recycle stream is transported to the first reaction zone.
    Type: Grant
    Filed: October 9, 2018
    Date of Patent: January 11, 2022
    Assignee: Dow Global Technologies LLC
    Inventors: Barry B. Fish, Peter E. Groenendijk, Davy L. S. Nieskens, Andrzej Malek, Brien A. Stears
  • Patent number: 11208363
    Abstract: A process for preparing C2 to C5 paraffins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C2 to C5 paraffins in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component and a microporous catalyst component. The metal oxide catalyst component satisfies: an atomic ratio of Cu/Zn from 0.01 to 3.00; an atomic ratio of Cr/Zn from 0.01 to 1.50; and percentage of (Al+Cr) from greater than 0.0 at % to 50.0 at % based on a total amount of metal in the metal oxide catalyst component.
    Type: Grant
    Filed: February 7, 2019
    Date of Patent: December 28, 2021
    Assignee: Dow Global Technologies LLC
    Inventors: Davy L. S. Nieskens, Glenn Pollefeyt, Andrzej Malek, Edward M. Calverley, Peter E. Groenendijk, Aysegul Ciftci Sandikci
  • Publication number: 20210371355
    Abstract: A process for preparing C2 to C5 olefins includes introducing a feed stream comprising hydrogen and at least one carbon-containing component selected from the group consisting of CO, CO2, and mixtures thereof into a reaction zone. The feed stream is contacted with a hybrid catalyst in the reaction zone, and a product stream is formed that exits the reaction zone and includes C2 to C5 olefins. The hybrid catalyst includes a methanol synthesis component and a solid microporous acid component that is selected from molecular sieves having 8-MR access and having a framework type selected from the group consisting of CHA, AEI, AFX, ERI, LTA, UFI, RTH, and combinations thereof. The methanol synthesis component comprises a metal oxide support and a metal catalyst. The metal oxide support includes titania, zirconia, hafnia or mixtures thereof, and the metal catalyst includes zinc.
    Type: Application
    Filed: October 11, 2018
    Publication date: December 2, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Alexey Kirilin, Adam Chojecki, Kyle C. Andrews, Vera P. Santos Castro, Aysegul Ciftci Sandikci, Davy L.S. Nieskens, Peter E. Groenendijk, Andrzej Malek
  • Publication number: 20210317004
    Abstract: Embodiments of the present disclosure are directed to hydrogen-selective oxygen carrier materials and methods of using hydrogen-selective oxygen carrier materials. The hydrogen-selective oxygen carrier material may comprise a core material, which includes a redox-active transition metal oxide; a shell material, which includes one or more alkali transition metal oxides; and a support material. The shell material may be in direct contact with at least a majority of an outer surface of the core material. At least a portion of the core material may be in direct contact with the support material. The hydrogen-selective oxygen carrier material may be selective to combust hydrogen in an environment that includes hydrogen and hydrocarbons.
    Type: Application
    Filed: August 27, 2019
    Publication date: October 14, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Brian W. Goodfellow, Manish Sharma, David F. Yancey, Andrzej Malek, Eric E. Stangland
  • Publication number: 20210292259
    Abstract: According to one or more embodiments described herein, a method for dehydrogenating hydrocarbons may include passing a hydrocarbon feed comprising one or more alkanes or alkyl aromatics into a fluidized bed reactor, contacting the hydrocarbon feed with a dehydrogenation catalyst in the fluidized bed reactor to produce a dehydrogenated product and hydrogen, and contacting the hydrogen with an oxygen-rich oxygen carrier material in the fluidized bed reactor to combust the hydrogen and form an oxygen-diminished oxygen carrier material. In additional embodiments, a dual-purpose material may be utilized which has dehydrogenation catalyst and oxygen carrying functionality.
    Type: Application
    Filed: August 27, 2019
    Publication date: September 23, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Kevin Blann, Alexey Kirilin, Andrzej Malek, Victor Sussman, Matthew T. Pretz, Brien A. Stears, Barry B. Fish, Eric E. Stangland, Brian W. Goodfellow, Manish Sharma