Abstract: A method and system for converting hydrocarbons into C2+ unsaturates is described. The method includes providing a structural member upstream of a reaction zone having a surface of a catalytic material, wherein the catalytic material is rendered catalytically active to promote the reaction of coke and/or coke precursors with hydrogen (H2) and/or an oxidant. Then, the method involves exposing a hydrocarbon stream to the catalytic material, wherein the hydrocarbon stream comprising coke and/or coke precursors react in the presence of the catalytic material to convert at least a portion of the coke and/or coke precursors to vapor products. Finally, the hydrocarbons in the hydrocarbon stream containing vapor products and hydrocarbons are converted in the reaction zone to produce a reactor product having C2+ unsaturates.

Abstract: This invention provides an integrated system and process for forming light olefins and polymers from oxygenates, and optionally from natural gas. The integrated system includes an air separation unit, which separates air components into an oxygen stream and a nitrogen stream, and which also forms a compressed air stream. According to the present invention, the oxygen stream, the nitrogen stream and/or the compressed air stream from the air separation unit may serve as a reactant in syngas generation, as a regeneration medium in the methanol-to-olefins reaction system, as a fluidizing stream, as a blanketing medium, as a stripping medium, as instrument air, and/or as a reactant in a sulfur removal unit.

Abstract: This invention is directed to removing contaminants from an oxygenate-containing feedstream for an oxygenate to olefin reaction system. Oxygenate feeds used in the conversion of oxygenates to olefins, and which contain contaminants, are heated to form a vapor stream and a liquid stream. The heating is conducted so that a majority of the metalloaluminophosphate molecular sieve catalyst contaminants is contained in the liquid stream. The vapor stream is separated from the liquid stream, and the separated vapor stream is contacted with the metalloaluminophosphate molecular sieve catalyst to form olefin product. The heating of the feedstream and the separation of the vapor stream can be carried out in one or more stages.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: This invention is directed to removing contaminants from an oxygenate-containing feedstream for an oxygenate to olefin reaction system. Oxygenate feeds used in the conversion of oxygenates to olefins, and which contain contaminants, are heated to form a vapor stream and a liquid stream. The heating is conducted so that a majority of the metalloaluminophosphate molecular sieve catalyst contaminants is contained in the liquid stream. The vapor stream is separated from the liquid stream, and the separated vapor stream is contacted with the metalloaluminophosphate molecular sieve catalyst to form olefin product. The heating of the feedstream and the separation of the vapor stream can be carried out in one or more stages.

Abstract: A feed vaporization process and apparatus for oxygenate to olefin conversion is provided, which uses a vapor-liquid disengaging drum to separate non-volatiles and/or low-volatiles from volatiles in the oxygenate feed and produce a vaporized effluent that is reduced in non-volatiles and/or low-volatiles while at the same time maintaining the effluent at optimal temperature and pressure as a feed for oxygenate to olefin conversion. The feed vaporization process and apparatus is particularly well suited for selectively removing non-volatile contaminants such as soot and rust from an oxygenate-containing feed, which may have become contaminated during shipping.

Abstract: Disclosed is a method of heat treating a molecular sieve. The method comprises providing a template-containing molecular sieve, heating the molecular sieve under conditions effective to remove a portion of the template from the molecular sieve, and cooling the heated molecular sieve to leave an amount of template effective to cover catalytic sites within the molecular sieve. A catalyst composition is also provided which comprises a molecular sieve having a microporous structure and a binder, wherein between 10 and 90 vol % of the microporous structure is occupied by a material, the material comprising a template or a carbonaceous residue of a template, and the catalyst composition exhibits a Davison Index of not greater than 30.

Abstract: The invention relates to a process for modifying tanker ships. More specifically, the invention is directed to a process for modifying a non-methanol-carrying tanker to carry a methanol cargo destined for a methanol to olefin reaction system. The process includes providing a tanker having one or more holds that previously stored a non-methanol material. The process includes one or more of the following steps: (1) cleaning the holds of the crude/naphtha-carrying tanker to remove residual deposits, wherein the holds previously stored a non-methanol material; (2) providing a fire suppression system specially designed to prevent methanol fires; and (3) replacing methanol intolerant pump seals and flange gaskets in the tanker with methanol resistant seals and gaskets.

