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: 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
  • Publication number: 20210268484
    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: Application
    Filed: June 20, 2019
    Publication date: September 2, 2021
    Applicant: 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: 20210268482
    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 aluminum and gallium, and a microporous catalyst component that is a molecular sieve having 8-MR pore openings. The metal oxide catalyst component includes anatomic ratio of chromium:zinc (Cr:Zn) from 0.35 to 1.00, and the at least one additional metal is present in an amount from 25.0 at % to 40.0 at %. A process for preparing C2 and C3 olefins comprising: a) introducing a feed stream comprising hydrogen gas and a carbon-containing gas selected from the group consisting of carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor; and b) converting the feed stream into a product stream comprising C2 and C3 olefins in the reaction zone in the presence of said hybrid catalyst.
    Type: Application
    Filed: June 20, 2019
    Publication date: September 2, 2021
    Applicant: 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: 20210245146
    Abstract: Embodiments of the present disclosure are directed to methods of producing a hydrogen- selective oxygen carrier material comprising combining one or more core material precursors and one or more shell material precursors to from a precursor mixture and heat-treating the precursor mixture at a treatment temperature to form the hydrogen-selective oxygen carrier material. The treatment temperature is greater than or equal to 100° C. less than the melting point of a shell material, and the hydrogen- selective oxygen carrier material comprises a core comprising a core material and a shell comprising the shell material. The shell material may be in direct contact with at least a majority of an outer surface of the core material.
    Type: Application
    Filed: August 27, 2019
    Publication date: August 12, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Manish Sharma, Brian W. Goodfellow, David F. Yancey, Andrzej Malek, Eric E. Stangland
  • Publication number: 20210198164
    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: Application
    Filed: October 9, 2018
    Publication date: July 1, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Barry B. Fish, Peter E. Groenendijk, Davy L.S. Nieskens, Andrzej Malek, Brien A. Stears
  • Publication number: 20210087120
    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: February 7, 2019
    Publication date: March 25, 2021
    Applicant: Dow Global Technologies LLC
    Inventors: Davy L.S. Nieskens, Glenn Pollefeyt, Andrzej Malek, Edward M. Calverley, Peter E. Groenendijk, Aysegul Ciftci Sandikci
  • Patent number: 10787611
    Abstract: A process for preparing C2 to C3 olefins includes introducing a feed stream having a volumetric ratio of hydrogen to carbon monoxide from greater than 0.5:1 to less than 5:1 into a reactor, and contacting the feed stream with a bifunctional catalyst. The bifunctional catalyst includes a Cr/Zn oxide methanol synthesis component having a Cr to Zn molar ratio from greater than 1.0:1 to less than 2.15:1, and a SAPO-34 silicoaluminophosphate microporous crystalline material. The reactor operates at a temperature ranging from 350° C. to 450° C., and a pressure ranging from 10 bar (1.0 MPa) to 60 bar (6.0 MPa). The process has a cumulative productivity of C2 to C3 olefins greater than 15 kg C2 to C3 olefins/kg catalyst.
    Type: Grant
    Filed: December 21, 2017
    Date of Patent: September 29, 2020
    Assignee: Dow Global Technologies LLC
    Inventors: Davy L. S. Nieskens, Aysegul Ciftci Sandikci, Peter E. Groenendijk, Andrzej Malek
  • Patent number: 10703689
    Abstract: A process for converting a feed stream to C2 to C5 hydrocarbons includes introducing a feed stream of hydrogen and at least one carbon-containing component selected from CO, CO2, and mixtures thereof into a reaction zone at an initial reactor pressure and an initial reactor temperature. The feed stream is contacted to a hybrid catalyst positioned in the reaction zone, and the hybrid catalyst includes a methanol synthesis component and a solid microporous acid material. The pressure within the reaction zone is increased during the contacting of the feed stream to the hybrid catalyst from the initial reactor pressure to a final reactor pressure. A temperature within the reaction zone at any time during the contacting of the feed stream to the hybrid catalyst is within ±20° C. of the initial reactor temperature.
    Type: Grant
    Filed: February 2, 2018
    Date of Patent: July 7, 2020
    Assignee: Dow Global Technologies LLC
    Inventors: Davy L. S. Nieskens, Aysegul Ciftci Sandikci, Peter E. Groenendijk, Andrzej Malek
  • Patent number: 10654035
    Abstract: The present disclosure provides an air-soak containing regeneration process reducing its time. The process includes (i) removing surface carbon species from a gallium-based alkane dehydrogenation catalyst in a combustion process in the presence of a fuel gas; (ii) conditioning the gallium-based alkane dehydrogenation catalyst after (i) in air-soak treatment at a temperature of 660° C. to 850° C. with (iii) a flow of oxygen-containing gas having (iv) 0.
    Type: Grant
    Filed: February 22, 2017
    Date of Patent: May 19, 2020
    Assignee: Dow Global Technologies LLC
    Inventors: Andrzej Malek, David Gordon Barton, Lin Luo