Abstract: In a process for the production of para-xylene, methanol is preheated to a first temperature, an aromatic feedstock comprising toluene and/or benzene is preheated to a second temperature and the preheated methanol and aromatic feedstocks are fed to a reactor at a first methanol to aromatic feedstock molar ratio. The preheated aromatic feedstock is contacted with the preheated methanol under alkylation conditions in the reactor in the presence of a catalyst so that the methanol reacts with the aromatic feedstock to produce an effluent comprising para-xylene. During the reaction, a temperature is measured within the reactor and is compared with a predetermined optimal temperature. The methanol to aromatic feedstock molar ratio is then adjusted in a manner to reduce any difference between the measured and predetermined optimal temperatures in the reactor.

Abstract: This invention relates to efficiently regenerating catalyst particles by minimizing the formation of localized “hot spots” and “cold spots” in a regeneration zone. Specifically this invention relates to a method for controlling regenerator temperature in an oxygenates-to-olefins system, comprising the steps of: contacting an oxygenate feed in a reactor with a catalytically effective amount of molecular sieve-containing catalyst under conditions effective for converting said oxygenate to a product containing light olefins and forming a coked catalyst; contacting a portion of the coked catalyst in a regenerator, having a catalyst bed height (Hc), an inlet height (Hi), and an outlet height (Ho), with an oxygen-containing regeneration medium under conditions effective to at least partially regenerate the coked catalyst; and conducting a portion of the catalyst from the regenerator to a catalyst cooler to form a cooled catalyst portion, wherein Ho is greater than Hi.

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: In a process for producing cyclohexanone, cyclohexylbenzene is oxidized to produce cyclohexylbenzene hydroperoxide and then the resultant cyclohexylbenzene hydroperoxide is cleaved to produce an effluent stream comprising phenol and cyclohexanone. At least a portion of the effluent stream is then fed to at least one hydrogenation reaction zone, where the effluent stream portion is contacted with hydrogen in the presence of a hydrogenation catalyst under conditions effective to convert at least part of the phenol in the effluent portion into cyclohexanone.

Abstract: In a process for producing cyclohexylbenzene, hydrogen and a liquid feed comprising benzene are introduced into a reaction zone and are contacted in the reaction zone under hydroalkylation conditions to produce cyclohexylbenzene. An effluent stream comprising cyclohexylbenzene and unreacted benzene is removed from the reaction zone and is divided into at least first and second portions, wherein the mass ratio of the effluent stream first portion to the effluent stream second portion is at least 2:1. The effluent stream first portion is then cooled and the cooled effluent stream first portion is recycled to the reaction zone.

Abstract: The invention relates to the integration of a dehydroaromatization process with the processes for the utilization of associated gas; gases comprising methane and higher hydrocarbons, and/or liquefied natural gas (LNG) production or usage.

Abstract: The present invention relates to processes for forming mixed alcohols containing methanol and ethanol. The mixed alcohol can then be used as a feedstock for an oxygenate-to-olefin reaction system for conversion thereof to ethylene, propylene, and the like. In addition, the olefins produced by the oxygenate-to-olefin reaction can then be used as monomers for a polymerization of olefin-containing polymers and/or oligomers.

Abstract: A method of producing synthesis gas for methanol synthesis that comprises the steps of: (a) obtaining a hydrogen stream that has greater than 5 mol % methane from an external process; (b) feeding into a reforming reactor: (i) a feed gas that comprises methane, (ii) water in a specified amount, (iii) oxygen in a specified amount, and (iv) the hydrogen stream in a specified amount; (c) reacting the feed gas, water, oxygen and the hydrogen stream in the reactor; and (d) withdrawing from the reactor the synthesis gas that is at a specific temperature, has less than 3 mol % methane, and has a stoichiometric number of from 1.9 to 2.3.

Abstract: In a process for converting methane to syngas and aromatic hydrocarbons, a feed containing methane is contacted with a dehydrocyclization catalyst under conditions effective to convert said methane to aromatic hydrocarbons and produce a first effluent comprising aromatic hydrocarbons and H2, wherein said first effluent comprises at least 5 wt % more aromatic hydrocarbons than said feed. At least part of the H2 from said first effluent is then reacted with an oxygen-containing species, such as carbon dioxide, to produce a second effluent having an increased H2 and CO content compared with said first effluent.

Abstract: This invention is directed to a method of rejuvenating a molecular sieve that has decreased catalytic activity as a result of contact with moisture, and a method of using the rejuvenated catalyst to make an olefin product from methanol feed. The molecular sieve can be rejuvenated by heating at a rate sufficient to increase the catalytic activity of the molecular sieve. The molecular sieve is considered to be rejuvenated when the molecular sieve has a CMCPS that is increased by at least 5% relative to that at a heat rate basis of 40° C./min over a temperature range of from 25° C. to 475° C.

Abstract: This invention is directed to a process for making a methanol product from a synthesis gas (syngas) feed using a fast fluid bed reactor. The reactor is operated at substantially plug flow type behavior. The heat from circulated catalyst is sufficient to initiate the reaction process with little to no preheating of feed required. In addition, little if any internal reactor cooling is needed.

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: 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 relates to efficiently regenerating catalyst particles by minimizing the formation of localized “hot spots” and “cold spots” in a regeneration zone. Specifically this invention relates to a method for controlling regenerator temperature in an oxygenates-to-olefins system, comprising the steps of: contacting an oxygenate feed in a reactor with a catalytically effective amount of molecular sieve-containing catalyst under conditions effective for converting said oxygenate to a product containing light olefins and forming a coked catalyst; contacting a portion of the coked catalyst in a regenerator, having a catalyst bed height (Hc), an inlet height (Hi), and an outlet height (Ho), with an oxygen-containing regeneration medium under conditions effective to at least partially regenerate the coked catalyst; and conducting a portion of the catalyst from the regenerator to a catalyst cooler to form a cooled catalyst portion, wherein Ho is greater than Hi.

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: 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: This invention is directed to a reactor and process for producing methanol. The reactor includes utilizes a plurality of beds of methanol synthesis catalyst in series to form methanol product from synthesis gas (syngas). A liquid layer continuously flows across the top of each catalyst bed, with one or more conduits (e.g., downcomers) that collect the flowing liquid and flow the collected liquid by gravity down to the next bed of catalyst in series. The downcomers are sealed so that vapor does not pass upwardly through the downcomers.

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 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: Processes for polymerizing propylene. About 40 wt % to about 80 wt % propylene monomer, based on total weight of propylene monomer and diluent, and about 20 wt % to about 60 wt % diluent, based on total weight of propylene monomer and diluent, can be fed into a reactor. The propylene monomer can be polymerized in the presence of a metallocene catalyst and an activator within the reactor at a temperature of about 80° C. or more and a pressure of about 13 MPa or more to produce a polymer product in a homogenous system. About 20 wt % to about 76 wt % (preferably About 28 wt % to about 76 wt %) propylene monomer, based on total weight of the propylene monomer, diluent, and polymer product, can be present at the reactor exit at steady state conditions.