Abstract: A process for converting methanol to light olefins is disclosed and claimed. The catalyst is a metalloaluminophosphate molecular sieve having the empirical formula (ExAlyPz)O2 where EL is a metal such as silicon or magnesium and “x”, “y” and “z” are the mole fractions of EL, Al and P respectively and specifically where “x” has a value of about 0.02 to about 0.08. A preferred molecular sieve is one which has predominantly a plate crystal morphology in which the average smallest crystal dimension is at least 0.1 microns and has an aspect ratio of no greater than 5. The process provides greater selectivity to ethylene and propylene versus C4+ byproducts.

Abstract: Disclosed is a catalytic method for operating an oxygenate to olefins conversion reaction to provide a substantial quantity of prime olefin in the product. The product is provided by operating within desired parameters of weight hourly space velocity and oxygenate partial pressure. Operating the reaction to supply oxygenate at an oxygenate proportion index of at least 0.5, and controlling weight hourly space velocity and molar flow rate of oxygenate to the reactor to maintain a partial pressure-velocity compensation factor of at least 0.1 psia−1hr−1, a prime olefin selectivity of at least 45 wt. % can be maintained.

Abstract: Hydrocarbon conversion process in which a feedstock is contacted with a non zeolitic molecular sieve to remove most, if not all, of the halogen contained in the catalyst. The halogen may be removed by one of several methods. One method includes heating the catalyst in a low moisture environment, followed by contacting the heated catalyst with air and/or steam. Another method includes steam-treating the catalyst at a temperature from 400° C. to 1000° C. The hydrocarbon conversion processes include the conversion of oxygenates to olefins, the conversion of oxygenates and ammonia to alkylamines, the conversion of oxygenates and aromatic compounds to alkylated aromatic compounds, cracking and dewaxing.

Abstract: A process for increasing the ethylene selectivity of a silicoaluminophosphate molecular sieve catalyst by using acetone in an oxygenate conversion process. Acetone can be added with the oxygenate feed at a concentration from about 1% to about 15% by weight, preferably about 1% to about 8% by weight, more preferably about 2% to about 5% by weight. Alternatively, acetone can be added as a pre-feed to the molecular sieve catalyst, particularly regenerated and fresh catalyst, in an contact zone. The pre-feed contacted catalyst is then directed to an oxygenate conversion zone. The acetone concentration in the pre-feed is from about 1% to about 99% by weight, preferably about 30% to about 70% by weight.

Abstract: A process for producing substantially pure isobutylene containing relatively small amounts of higher oligomer byproducts. The process may employ a Y-zeolite catalyst having a silica to alumina ratio of less than or equal to about ten.

Abstract: Disclosed is a method of rejuvenating a molecular sieve. The method includes contacting a molecular sieve having a methanol uptake of less than 1, or a catalyst containing molecular sieve having a methanol up of less than 1, with anhydrous liquid or vapor until the methanol uptake ratio is increased by at least 10%. The rejuvenated molecular sieve or catalyst can be used to make an olefin product from an oxygenate-containing feedstock. The preferred molecular sieve is a silicoaluminophosphate (SAPO) molecular sieve.

Abstract: A method is provided for converting oxygenates, e.g., methanol, to olefins, e.g., ethylene and propylene, comprising contacting said oxygenates and an aromatics co-feed, e.g., xylenes, with a framework gallium-containing molecular sieve catalyst comprising pores having a size ranging from about 5.0 Angstroms to about 7.0 Angstroms, e.g., ZSM-5, under production conditions effective to produce olefins. A catalyst composition is also provided, comprising a ZSM-5 zeolite-bound ZSM-5 zeolite having a bound zeolite of framework Ga-containing zeolite having a Si/Ga molar ratio ranging from 5 to 500 and a binder of Ga-modified, e.g., Ga-exchanged and/or Ga-impregnated, zeolite having a Si/Ga molar ratio ranging from 5 to ∞.

Abstract: A molecular sieve and a molecular sieve catalyst containing a surface heat impregnated with a metal. The molecular sieve is heated in the presence of a metal containing solution at a temperature between 30° C. and 400° C. then separated from the metal containing solution. The molecular sieve and molecular sieve catalyst is used to make olefin from an oxygenate feedstock.

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 from a slurry of formulation composition of a synthesized molecular sieve that has not been fully dried, a binder and an optional matrix material. In a more preferred embodiment, the weight ratio of the binder to the molecular sieve and/or the solid content of the slurry is controlled to provide an improved attrition resistant catalyst composition, particularly useful in a conversion process for producing olefin(s), preferably ethylene and/or propylene, from a feedstock, preferably an oxygenate containing feedstock.