Abstract: The invention is directed to a method for making a silicoaluminophosphate (SAPO) molecular sieve from a reaction mixture comprising components present in amounts sufficient to form the SAPO, the reaction mixture having a first pH. The method comprises the steps of: adding an acid to the reaction mixture after the reaction mixture undergoes a change in pH from the first pH; and crystallizing the SAPO from the reaction mixture. The present invention is also directed to a silicoaluminophosphate molecular sieve made by this process.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: A feed vaporization process and apparatus for oxygenate to olefin conversion is provided, which uses a vapor-liquid disengaging drum to separate non-volatiles and/or low-volatiles from volatiles in the oxygenate feed and produce a vaporized effluent that is reduced in non-volatiles and/or low-volatiles while at the same time maintaining the effluent at optimal temperature and pressure as a feed for oxygenate to olefin conversion. The feed vaporization process and apparatus is particularly well suited for selectively removing non-volatile contaminants such as soot and rust from an oxygenate-containing feed, which may have become contaminated during shipping.

Abstract: The invention relates to a process for modifying tanker ships. More specifically, the invention is directed to a process for modifying a non-methanol-carrying tanker to carry a methanol cargo destined for a methanol to olefin reaction system. The process includes providing a tanker having one or more holds that previously stored a non-methanol material. The process includes one or more of the following steps: (1) cleaning the holds of the crude/naphtha-carrying tanker to remove residual deposits, wherein the holds previously stored a non-methanol material; (2) providing a fire suppression system specially designed to prevent methanol fires; and (3) replacing methanol intolerant pump seals and flange gaskets in the tanker with methanol resistant seals and gaskets.

Abstract: This invention is directed to removing contaminants from an oxygenate-containing feedstream for an oxygenate to olefin reaction system. Oxygenate feeds used in the conversion of oxygenates to olefins, and which contain contaminants, are heated to form a vapor stream and a liquid stream. The heating is conducted so that a majority of the metalloaluminophosphate molecular sieve catalyst contaminants is contained in the liquid stream. The vapor stream is separated from the liquid stream, and the separated vapor stream is contacted with the metalloaluminophosphate molecular sieve catalyst to form olefin product. The heating of the feedstream and the separation of the vapor stream can be carried out in one or more stages.

Abstract: This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

Abstract: Disclosed is a method of recovering olefin from purge streams in a polyolefin production process. The method includes reacting a purge stream containing olefin and impurities with water in the presence of a hydrating catalyst to produce an alcohol containing stream. The impurities can include methane, ethane, butylenes, and hydrogen. The alcohol containing stream can be used to produce olefins in an oxygenate to olefin production process.

Abstract: Disclosed is a method for recovering carbon dioxide from an ethylene oxide production process and using the recovered carbon dioxide as a carbon source for methanol synthesis. More specifically, carbon dioxide recovered from an ethylene oxide production process is used to produce a syngas stream. The syngas stream is then used to produce methanol.

Abstract: Disclosed is a method of recovering olefin from purge streams in a polyolefin production process. The method includes reacting a purge stream containing olefin and impurities with water in the presence of a hydrating catalyst to produce an alcohol containing stream. The impurities can include methane, ethane, butylenes, and hydrogen. The alcohol containing stream can be used to produce olefins in an oxygenate to olefin production process.

Abstract: Disclosed is a method for recovering olefin in an oxygenate to olefin production process. The method includes reacting a stream containing olefin with water in the presence of a hydrating catalyst to produce an alcohol containing stream. The alcohol containing stream can be used as an oxygenate feed in the oxygenate to olefin production process.

Abstract: The invention is directed to a method for making a silicoaluminophosphate (SAPO) molecular sieve from a reaction mixture comprising components present in amounts sufficient to form the SAPO, the reaction mixture having a first pH. The method comprises the steps of: adding an acid to the reaction mixture after the reaction mixture undergoes a change in pH from the first pH; and crystallizing the SAPO from the reaction mixture. The present invention is also directed to a silicoaluminophosphate molecular sieve made by this process.

Abstract: Disclosed is a method of heat treating a molecular sieve. The method comprises providing a template-containing molecular sieve, heating the molecular sieve under conditions effective to remove a portion of the template from the molecular sieve, and cooling the heated molecular sieve to leave an amount of template effective to cover catalytic sites within the molecular sieve. A catalyst composition is, also provided which comprises a molecular sieve having a microporous structure and a binder, wherein between 10 and 90 vol % of the microporous structure is occupied by a material, the material comprising a template or a carbonaceous residue of a template, and the catalyst composition exhibits a Davison Index of not greater than 30.