Saudi Arabian Oil Company

Aramco Services Company

Munir D Khokhar

Sohel K Shaikh

Faisal H Alshafei

Raed H Abudawoud

Noor A Sulais

Mohammed R Alalouni

Zhonglin Zhang

Afnan Alghannam

Brian S Hanna

Furqan Aljumah

Bandar A Fadhel

Miao Sun

Rami A Bamagain

Mohammed A Albuali

Mark P Kaminsky

Thamer Mohammad

Wajdi Issam Al Sadat

Zahra N Almisbaa

Gopal Juttu

Anne Madden

Zahra Almisbaa

According to embodiments, a method of producing a catalyst composition may include forming a slurry including an initial zeolite material, a surfactant, silica, and metal precursors, wherein the metal precursors contain a nickel-containing compound and a silver-containing compound, extruding the slurry to produce an extrudate, drying and calcining the extrudate to form a dried and calcined extrudate, hydrothermally treating the dried and calcined extrudate to form a hydrothermally-treated extrudate, and drying and calcining the hydrothermally-treated extrudate to produce the catalyst composition, wherein the catalyst composition includes zeolite, one or more oxides of nickel, and one or more oxides of silver.

Methods of producing catalysts comprising one or more oxides of nickel and one or more oxides of silver

Processes for producing olefins include integration of steam cracking with a dual catalyst metathesis process. The processes include steam cracking a hydrocarbon feed to form a cracking reaction effluent containing butenes, separating the cracking reaction effluent to produce a cracking C4 effluent including normal butenes, isobutene, and 1,3-butadiene, subjecting the cracking C4 effluent to selective hydrogenation to convert 1,3-butadiene in the cracking C4 effluent to normal butenes, removing isobutene from a hydrogenation effluent to produce a metathesis feed containing normal butenes, and contacting the metathesis feed with a metathesis catalyst and a cracking catalyst directly downstream of the metathesis catalyst to produce a metathesis reaction effluent. Contacting with the metathesis catalyst causes metathesis of normal butenes to produce ethylene, propene, and C5+ olefins, and contacting with the cracking catalyst causes C5+ olefins produced through metathesis to undergo cracking reactions to produce additional propene, ethylene, or both.

Systems and processes integrating steam cracking with dual catalyst metathesis for producing olefins

Methods of producing an isomerization catalyst include preparing a catalyst precursor solution, hydrothermally treating the catalyst precursor solution to produce a magnesium oxide precipitant, calcining the magnesium oxide precipitant to produce an isomerization catalyst precursor, soaking the isomerization catalyst precursor in an acid solution comprising sulfuric acid to product a isomerization catalyst precursor precipitant, and calcining the isomerization catalyst precursor precipitant to produce the isomerization catalyst. The catalyst precursor solution includes at least a magnesium precursor, a hydrolyzing agent, and cetrimonium bromide. Methods of producing 1-butene from a 2-butene-containing feedstock with the isomerization catalyst are also disclosed.

Methods of producing isomerization catalysts

Methods of producing an isomerization catalyst include preparing a catalyst precursor solution, hydrothermally treating the catalyst precursor solution to produce a magnesium oxide precipitant, and calcining the magnesium oxide precipitant to produce the isomerization catalyst. The catalyst precursor solution includes at least a magnesium precursor, a hydrolyzing agent, and polyethylene glycol. Methods of producing propene from a butene-containing feedstock with the isomerization catalyst and a metathesis catalyst are also disclosed.

A system and a method for isomerizing a 2-butene feed stream to form a 1-butene product stream are provided. An exemplary method includes calcining the red mud, flowing a butene feedstock over the red mud in an isomerization reactor, and separating 1-butene from a reactor effluent.

Acid modified red mud as a catalyst for olefin isomerization

A systems and a method for isomerizing a feedstock to form an alpha-olefin product stream are provided. An exemplary method includes calcining the red mud, flowing an olefin feedstock over the red mud in an isomerization reactor, and separating the alpha-olefin from a reactor effluent.

Red mud as a catalyst for the isomerization of olefins

Processes for producing olefins include introducing a hydrocarbon feed to a high-severity fluidized catalytic cracking system, contacting the hydrocarbon feed with a cracking catalyst under high-severity conditions in the high-severity fluidized catalytic cracking system to produce a cracking reaction effluent comprising butene, and passing at least a portion of the cracking reaction effluent, which includes at least butene, to a metathesis system. The processes further include contacting the portion of the cracking reaction effluent with a metathesis catalyst in the metathesis system, which causes at least a portion of the butene in the cracking C4 effluent to undergo a metathesis reaction to produce a metathesis reaction effluent comprising at least one of ethylene, propene, or both. The processes may further include separating a metathesis C5+ effluent from the metathesis reaction effluent and passing the metathesis C5+ effluent back to the high-severity fluidized catalytic cracking unit.

