Abstract: The present process provides a method for converting an oxygenate-containing feed stream to an olefin-containing product stream. The method includes: (1) providing a first fluidized catalytic reactor for converting methanol to propylene, the first reactor having a fluidized catalyst system comprising a first catalyst and a second catalyst; (2) providing a second fluidized catalytic reactor communicating with the first fluidized catalytic reactor for cracking heavy olefins having four carbon atoms or greater into propylene, the second reactor having the fluidized catalyst system; (3) providing an oxygenate containing feed to the first reactor; and (4) fluidizing the catalyst system with the oxygenate containing feed.

Abstract: The invention relates to a conversion process for making olefin(s) using a molecular sieve catalyst composition. More specifically, the invention is directed to a process for converting a feedstock comprising an oxygenate in the presence of a molecular sieve catalyst composition, wherein the air feed to the catalyst regenerator is free of or substantially free of metal salts. The air feed is preferably purified by passage through a rotary adsorbent contactor or adsorbent wheel.

Abstract: A method of converting methanol feedstock to olefins is provided and includes contacting the methanol feedstock in a first conversion zone with a catalyst at reaction conditions effective to produce a first reaction zone effluent comprising DME, unreacted methanol and water, and recycling at least a portion of an overhead vapor product to the first conversion zone and/or to the second conversion zone.

Abstract: The invention relates to a conversion process for making olefin(s) using a molecular sieve catalyst composition. More specifically, the invention is directed to a process for converting a feedstock comprising an oxygenate in the presence of a molecular sieve catalyst composition, wherein the air feed to the catalyst regenerator is free of or substantially free of metal salts.

Abstract: The present invention relates to a process for the production of light weight olefins comprising olefins having from 2 to 3 carbon atoms per molecule from an oxygenate feedstock. The process comprises passing the oxygenate feedstock to an oxygenate conversion zone containing a metal aluminophosphate catalyst to produce a light weight olefin stream. A propylene stream and/or mixed butylene is fractionated from said light weight olefin stream and a medium weight C4 to C7 stream is cracked in a separate olefin cracking reactor to enhance the yield of ethylene and propylene products.

Abstract: The present invention provides a reactor system for converting an oxygenate-containing feed stream to an olefin-containing product stream. The system includes: (1) a first fluidized catalytic reactor for converting methanol to propylene, the first reactor having a fluidized catalyst system comprising a first catalyst and a second catalyst; (2) a second fluidized catalytic reactor communicating with the first fluidized catalytic reactor for cracking heavy olefins having four carbon atoms or greater into propylene, the second reactor having the fluidized catalyst system; (3) wherein the first catalyst is a non-zeolite molecular sieve catalyst; and (4) wherein the second catalyst is a zeolite molecular sieve catalyst.

Abstract: The present invention provides a reactor system for converting an oxygenate-containing feed stream to an olefin-containing product stream. The system includes: (1) a first fluidized catalytic reactor for converting methanol to propylene, the first reactor having a fluidized catalyst system comprising a first catalyst and a second catalyst; (2) a second fluidized catalytic reactor communicating with the first fluidized catalytic reactor for cracking heavy olefins having four carbon atoms or greater into propylene, the second reactor having the fluidized catalyst system; (3) wherein the first catalyst is a non-zeolite molecular sieve catalyst; and (4) wherein the second catalyst is a zeolite molecular sieve catalyst.

Abstract: Improved processing for the production of light olefins is provided involving synthesis gas conversion to form an effluent including product dimethyl ether, subsequent separation of the product dimethyl ether and conversion thereof to the desired light olefins. The synthesis gas conversion effluent may also desirably include methanol and at least a portion of such methanol may be employed to effect the separation of the product dimethyl ether.