Abstract: A process for producing isobutylene and methanol comprising:

Abstract: There is provided a process for converting methanol and/or dimethyl ether to a product containing olefin, e.g., C2 to C4 olefins, C9+ aromatics and non-C9+ aromatics which comprises: 1) contacting a feed which contains methanol and/or dimethyl ether with a catalyst comprising a porous crystalline material, said contacting step being conducted in the presence of aromatics comprising C9 or C9+ aromatic compound produced in said process under conversion conditions including a temperature of 350° C. to 480° C. and a methanol partial pressure in excess of 10 psia (70 kPa), said porous crystalline material having a Diffusion Parameter for 2,2-dimethylbutane of about 0.1 sec−1 to about 20 sec−1 when measured at a temperature of 120° C.

Abstract: This invention is directed to a method of removing dimethyl ether from an olefin stream. Dimethyl ether is removed from the olefin stream by first separating the olefin stream into a first stream comprising dimethyl ether and lighter boiling point compounds, and a second stream comprising C4+ olefin and higher boiling point hydrocarbons. The dimethyl ether is then separated from the first stream using extractive distillation.

Abstract: Disclosed is a method for converting an oxygenate feedstock to an olefin product. In particular, the method incorporates the use of a silicoaluminophosphate molecular sieve catalyst in the manufacture of ethylene and propylene. The method includes contacting an oxygenate-containing feedstock with a silicoaluminophosphate molecular sieve catalyst to form the olefin-containing product in a fluidized bed reactor apparatus including at least a reaction zone and a recirculation zone. Certain ratios of the mass of catalyst in the reaction zone to that of the sum of the mass of catalyst in both the reaction zone and the recirculation zone within the reactor apparatus are specified.

Abstract: The present invention refers to a crystalline material of zeolitic nature named ITQ-3 characterized by its characteristic X-ray diffraction pattern and its microporous properties, to the process of preparation thereof characterized by the use of one or several organic additives in a reaction mixture that is made to crystallize by heating and to the use thereof in processes of separation and transformation of organic compounds, which material has the empirical formula x(M1/nXO2):yYO2:SiO2 where x has a value lower than 0.15 and may be equal to zero; and y has a value lower than 0.1 and may be equal to zero; M is H+ or an inorganic cation of charge +n, X is a chemical element with oxidation state (Al, Ge, B and Cr), Y is a chemical element with oxidation state (Ti, Ge and V), and when x=0 and y=0 can be described as a new polymorphous of silica of microporous nature.

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 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: In accordance with the present invention there is provided a novel catalyst system in which the catalytic structure is tailormade at the nanometer scale using the invention's novel ship-in-a-bottle synthesis techniques. The invention describes modified forms of solid catalysts for use in heterogeneous catalysis that have a microporous structure defined by nanocages. Examples include zeolites, SAPOs, and analogous materials that have the controlled pore dimensions and hydrothermal stability required for many industrial processes. The invention provides for modification of these catalysts using reagents that are small enough to pass through the windows used to access the cages. The small reagents are then reacted to form larger molecules in the cages.

Abstract: An improved method for the production of methanol and hydrocarbons from a methane-containing gas, such as natural gas. The improved method integrates a hydrocarbon synthesis unit with a methanol synthesis unit. The invention combines a syngas stream from a steam reformer, a syngas stream from an oxidation reformer and additional carbon dioxide to form an optimal syngas composition that is directed to a methanol synthesis reactor. The invention also integrates other process parameters and process components of a methanol and hydrocarbon synthesis process plant to effectively convert most of the carbon in the natural gas to commercial-value products. The invention is also directed to a method of making olefin from the methanol produced by the process of the invention.

Abstract: A method for converting oxygenates to light olefins.

Abstract: The present invention relates to a process for catalytically converting a feedstock comprising an oxygenate to olefins utilizing a heat exchange device to transfer heat from at least a portion of an effluent of an oxygenate conversion reactor to the feedstock to cause at least a portion of the feedstock to vaporize.

Abstract: Disclosed is a method of rejuvenating molecular sieve and molecular sieve catalyst. The method includes freeze drying a molecular sieve having a methanol conversion ratio of less than 1, or a catalyst containing molecular sieve and a binder having a methanol conversion ratio of less than 1. The rejuvenated molecular sieve or catalyst is used to make an olefin product from an oxygenate. The olefin product containing ethylene and propylene can then be used to make polyethylene and polypropylene, respectively.