Systems and processes integrating fluidized catalytic cracking with metathesis for producing olefins

Methods of producing 1-butene from a 2-butene-containing feedstock include feeding a hydrocarbon feed comprising 2-butene to a reactor, the reactor containing an isomerization catalyst and contacting the hydrocarbon feed with the isomerization catalyst in the reactor at a temperature from 150&#xb0; C. to 350&#xb0; C. to produce an isomerization reaction effluent comprising 1-butene. Further, the isomerization catalyst comprises a MCM-48 catalyst with WOincorporated into a silica framework of the MCM-48 catalyst.

Methods for low temperature production of 1-butene

Methods of producing an isomerization catalyst include preparing a catalyst precursor solution, hydrothermally treating the catalyst precursor solution to produce a magnesium oxide precipitant, and calcining the magnesium oxide precipitant to produce the isomerization catalyst. The catalyst precursor solution includes at least a magnesium precursor, a hydrolyzing agent, and cetrimonium bromide. Methods of producing 1-butene from a 2-butene-containing feedstock with the isomerization catalyst are also disclosed.

Embodiments of methods of synthesizing a metathesis catalyst system, which include impregnating tungsten oxide on silica support in the presence of a precursor to produce a base catalyst; calcining the base catalyst; dispersing a solid metal-based co-catalyst onto the surface of the base catalyst to produce a doped catalyst; and calcining the doped catalyst to produce a metathesis catalyst system. Further embodiments of processes for the production of propylene, which include contacting a hydrocarbon feedstock comprising a mixture of 1-butene and 2-butene with embodiments of the metathesis catalyst system to produce, via metathesis conversion, a product stream comprising propylene.

Catalyst systems that include metal co-catalysts for the production of propylene

Embodiments of methods of synthesizing a metathesis catalyst system, which include impregnating tungsten oxide on silica support in the presence of a precursor to produce a base catalyst; calcining the base catalyst; impregnating a metal oxide co-catalyst comprising a metal oxide onto the surface of the base catalyst to produce a doped catalyst; and calcining the doped catalyst to produce a metathesis catalyst system. Further embodiments of processes for the production of propylene, which include contacting a hydrocarbon feedstock comprising a mixture of 1-butene and 2-butene with embodiments of the metathesis catalyst system to produce, via metathesis conversion, a product stream comprising propylene.

Catalyst systems that include metal oxide co-catalysts for the production of propylene

Embodiments of processes and multiple-stage catalyst systems for producing propylene comprising introducing a hydrocarbon stream comprising 2-butene to an isomerization catalyst zone to isomerize the 2-butene to 1-butene, passing the 2-butene and 1-butene to a metathesis catalyst zone to cross-metathesize the 2-butene and 1-butene into a metathesis product stream comprising propylene and C-Colefins, and cracking the metathesis product stream in a catalyst cracking zone to produce propylene. The isomerization catalyst zone comprises a silica-alumina catalyst with a ratio by weight of alumina to silica from 1:99 to 20:80. The metathesis catalyst comprises a mesoporous silica catalyst support impregnated with metal oxide. The catalyst cracking zone comprises a mordenite framework inverted (MFI) structured silica catalyst.

Multiple-stage catalyst system for self-metathesis with controlled isomerization and cracking

Composite catalysts includes zeolite particles at least partially embedded in a catalyst support material and at least one catalytically active compound deposited on the outer surfaces and pore surfaces of the catalyst support material, zeolite particles, or both. A method of making the composite catalysts may include preparing a catalyst precursor mixture that includes the zeolite, catalyst support material, triblock copolymer surfactant, and the catalytically active compound precursor and spray drying the catalyst precursor mixture. The composite catalysts may be used as a single catalyst for conducting olefin metathesis and cracking reactions. A method for producing propene may include contacting a butene-containing feed with the composite catalysts.

Dual functional composite catalyst for olefin metathesis and cracking

Provided here are methods and systems to enhance the production of ethylene and MTBE from propylene using integrated metathesis and cracking processes. Also disclosed is a method for producing ethylene by at least partially metathesizing propylene in the presence of a metathesis catalyst in a reactor to produce ethylene and butenes, and at least partially cracking the butenes to further produce ethylene using a cracking catalyst positioned downstream of the metathesis catalyst in the same reactor, and further producing MTBE.

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Dhahran, Saudi Arabia

Munir D Khokhar