Exxonmobil Research and Engineering Company

Exxonmobil Chemical Patents Inc.

University of Delaware

Rohit Vijay

Stephen John McCarthy

Michel A Daage

Brett Thomas Loveless

Ajit Bhaskar Dandekar

Bradley R Fingland

Christopher Gordon Oliveri

Stephen Harold Brown

Wenyih Frank Lai

Krista Marie Prentice

Mohsen N Harandi

John Scott Buchanan

Lorenzo C DeCaul

Mayank Shekhar

Samia Ilias

Frank Hershkowitz

Paul F Keusenkothen

Machteld Maria Mertens

Samuel A Tabak

Scott Jeffrey Weigel

David L Johnson

Edward Stanley Ellis

Christine Nicole Elia

Jeevan Sahib Abichandani

Michael F Raterman

Timothy Lee Hilbert

Tilman W Beutel

Reed Jacob Hendershot

Darryl Donald Lacy

Lu Han

John D Ou

Suriyanarayanan Rajagopalan

Eric B Shen

Bing Du

Clay R Sutton

Mitch L Hindman

Christopher M Snively

Zhongcheng Wang

Jochen Lauterbach

Linelle T Jacob

Matthew Bennett

Ben Feist

Stephen J Mccarthy

Brett Loveless

Christopher G Oliveri

Frank Wenyih Lai

Catalyst compositions including a zeolite having a molar ratio of silicon to aluminum of about 10.0 to about 300.0; a Group 10-12 element and combinations thereof; a Group 15 element and combinations thereof; and optionally, a binder, wherein the catalyst composition has a molar ratio of Group 15 element to Group 10-12 element of about 0.01 to about 10.0 are disclosed. Methods of converting organic compounds to aromatics using such catalyst compositions are also disclosed.

Catalyst for conversion of oxygenates to aromatics

A catalyst composition includes a zeolite, a binder, and a Group 12 transition metal selected from the group consisting of Zn, Cd, or a combination thereof, the zeolite having a silicon to aluminum ratio of at least about 10, the catalyst composition comprising about 50 wt % or less of the binder based on a total weight of the catalyst composition, the catalyst composition having a micropore surface area of at least about 340 m/g, a molar ratio of Group 12 transition metal to aluminum of about 0.1 to about 1.3, and at least one of (a) a mesoporosity of greater than about 20 m/g; (b) a diffusivity for 2,2-dimethylbutane of greater than about 1&#xd7;10secwhen measured at a temperature of about 120&#xb0; C. and a 2,2-dimethylbutane pressure of about 60 torr (about 8 kPa).

Bound catalyst for selective conversion of oxygenates to aromatics

A catalyst composition comprising a zeolite, an alumina binder, and a Group 12 transition metal selected from Zn and/or Cd, the zeolite having a Si/Al ratio of at least about 10 and a micropore surface area of at least about 340 m/g, the catalyst composition comprising about 50 wt % or less of the binder, based on a total weight of the catalyst composition, and having a micropore surface area of at least about 290 m/g, a molar ratio of Group 12 transition metal to aluminum of about 0.1 to about 1.3, and at least one of: a mesoporosity of about 20 m/g to about 120 m/g; a diffusivity for 2,2-dimethylbutane of greater than about 1&#xd7;10secwhen measured at a temperature of about 120&#xb0; C. and a 2,2-dimethylbutane pressure of about 60 torr (8 kPa); and a combined micropore surface area and mesoporosity of at least about 380 m/g.

Alumina bound catalyst for selective conversion of oxygenates to aromatics

In a process for the catalytic conversion of organic oxygenates to hydrocarbons, a feed comprising at least one organic oxygenate is contacted with a zeolite catalyst under conditions effective to produce a hydrocarbon product comprising aromatics, olefins and paraffins. At least a fraction of the hydrocarbon product containing Chydrocarbons, including at least part of the olefins, is then contacted with hydrogen in the presence of a hydrogenation catalyst under conditions effective to saturate at least part of the olefins in the C-containing fraction and produce a hydrogenated effluent containing less than 1 wt % olefins. The hydrogenated effluent is useful as a diluent for heavy crude oils.

Conversion of organic oxygenates to hydrocarbons

Apparatuses and processes for converting an oxygenate feedstock, such as methanol and dimethyl ether, in a fluidized bed containing a catalyst to hydrocarbons, such as gasoline boiling components, olefins and aromatics are provided herein.

Apparatus and process for producing gasoline, olefins and aromatics from oxygenates

A catalyst composition comprises a self-bound zeolite and a Group 12 transition metal selected from the group consisting of Zn, Cd, or a combination thereof, the zeolite having a silicon to aluminum ratio of at least about 10, the catalyst composition having a micropore surface area of at least about 340 m/g, a molar ratio of Group 12 transition metal to aluminum of about 0.1 to about 1.3, and at least one of: (a) a mesoporosity of greater than about 20 m/g; (b) a diffusivity for 2,2-dimethylbutane of greater than about 1&#xd7;10secwhen measured at a temperature of about 120&#xb0; C. and a 2,2-dimethylbutane pressure of about 60 torr (about 8 kPa).

