Abstract: This invention relates to a process to polymerize olefins comprising contacting propylene, at a temperature of 65° C. to 150° C. and a pressure of 1.72 to 34.

Abstract: The present invention is directed to a method and system for integrating a catalyst regeneration system with a plurality of hydrocarbon conversion apparatuses, preferably, a plurality of multiple riser reactor units. One embodiment of the present invention is a reactor system including a plurality of reactor units, at least one reactor unit preferably comprising a plurality of riser reactors. The system also includes a regenerator for converting an at least partially deactivated catalyst to a regenerated catalyst. A first conduit system transfers the at least partially deactivated catalyst from the reactor units to the regenerator, and a second conduit system transfers regenerating catalysts from the regenerator to the plurality of reactor units. Optionally, catalysts from a plurality of hydrocarbon conversion apparatuses may be directed to a single stripping unit and/or a single regeneration unit.

Abstract: The present invention relates to a method for preparing olefin comonomers from ethylene. The comonomer generated can be used in a subsequent process, such as a polyethylene polymerization reactor. The comonomer generated can be transported, optionally without isolation or storage, to a polyethylene polymerization reactor. One method includes the steps of: feeding ethylene and a catalyst in a solvent/diluent to one or more comonomer synthesis reactors; reacting the ethylene and the catalyst under reaction conditions sufficient to produce an effluent comprising a desired comonomer; forming a gas stream comprising unreacted ethylene, and a liquid/bottoms stream comprising the comonomer, optionally by passing the effluent to one or more downstream gas/liquid phase separators; and purifying at least a portion of said liquid/bottoms stream by removing at least one of solid polymer, catalyst, and undesirable olefins therefrom.

Abstract: The present invention provides a method for adding heat to a reactor system used to convert oxygenates to olefin, in which supplemental heat is added with a heating fuel, e.g., a torch oil, having low autoignition temperature, low sulfur, and low nitrogen content.

Abstract: This invention is directed to a process for making a methanol product from a synthesis gas (syngas) feed. Preferably, the process uses a reaction system with three reactors. Particular benefits of a three reactor system are provided by arranging each of the reactors in series, with at least one of the reactors being cooled by evaporative cooling.

Abstract: This invention is directed to a process of making a methanol product using a slurry bubble reactor. The reactor is operated in the liquid phase, with catalyst particles being suspended in the liquid. The invention provides for efficient use of heat and recovery of product by feeding cool syngas into the reactor, while maintaining a high degree of backmixing within the reactor. Complex cooling equipment is not required in the reaction process.

Abstract: This invention is directed to a process for making a methanol product from a synthesis gas (syngas) feed using a fluid bed reactor. Internal reactor heat transfer is balanced between feed preheat and catalyst bed temperature using appropriate backmixing of feed and catalyst. Backmixing can be appropriately controlled using a number of control points, including any one or more of superficial gas velocity, catalyst density in the reactor, reactor height to diameter ratio (preferably at least in the region of the dense catalyst bed), and catalyst particle size.

Abstract: This invention is directed to a process for producing methanol. The methanol product that is produced according to this invention is achieved with a high conversion of synthesis gas. The high conversion of synthesis gas is achieved by flowing a liquid layer across a plurality of catalyst beds countercurrent to the gas flow. The gas containing methanol product exiting each bed flows through the liquid layer. The liquid acts to extract methanol from the gas, as well as cool the gas.

Abstract: The present invention provides a process for producing synthesis gas blends which are especially suitable for conversion either into oxygenates such as methanol or into Fischer-Tropsch liquids. Such a process involves reforming of two separate gaseous hydrocarbon feedstreams (formed, for example, by dividing a natural gas feedstock) in a steam-reforming unit and an oxygen-blown reforming unit, respectively. The syngas effluent from each reforming unit is then combined, after appropriate pressure adjustments, to realize a synthesis gas blend containing selected amounts and ratios of H2, CO and CO2. In further invention embodiments, processes are provided for converting the resulting syngas blends into oxygenates or Fischer-Tropsch hydrocarbons. Further conversion of the oxygenates so produced into light olefins also constitutes part of this invention.

Abstract: Synthesis gas is produced according to this invention using a combination of steam reforming and oxidation chemistry. The process incorporates the use of solids to heat the hydrocarbon feed, and to cool the gas product. According to the invention, heat can be conserved by directionally reversing the flow of feed and product gases at intermittent intervals.