Abstract: A method of converting methanol feedstock to olefins is provided and includes contacting the methanol feedstock in a first conversion zone with a catalyst at reaction conditions effective to produce a first reaction zone effluent comprising DME, unreacted methanol and water; cooling the first reaction zone effluent to separate DME as a first vapor product from the first reaction zone effluent and to form a first aqueous stream comprising water, unreacted methanol, soluble DME and oxygenates; contacting the first vapor product in a second conversion zone with a catalyst at reaction conditions effective to produce a second reaction zone effluent comprising light olefins, unreacted DME, water and oxygenates; cooling the second reaction zone effluent to separate the light olefins and the unreacted DME as a second vapor product from the second reaction zone effluent and to form a second aqueous stream comprising water, soluble DME and oxygenates; compressing the unreacted DME and the light olefins; separating DME

Abstract: A reactor for converting a feedstream having one or more oxygenated compounds to a product containing olefins is provided. The reactor comprises a fluidized reaction zone defined by a reactor wall and a feedstream inlet located adjacent the reaction zone. The feedstream inlet is operative to feed the reaction zone with said feedstream. A riser extends from said reaction zone and carries a vaporized combination of said feedstream and said catalyst from said reaction zone to a disengaging zone fed by the riser. At least one cooling tube is disposed within the reactor and extends substantially vertically and substantially parallel to the reactor wall. The cooling tube is located adjacent the reactor wall and extends from an upper portion of the reaction zone towards a lower portion of the reaction zone. Also provided is a cooling system for a methanol to olefin reactor. Finally, a method of producing olefins from a feedstream having an oxygenate is provided.

Abstract: The average propylene cycle selectivity of an oxygenate to propylene (OTP) process using a dual-function oxygenate conversion catalyst is substantially enhanced by the use of a combination of: 1) moving bed reactor technology in the hydrocarbon synthesis portion of the OTP flow scheme in lieu of the fixed bed technology of the prior art; 2) a hydrothermally stabilized and dual-functional catalyst system comprising a molecular sieve having dual-function capability dispersed in a phosphorus-modified alumina matrix containing labile phosphorus and/or aluminum anions; and 3) a catalyst on-stream cycle time of 400 hours or less. These provisions stabilize the catalyst against hydrothermal deactivation and hold the build-up of coke deposits on the catalyst to a level which does not substantially degrade dual-function catalyst activity, oxygenate conversion and propylene selectivity, thereby enabling maintenance of average propylene cycle yield near or at essentially start-of-cycle levels.

Abstract: The present invention relates to a process for the production of light weight olefins comprising olefins having from 2 to 3 carbon atoms per molecule from an oxygenate feedstock. The process comprises passing the oxygenate feedstock to an oxygenate conversion zone containing a metal alumino phosphate catalyst to produce a light weight olefin stream. A propylene stream and/or mixed butylene is fractionated from said light weight olefin stream and a medium weight C4 to C7 stream is cracked in a separate olefin cracking reactor to enhance the yield of ethylene and propylene products.

Abstract: The present invention comprises a process for producing propylene comprising the steps of contacting an olefin feed containing between about 40 and about 80 wt-% olefins and between about 20 and about 60 wt-% olefins and aromatics with a spherical catalyst to form a cracked product, the catalyst comprising about 30 to about 80 wt-% of a crystalline zeolite, the reaction conditions including a temperature from about 500° to 650° C., a hydrocarbon partial pressure of 70 to 280 kPa (10 to 40 psia), a liquid hourly space velocity in the range of 5 to 40 hr?1 and wherein propylene comprises at least 90 mol-% of the total C3 products.

Abstract: A process and apparatus cools a heat exchange type reaction zone by passing the incoming reactants through heat exchange channels in heat exchange relationship with the reaction zone. The invention simplifies the operation and construction of the heat exchanging type reaction zone by directly communicating reaction channels that contain the reaction with the heating channels that heat reactant across an open manifold located at the end of the channels. Additional reactants, cooling fluids, or other diluents may enter the process directly through the manifold space to permit further temperature control of the reaction zone. The invention promotes better heat transfer efficiency than tube and shell heat transfer arrangements that have been used for similar purposes. The narrow channels are preferably defined by corrugated plates. The reaction channels will contain a catalyst for the promotion of the primary reaction.

