Abstract: Disclosed is a method and apparatus for reducing the amount of metal catalyzed side-reaction byproducts formed in the feed vaporization and introduction system of a methanol to olefin reactor system by monitoring and/or maintaining the temperature of at least a portion of the feed vaporization and introduction system and/or of the feedstock contained therein below about 400° C., 350° C., 300° C., 250° C., 200° C. or below about 150° C. The temperature can be maintained in the desired range by jacketing at least a portion of the feed vaporization and introduction system, such as at least a portion of the feed introduction nozzle, with a thermally insulating material or by implementing a cooling system.

Abstract: The invention relates to a molecular sieve catalyst composition, to a method of making or forming the molecular sieve catalyst composition, and to a conversion process using the catalyst composition. In particular, the invention is directed to a catalyst composition comprising a molecular sieve having a framework including at least [AlO4] and [PO4] tetrahedral units, at least one of a binder and a matrix material and at least one phosphorus compound separate from said molecular sieve wherein, after calcination at 760° C. for 3 hours, said catalyst composition has a microporous surface area in excess of 20% of the microporous surface area of said molecular sieve after calcination at 650° C. in nitrogen for 2 hours. The catalyst composition is particularly useful in a conversion process for producing olefin(s), preferably ethylene and/or propylene, from a feedstock, preferably an oxygenate containing feedstock.

Abstract: The invention is directed to methods for protecting metalloaluminophosphate molecular sieves, particularly silicoaluminophosphate (SAPO) molecular sieves, from loss of catalytic activity due to contact with a gas containing water. The methods of the invention provide procedures that enable activated sieve to contact water vapor, within a certain range of time, temperature, and water partial pressure conditions, before the sieve becomes substantially deactivated.

Abstract: A catalyst composition for use in the conversion of oxygenates to olefins comprises a first crystalline silicoaluminophosphate molecular sieve comprising at least one intergrown form of an AEI structure type material and a CHA structure type material, and a second crystalline material different from said first molecular sieve and resulting from dehydration of an aluminophosphate or silicoaluminophosphate hydrate.

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: This invention provides an attrition resistant metalloaluminophosphate molecular sieve catalyst composition, methods of making the catalyst composition and processes for using the catalyst composition. The metalloaluminophosphate molecular sieve catalyst composition is highly attrition resistant in dried as well as fully calcined forms.

Abstract: A silicoaluminophosphate molecular sieve is disclosed that comprises first and second intergrown phases of a CHA framework type and an AEI framework type, wherein said first intergrown phase has an AEI/CHA ratio of from about 5/95 to about 40/60 as determined by DIFFaX analysis, the second intergrown phase has an AEI/CHA ratio of about 30/70 to about 55/45 as determined by DIFFaX analysis and said molecular sieve has a silica to alumina molar ratio (Si/Al2) from about 0.13 to about 0.24.

Abstract: The invention relates to a molecular sieve catalyst composition, to a method of making or forming the molecular sieve catalyst composition, and to a conversion process using the catalyst composition. In particular, the invention is directed to a making a molecular sieve catalyst composition by forming a slurry by combining a molecular sieve, a binder and a matrix material, wherein the slurry has a pH, above or below the isoelectric point of the molecular sieve. The catalyst composition has improved attrition resistance, particularly useful in a conversion process for producing olefin(s), preferably ethylene and/or propylene, from a feedstock, preferably an oxygenate containing feedstock.

Abstract: The present invention provides various processes for fluidizing molecular sieve catalyst compositions in a fluidized bed reaction system. The invention comprises fluidizing a molecular sieve catalyst composition with a reactive fluidizing medium under conditions effective to convert at least a portion of the fluidizing medium to additional product. The invention is ideally suited for implementation into an oxygenate to olefin reaction system, in which the fluidizing medium optionally comprises byproducts of the oxygenate to olefin conversion reaction.

Abstract: An apparatus and process are described in which a plurality of preloaded catalyst samples tubes can be serially and automatically moved from a support to a reaction zone where each catalyst sample can be heated and a preheated reagent feed contacted with the sample and the effluent fed to a product collection and analysis system.