Catalyst for selective conversion of oxygenates to aromatics

Methods are provided for improving the yield of aromatics during conversion of oxygenate feeds. An oxygenate feed can contain a mixture of oxygenate compounds, including one or more compounds with a hydrogen index of less than 2, so that an effective hydrogen index of the mixture of oxygenates is between about 1.4 and 1.9. Methods are also provided for converting a mixture of oxygenates with an effective hydrogen index greater than about 1 with a pyrolysis oil co-feed. The difficulties in co-processing a pyrolysis oil can be reduced or minimized by staging the introduction of pyrolysis oil into a reaction system. This can allow varying mixtures of pyrolysis oil and methanol, or another oxygenate feed, to be introduced into a reaction system at various feed entry points.

Production of aromatics from methanol and co-feeds

Methods are provided for forming aromatic compounds from a highly unsaturated aliphatic feeds optionally in combination with methanol. The method can include dehydrogenating a feed containing at least about 50 vol % C-Calkanes under dehydrogenation conditions to form a dehydrogenation effluent containing at least about 25 vol % alkynes. Alternatively, other sources of alkyne-containing feeds can be used. At least a portion of the alkyne-containing feed can then be converted under effective conversion conditions to form a conversion effluent comprising a hydrocarbon product containing aromatic compounds.

Conversion of acetylene and methanol to aromatics

Embodiments of the invention provide processes for catalytically converting oxygenates to hydrocarbon products having an increased C-Caromatics content therein. Particular processes include (a) providing a first mixture comprising &#x2267;10.0 wt. % of at least one oxygenate, based on the weight of the first mixture; (b) contacting the first mixture with a catalyst to convert the first mixture to a product stream including water, one or more hydrocarbons, hydrogen, and one or more oxygenates, wherein the catalyst comprises at least one molecular sieve and at least one element selected from Groups 2-14 of the Periodic Table and the hydrocarbons comprise &#x2267;30.0 wt. % of aromatics, based on the weight of the hydrocarbons in the product stream; and (c) separating from the product stream at least one water-rich stream, at least one aromatic-rich hydrocarbon stream, and at least one aromatic-depleted hydrocarbon stream.

Process for converting oxygenates to aromatic hydrocarbons

An integrated process for producing naphtha fuel, diesel fuel and/or lubricant base oils from feedstocks under sour conditions is provided. The ability to process feedstocks under higher sulfur and/or nitrogen conditions allows for reduced cost processing and increases the flexibility in selecting a suitable feedstock. The sour feed can be delivered to a catalytic dewaxing step without any separation of sulfur and nitrogen contaminants. The integrated process includes an initial dewaxing of a feed under sour conditions, optional hydrocracking of the dewaxed feed, and a separation to form a first diesel product and a bottoms fraction. The bottoms fraction is then exposed to additional hydrocracking and dewaxing to form a second diesel product and optionally a lubricant base oil product. Alternatively, a feedstock can be hydrotreated, fractionated, dewaxed, and then hydrocracked to form a diesel fuel and a dewaxed, hydrocracked bottoms fraction that is optionally suitable for use as a lubricant base oil.

Integrated hydrocracking and dewaxing of hydrocarbons

Methods are provided for improving the yield of distillate products from hydroprocessing of gas oil feedstocks, such as vacuum gas oils. It has been unexpectedly found that stripping of gases or fractionation to separate out a distillate fraction during initial hydrotreatment of a feed can provide a substantial increase in distillate yield at a desired amount of feedstock conversion. The improvement in yield of distillate products can allow a desired level of conversion to be performed on a feedstock for generating lubricating base oil products while reducing or minimizing the amount of naphtha (or lower) boiling range products. Alternatively, the improvement in yield of distillate products can correspond to an improved yield during a single pass through a reaction system, so that distillate yield is increased even though a lubricant boiling range product is not generated.

Hydrocracking of gas oils with increased distillate yield

Processes are provided for using employing lower activity hydrodesulfurization catalysts while achieving a desired product sulfur content. After determining effective reaction conditions for hydrodesulfurization using a reference catalyst system, an upstream portion of the catalyst system can be replaced with a lower activity upstream portion. The process allows tailored product sulfur levels to be achieved using reaction conditions similar to those for the reference catalyst system.

Stacking of low activity or regenerated catalyst above higher activity catalyst

An integrated process for producing naphtha fuel, diesel fuel and/or lubricant base oils from feedstocks under sour conditions is provided. The ability to process feedstocks under higher sulfur and/or nitrogen conditions allows for reduced cost processing and increases the flexibility in selecting a suitable feedstock. The sour feed can be delivered to a catalytic dewaxing step without any separation of sulfur and nitrogen contaminants, or with only a high pressure separation so that the dewaxing still occurs under sour conditions. Various combinations of hydrotreating, catalytic dewaxing, hydrocracking, and hydrofinishing can be used to produce fuel products and lubricant base oil products.

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Bridgewater, NJ, United States of America

Rohit Vijay