Abstract: A novel process for the direct oxidation of hydrogen and hydrocarbons is disclosed, where the explosion risks inherent in gas phase oxidations are substantially eliminated. Gaseous oxidation reactants are soluble in a first reaction solvent phase such as a perfluorocarbon (e.g. C8F18) and the oxidation product is preferentially soluble in a second product solvent phase such as water or a dilute acid. A solid catalyst such as palladium on alumina is then contacted with the dissolved reactants. The oxidation product such as hydrogen peroxide may be separated from the reaction solvent phase by extraction into the immiscible product solvent phase and then separated from it by distillation, thereby allowing re-use of the aqueous phase. The present invention may be carried out using a two-phase reaction system whereby both the reaction solvent and product solvent are contained within a reaction vessel into which the solid catalyst is slurried and mechanically agitated to promote the reaction.

Abstract: The present invention relates to a process for the production of light weight olefins comprising olefins having from 2 to 3 carbon atoms per molecule from an oxygenate feedstock. The process comprises passing the oxygenate feedstock to an oxygenate conversion zone containing a metal aluminophosphate catalyst to produce a light weight olefin stream. A propylene stream and/or mixed butylene is fractionated from said light weight olefin stream and a medium weight C4 to C7 stream is cracked in a separate olefin cracking reactor to enhance the yield of ethylene and propylene products.

Abstract: The present invention comprises a process for producing propylene comprising the steps of contacting an olefin feed containing between about 40 and about 80 wt- % olefins and between about 20 and about 60 wt- % olefins and aromatics with a spherical catalyst to form a cracked product, the catalyst comprising about 30 to about 80 wt- % of a crystalline zeolite, the reaction conditions including a temperature from about 500° to 650 ° C., a hydrocarbon partial pressure of 70 to 280 kPa (10 to 40 psia), a liquid hourly space velocity in the range of 5 to 40 hr−1 and wherein propylene comprises at least 90 mol- % of the total C3 products.

Abstract: An arrangement for a falling film type reactor uses corrugated plates to improve the distribution and dispersion of the gaseous reactant into the liquid. Corrugated plates introduce increased turbulence for promoting better distribution and dispersion of the gas. Corrugation angles can be varied to suit the fluid flow properties of the liquid reactant. The reactor arrangement can also include heat transfer channels defined by the corrugated plates in an alternate arrangement of heat transfer channels and gas liquid contacting channels. The corrugations may also be varied to suit the particular heat transfer requirements of the reactions. The corrugated plates are spaced apart in the contacting channels to prevent localized film contact and placed in contact in the heat exchange portion to stabilize the plate elements defining the corrugations.

Abstract: Carbonyl compounds (e.g. acetone and acetaldehyde) are often present as impurities in oxygenated organic liquids such as acetic acid made by the carbonylation of methanol or in phenol produced by the oxidation of cumene. These impurities can render petrochemical products unsuitable for long-term storage or otherwise adversely affect downstream processing operations. It has now been found that detrimental carbonyl impurities can be easily removed from oxygenated organic liquids by contact with resins having amine functional groups.

Abstract: A catalytic distillation packing that has continuous smooth channels over its entire length is used to change out catalyst in a catalyst distillation arrangement without replacement of packing units and long turnaround times. The long, continuous channels are formed from perforated, corrugated plates that have a sufficient thickness to maintain the geometry of the channels and permit free catalyst flow for catalyst change out. The thickness of the plates also eliminates the need for complicated bracing and attachment arrangements that adds to the expense of the packing arrangement and can obstruct the movement of catalyst therethrough. The long, continuous channels are used with an inlet arrangement that provides ready adjustment of the number of channels that are filled with catalyst and channels that are free of catalyst. It is also possible in this arrangement to operate with a channel arrangement wherein all channels are filled with catalyst.