Abstract: This invention provides methods of making molecular sieve catalyst particles, molecular sieve slurries that can be used in such methods, molecular sieve catalyst compositions and their use in catalytic hydrocarbon conversion processes. In one of its aspects, the invention provides a method of making molecular sieve catalyst particles, the method comprising the steps of: a) providing a solution or suspension of an aluminum-containing inorganic oxide precursor in a liquid medium; b) combining the solution or suspension of aluminum-containing inorganic oxide precursor with a molecular sieve, and optionally other formulating agents, to form a catalyst formulation slurry; c) aging the catalyst formulation slurry to generate in said slurry a percentage, or increase in said slurry the existing percentage, of aluminum atoms of the aluminum-containing precursor in the form of oligomers having a sharp 27Al NMR peak at 62-63 ppm; and d) forming molecular sieve catalyst particles from the catalyst formulation slurry.

Abstract: The present invention provides various processes for selectively removing undesirably sized catalyst particles from a reaction system. In one embodiment, a plurality of catalyst particles, having a first median particle diameter, is withdrawn from the reaction system and is directed to a separation unit such as a counter flow cyclone separator. In the separation unit, the particles are separated into a small catalyst stream and a large catalyst stream, the small catalyst stream having a second median particle diameter less than the first median particle diameter, and the large catalyst stream having a third median particle diameter greater than the first median particle diameter. At least a portion of the small or large catalyst stream is then directed back to the reaction system in order to maintain a desirable particle size distribution therein.

Abstract: The invention relates to a molecular sieve catalyst composition, to a method of making or forming the molecular sieve catalyst composition, and to a conversion process using the catalyst composition. In particular, the invention is directed to making a formulated molecular sieve catalyst composition with a synthesized molecular sieve having been recovered using a flocculant. The formulated composition is particularly useful in a conversion process for producing olefin(s), preferably ethylene and/or propylene, from a feedstock, preferably an oxygenate containing feedstock.

Abstract: The present invention provides various processes for selectively removing undesirably sized catalyst particles from a catalyst synthesis system. In one embodiment, a slurry is formed containing a molecular sieve, a matrix material, a slurring agent, and optionally a binder. At least a portion of the slurry is dried to produce a first catalyst mixture. At least a portion of catalyst particles are selectively removed from the first catalyst mixture based on their size. The selective removal of particles preferably occurs in a counter-flow cyclone separator. By selectively removing undesirably-sized catalyst particles from the formulated catalyst mixture, desirable fluidization and catalytic activity characteristics can be realized in an OTO reaction system.

Abstract: The invention provides low metal content molecular sieve catalyst compositions, processes for making such catalysts, and processes for using such catalysts in the conversion of an oxygenate into one or more light olefins. Preferably, the catalyst composition comprises a matrix material having a low metal content. By utilizing matrix materials having low metal contents, the amount of metal-catalyzed side reaction byproducts formed in a reaction system, particularly in an oxygenate-to-olefin reaction system, can be advantageously reduced.

Abstract: The invention is directed to methods of shutting down reaction systems. The reaction systems are those that use catalysts that comprise molecular sieves, particularly metalloaluminophosphate molecular sieves, especially metalloaluminophosphate molecular sieves which are susceptible to loss of catalytic activity due to contact with water molecules. The methods provide appropriate mechanisms of stopping feed to the reactor and unloading catalyst to protect against loss of catalytic activity that can occur due to contact with water molecules.

Abstract: The invention is directed to methods of starting up reaction systems. The reaction systems are those that use catalysts that comprise molecular sieves, particularly metalloaluminophosphate molecular sieves, especially metalloaluminophosphate molecular sieves which are susceptible to loss of catalytic activity due to contact with water molecules. The methods provide appropriate mechanisms of heating and loading the activated molecular sieves to protect against loss of catalytic activity that can occur due to contact with water molecules.

Abstract: This invention is directed to a molecular sieve composition or a catalyst containing molecular sieve which has a relatively high residual silica index, preferably at least about 1.5. The molecular sieve or catalyst can be made by contacting a template-containing molecular sieve with a silicon containing material having an average kinetic diameter that is larger than the average pore diameter of the sieve or catalyst, and heating to leave residual silica at the sieve or catalyst surface. The molecular sieve or catalyst is particularly effective in making an olefin product from an oxygenate feedstock.

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 feedstock is free of or substantially free of metal salts.