Abstract: The present invention is directed to a hydrocarbon conversion apparatus and process. The apparatus comprises the following: a plurality of riser reactors, each having a first end into which a catalyst is fed, a second end through which the catalyst can exit, and optionally a center axis extending therebetween. The apparatus also includes a separation zone having a plurality of inlets, each inlet not being oriented along the center axes of the riser reactors, the separation zone being provided to separate the catalyst from products of a reaction conducted in the hydrocarbon conversion apparatus. A plurality of deviating members are also provided, each deviating member being in fluid communication between the second end of a respective riser reactor and a respective inlet of the separation zone. The apparatus also includes a catalyst retention zone provided to contain catalyst, which is fed to the riser reactors.

Abstract: The present invention provides processes for producing light olefins from a feedstock comprising methanol and ethanol. The ethanol is converted to ethylene and water over a dehydration catalyst, while the methanol is converted to light olefins and water over a molecular sieve catalyst. These conversion steps may occur in two separate reactors operating in series or in parallel, or in a single reactor containing a mixture of dehydration catalyst and molecular sieve catalyst.

Abstract: This invention is directed to methods for forming an olefin stream from a methanol stream. A lower grade methanol, such as chemical grade or crude methanol, can be used as feed to form the olefin stream. The process uses a relatively simple distillation type step to vaporize a portion of the methanol feed stream and send the resulting vapor stream to a reaction unit to form the olefin stream. In addition, the invention provides the ability to operate the downstream recovery units with reduced fouling or plugging due to the presence of fine solids components.

Abstract: This invention provides processes for transporting catalyst, preferably in an oxygenate to olefins reaction system. In one embodiment, an oxygenate contacts molecular sieve catalyst particles in a reactor under conditions effective to form an effluent stream comprising light olefins and forming coked catalyst particles. At least a portion of the coked catalyst particles are transported from the reactor or a device associated therewith to a catalyst regenerator through a conduit in a fluidized manner with a fluidizing medium comprising air and steam. At least a portion of the coked catalyst particles are regenerated in the catalyst regenerator to form regenerated catalyst particles, which are ultimately directed back to the reactor.

Abstract: This invention provides processes, systems and devices for cooling catalyst, preferably regenerated catalyst, by superheating steam and boiling water. The inventive process advantageously provides ideal cooling conditions while ensuring minimal hydrothermal deactivation of the catalyst during the cooling process. The invention is particularly well-suited for cooling catalyst in an oxygenate to olefins reaction system.

Abstract: Catalyst losses are prevented in riser reactor systems by using a low inlet velocity for the first cyclone separator in each multi-stage cyclone separator in the reactor. Catalyst particles not separated from the product output flow in an oxygenate-to-olefin reactor are also recaptured by cooling the product output flow and passing the flow through an electrostatic precipitator.

Abstract: This invention is directed to a process for condensing and removing condensable compounds from an olefin stream containing light olefin compounds, and recovering the light olefin compounds. The process of the invention is particularly effective in removing water and heavy hydrocarbons, particularly aromatic hydrocarbons, from an olefin stream made from the catalytic conversion of oxygenate, and recovering light olefins such as ethylene, propylene, butylene, or a mixture thereof.

Abstract: This invention provides processes for maintaining a desired particle size distribution in an oxygenate to olefin reaction system. In one embodiment, the invention comprises replacing lost catalyst fines with less active co-catalyst particles. By adding less active co-catalyst particles to the reaction system, desirable fluidization characteristics and hydrodynamics can be maintained without affecting the overall (or primary catalyst) performance and product selectivities. The invention is also directed to a population of catalyst particles having a desirable particle size distribution well-suited for realizing ideal fluidization and hydrodynamic characteristics.

Abstract: The invention relates to a process for converting an oxygenate feedstock into an olefin product stream comprising (a) contacting an oxygenate feedstock with a molecular sieve catalyst in a reactor under conditions effective to convert the feedstock into an olefin product stream and to form carbonaceous deposits on the catalyst; (b) contacting at least a portion of the catalyst having said carbonaceous deposits with an oxygen containing gas under conditions effective to obtain a regenerated catalyst having a reduced carbonaceous deposit level and having an increased molecular oxygen content; (c) removing at least 60% by volume of said molecular oxygen from the regenerated catalyst based upon the total volume of molecular oxygen; (d) returning said regenerated catalyst to said reactor; and (e) repeating steps (a)-(d).

Abstract: The present invention is directed to a hydrocarbon conversion apparatus. The apparatus comprises the following: a plurality of riser reactors, each of the riser reactors having a first end into which a catalyst can be fed and a second end through which the catalyst can exit the riser reactor, a separation zone into which the second ends of the riser reactors extend, the separation zone being provided to separate the catalyst from products of a reaction conducted in the hydrocarbon conversion apparatus; and at least one catalyst return in fluid communication with the separation zone and the first ends of the riser reactors, the catalyst return being provided to transfer the catalyst from the separation zone to the first ends of the riser reactors.