Abstract: A method for increasing light olefin yield during conversion of oxygenates to olefins comprising: contacting an oxygenate feed in a primary reactor with a non-zeolitic molecular sieve catalyst under conditions effective to produce a first product comprising light olefins; separating the first product into light olefins and a heavy hydrocarbon fraction; feeding the heavy hydrocarbon fraction either back into the primary reactor or to a separate auxiliary reactor; and, subjecting the heavy hydrocarbon fraction to conditions effective to convert at least a portion of the heavy hydrocarbons to light olefins.

Abstract: A catalyst system comprising a silicoaluminophosphate impregnated with a compound selected from the group consisting of phosphoric acid, boric acid, tributyltin acetate, and combinations of any two or more thereof, and a method of preparing such catalyst system, are disclosed. The thus-obtained catalyst system is employed as a catalyst in the conversion of a hydrocarbon feedstock comprising oxygenated hydrocarbons to olefins and/or ethers.

Abstract: The invention provides a method of making ethylene, propylene, and butylene by contacting a molecular sieve catalyst with an oxygenate to convert a portion of the oxygenate to a product containing olefin; separating the catalyst from the olefin product and directing a portion of the separated catalyst to a regenerator; contacting, in an alcohol contact zone, the regenerated catalyst with an alcohol selected from methanol, ethanol, 1-propanol, 1-butanol, or mixtures thereof; and directing the catalyst from the alcohol contact zone to an oxygenate conversion zone. The relative amounts of ethylene, proplyene, and butylene produced by the process is in part dependant upon the composition of the alcohol used to contact the regenerated catalyst.

Abstract: A process for increasing the ethylene selectivity of a silicoaluminophosphate molecular sieve catalyst by using acetone in an oxygenate conversion process. Acetone can be added with the oxygenate feed at a concentration from about 1% to about 15% by weight, preferably about 1% to about 8% by weight, more preferably about 2% to about 5% by weight. Alternatively, acetone can be added as a pre-feed to the molecular sieve catalyst, particularly regenerated and fresh catalyst, in an contact zone. The pre-feed contacted catalyst is then directed to an oxygenate conversion zone. The acetone concentration in the pre-feed is from about 1 % to about 99% by weight, preferably about 30% to about 70% by weight.

Abstract: Molecular sieves comprising (1) phosphorus oxide; (2) a first oxide comprising an oxide of silicon, germanium or mixtures thereof; and (3) a second oxide comprising an oxide of aluminum, boron or mixtures thereof, said molecular sieve having a mole ratio of the first oxide to the second oxide of greater than 1, containing at least about 10 weight percent phosphorus oxide in the crystal framework, and having pores greater than 5 Å in diameter are useful as catalysts in hydrocarbon conversion reactions.

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 method for increasing light olefin yield during conversion of oxygenates to olefins comprising: contacting an oxygenate feed in a primary reactor with a non-zeolitic molecular sieve catalyst under conditions effective to produce a first product comprising light olefins; separating the first product into light olefins and a heavy hydrocarbon fraction; feeding the heavy hydrocarbon fraction either back into the primary reactor or to a separate auxiliary reactor; and, subjecting the heavy hydrocarbon fraction to conditions effective to convert at least a portion of the heavy hydrocarbons to light olefins.

Abstract: The present invention provides a method for converting a feed containing oxygenates to olefins and comprises the following steps: providing a feed including an oxygenate; contacting the feed in a reactor apparatus with a catalyst including a molecular sieve, the contacting taking place under conditions effective to convert the oxygenate to a product including a light olefin, the conditions including a gas superficial velocity of at least two meters per second; and recirculating a first portion of the catalyst to recontact the feed.

Abstract: This invention is directed to a molecular sieve having acid catalyst sites and a method of maintaining the acid catalyst sites of a template-containing silicoaluminophosphate molecular sieve. The method comprises providing a template-containing silicoaluminophosphate molecular sieve and heating the molecular sieve in an oxygen depleted environment under conditions effective to maintain or preserve the number of acid catalyst sites. The heated molecular sieve exhibits at least one peak in the infrared region in a range of from 3630 cm−1 to 3580 cm−1. Preferably, the heated molecular sieve exhibits a combined peak area in the 3630 cm−1 to 3580 cm−1 range of at least 10% of a total peak area of all peaks in an infrared region between 4000 cm−1 to 3400 cm−1.

Abstract: A process is provided for the concentration and recovery of ethylene and heavier components from an oxygenate conversion process. A separation process such as a pressure swing adsorption (PSA) process is used to remove hydrogen and methane from a demethanizer overhead stream comprising hydrogen, methane and C2 hydrocarbons and subsequently return the recovered C2 hydrocarbons to be admixed with the effluent from the oxygenate conversion process. This integration of a separation zone with a fractionation scheme in an ethylene recovery scheme using an initial demethanizer zone resulted in significant capital and operating cost savings by the elimination of cryogenic ethylene-based refrigeration from the overall recovery scheme.

Abstract: An improved method for the production of methanol and hydrocarbons from a methane-containing gas, such as natural gas. The improved method integrates a hydrocarbon synthesis unit with a methanol synthesis unit without the need to recycle unreacted syngas exiting the methanol synthesis reactor. The invention combines a syngas stream and additional carbon dioxide from the hydrocarbon synthesis unit to form an optimal syngas composition for methanol and hydrocarbon synthesis. The invention also integrates other process parameters and process components of a methanol and hydrocarbon synthesis process plant to effectively convert most of the carbon in the natural gas to commercial-value products. The invention is also directed to a method of making olefin from the methanol produced by the process of the invention.

Abstract: A method for converting heavy olefins present in a product stream exiting a first reaction zone into light olefins and carbonaceous deposits on a catalyst without separation of the heavy olefins from the product stream exiting the first reaction zone. The method comprises creating the product stream exiting the first reaction zone, the product stream exiting the first reaction zone comprising the heavy olefins, moving the product stream exiting the first reaction zone to a second reaction zone without separation of the heavy olefins from the product stream exiting the first reaction zone, and contacting the product stream exiting the first reaction zone with the catalyst under conditions effective to form the light olefins, the contacting causing the carbonaceous deposits to form on at least a portion of the catalyst.

Abstract: The invention provides a method of making ethylene, propylene, and butylene by contacting a molecular sieve catalyst with an oxygenate to convert a portion of the oxygenate to a product containing olefin; separating the catalyst from the olefin product and directing a portion of the separated catalyst to a regenerator; contacting, in an alcohol contact zone, the regenerated catalyst with an alcohol selected from methanol, ethanol, 1-propanol, 1-butanol, or mixtures thereof; and directing the catalyst from the alcohol contact zone to an oxygenate conversion zone. The relative amounts of ethylene, prtoplyene, and butylene produced by the process is in part dependant upon the composition of the alcohol used to contact the regenerated catalyst.

Abstract: This invention relates to a method for converting an oxygenate feedstock to an olefin product. In particular, this invention relates to a method for converting an oxygenate feedstock, including a diluent co-feed, to an olefin product, by contacting the feedstock with a silicoaluminophosphate catalyst at a high total pressure of the feedstock while maintaining a low partial pressure of the oxygenates undergoing reaction.

Abstract: Disclosed is a method of rejuvenating molecular sieve and molecular sieve catalyst. The method includes freeze drying a molecular sieve having a methanol conversion ratio of less than 1, or a catalyst containing molecular sieve and a binder having a methanol conversion ratio of less than 1. The rejuvenated molecular sieve or catalyst is used to make an olefin product from an oxygenate. The olefin product containing ethylene and propylene can then be used to make polyethylene and polypropylene, respectively.

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: Disclosed is a method for making olefin product from an oxygenate-containing feedstock. In the method, a silicoaluminophosphate molecular sieve catalyst is contacted with the oxygenate-containing feedstock in a reactor at an average catalyst feedstock exposure index of at least 1.0. The method produces lower coke yield and provides an olefin product which is low in C1-C4 paraffin content. The invention is particularly effective in producing an olefin product having a very low propane content.

Abstract: A method for converting methoxy compounds, such as methanol and dimethyl ether, into olefins, preferably ethylene, by contact with catalyst specifically prepared and/or conditioned to achieve a high yield of ethylene from the quantity of methoxy compound converted. Diffusity of the catalyst is increased by reducing it to a fine particle size and reaction conditions are controlled to ensure that less than 100% of the methoxy compound fed to a fixed bed of such catalyst is converted so as to produce a yield of ethylene of greater than 60%.

Abstract: There is provided a process for converting methanol and/or dimethyl ether to a product containing C2 to C4 olefins which comprises the step of contacting a reaction mixture which contains methanol and/or dimethyl ether and at least 10 wt % of a polymethylbenzene component selected from trimethylbenzenes, tetramethylbenzenes and mixtures thereof with a catalyst comprising a porous crystalline material. The contacting step is conducted under conversion conditions including a temperature of about 250° C. to about 500° C. and a methanol and/or dimethyl ether partial pressure of about 5 to about 250 psia (35 to 1725 kPa). The porous crystalline material used in the catalyst has a pore size greater than the critical diameter of the aromatic compound and a Diffusion Parameter for 2,2-dimethylbutane of at least 500 sec−1 when measured at a temperature of 120° C. and a 2,2-dimethylbutane pressure of 60 torr (8 kPa).

Abstract: The present invention relates to a process for catalytically converting a feedstock comprising an oxygenate to olefins utilizing a heat exchange device to transfer heat from at least a portion of an effluent of an oxygenate conversion reactor to the feedstock to cause at least a portion of the feedstock to vaporize.

Abstract: The present invention relates to a process for the recovering heat and removing impurities from a reactor effluent stream withdrawn from a fluidized exothermic reaction zone for the conversion of oxygenates into light olefins from an oxygenate feedstream. The process comprises a novel two-stage quench tower system to remove water from the reactor effluent stream in the first tower and recover heat from the reactor effluent to at least partially vaporize the feedstream by indirect heat exchange between the oxygenate feedstream and either a first stage overhead stream or a first stage pumparound stream. A drag stream withdrawn from the first tower comprises the majority of the impurities and any higher boiling oxygenates. The second stage tower further removes water from the light olefin product stream and provides a purified water stream which requires only minimal water stripping to produce a high purity water stream.

Abstract: This invention is directed to a method of making a crystalline silicoaluminophosphate molecular sieve. The method includes adding to a vessel a mixture comprising a silicon containing composition, an aluminum containing composition, a phosphorus containing composition, and a template, and continuously stirring the mixture while applying heat at a temperature and duration effective to form a crystalline silicoaluminophosphate molecular sieve, wherein stirring is applied for 20-95% of the duration that heat is applied. The result is a substantial increase in crystalline molecular sieve product.

Abstract: A process for converting methoxy compounds, like methanol or dimethyl ether, into olefins, preferably ethylene, by contacting such methoxy compounds over a series of fixed catalyst beds.

Abstract: A process for selectively converting a feed comprising oxygenate to normally liquid boiling range C5+ hydrocarbons in a single step is provided which comprises a) contacting the feed under oxygenate conversion conditions with a catalyst comprising a unidimensional 10-ring zeolite, e.g., one selected from the group consisting of ZSM-22, ZSM-23, ZSM-35, ZSM-48, ZSM-57, and ferrierite, at temperatures below 350° C. and oxygenate pressures above 40 psia (276 kPa); and b) recovering a normally liquid boiling range C5+ hydrocarbons-rich product stream, e.g, gasoline and distillate boiling range hydrocarbons or C4 to C12 olefins.

Abstract: Disclosed is a molecular sieve catalyst which contains molecular sieve-containing attrition particles and virgin molecular sieve, the attrition particles having been recycled from a catalyst manufacture process or from a reaction system. The catalyst can be used in a variety of catalytic reaction processes. A desired process is making olefins from an oxygenate feedstock. The recovery and use of the attrition particles in the catalyst is beneficial in minimizing waste, thereby reducing problems relating to both environmental and economic constraints.

Abstract: A method for converting oxygenates to light olefins.

Abstract: A process is provided for the concentration and recovery of ethylene and heavier components from an oxygenate conversion process. A separation process such as a pressure swing adsorption (PSA) process is used to remove hydrogen and methane from a demethanizer overhead stream comprising hydrogen, methane and C2 hydrocarbons and subsequently return the recovered C2 hydrocarbons to be admixed with the effluent from the oxygenate conversion process. This integration of a separation zone with a fractionation scheme in an ethylene recovery scheme using an initial deethanizer zone resulted in significant capital and operating cost savings by the elimination of cryogenic ethylene-based refrigeration from the overall recovery scheme.

Abstract: Microporous crystalline silico-alumino-phosphate (SAPO) compositions, catalytic materials comprising the composition, and use of these for production of olefins from methanol. The catalysts contain silico-alumino-phosphate materials with AEI/CHA-mixed phase composition. The catalysts have prolonged life compared to those belonging to the prior art.

Abstract: A solid acid-base catalyst contains vanadium pentoxide hydrate.