Exxon Research and Engineering Company

Exxonmobil Chemical Patents Inc.

Exxonmobil Research and Engineering Company

Exxon Chemical Patents, Inc.

Electric Power Research Institute Incorporated

Exxonmobile Chemical Patents Inc.

Exxon Research & Engineering

Shun Chong Fung

Stephen Neil Vaughn

Samuel J Tauster

Nicolas P Coute

Kenneth Ray Clem

Machteld Maria Mertens

Luc R M Martens

Marcel J G Janssen

Ronald G Searle

Wilfried Jozef Mortier

Marcel Johannes Janssen

Cornelius W M Van Oorschot

Richard B Hall

Keith Holroyd Kuechler

Luc Roger Marc Martens

Walter S Kmak

Jay Y Koo

James Richardson Lattner

Teng Xu

Karl Gottlieb Strohmaier

Tan-Jen Chen

Walter Weissman

Peter Loezos

John Joseph Steger

William A Wachter

Chunshe J Cao

Jeffrey Scott Smith

Albert Edward Schweizer

Jar-Lin Kao

James L Carter

James H Beech

Virginia R Cross

Jose G Santiesteban

Doron Levin

Teh Chung Ho

Gordon Frederick Stuntz

John E Asplin

Yi-Gang Xiong

Yao-Jyh Robert Huang

Richard W Rice

Daniel Paul Leta

Gary Brice McVicker

Thomas H Vanderspurt

Paul K Ladwig

Richard Edwards Walter

William E Gates

Angelo A Montagna

Brian Erik Henry

John L Robbins

Jeffrey L White

Elise Marucchi-Soos

Kenneth R Poeppelmeier

William L Kuechler, Sr

Theodore D Trowbridge

Yen-Chi Pan

Walter G Funk

John Francis Walsh

Hafedh Kochkar

Ming Chow

Lawrence L Murrell

Hsiang-Ning Sun

Luc Roger Martens

Joseph P Boyle

Edwin L Kugler

Dean C Draemel

David C Skouby

Paul N Chisholm

Robert Charles Welch

John K Pierce

B Erik Henry

Patrick Joseph Maher

John Ernest Asplin

Joseph F Carpency

Jay F Carpency

Ron G Searle

Brian Eric Henry

Andrew Brennek

Peter N Loezos

Patrick J Maher

The present invention relates to an apparatus and a process for the high-throughput, quick screening, optimization, regeneration, reduction and activation of catalysts. More specifically, the present invention is a method and apparatus to quickly screen, optimize and regenerate multiple fast deactivating catalysts while maintaining a predefined range of time-on-stream.

Method and apparatus for high throughput catalysts screening and optimization

A method for maintaining the activity of silicoaluminophosphate (SAPO) molecular sieve catalyst particles during oxygenate to olefin conversion reactions. After regeneration of SAPO catalyst particles, the regenerated particles are mixed with particles having coke on their surface in a manner that maintains their catalytic activity at a predetermined level.

Method for stabilizing catalyst activity during MTO unit operation

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.

Protecting catalytic activity of a SAPO molecular sieve

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.

Maintaining molecular sieve catalytic activity under water vapor conditions

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.

Method of shutting down a reaction system

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.

Method of starting up a reaction system

A process is described for converting an oxygenate-containing feedstock into one or more olefins in a moving bed reactor system operating in countercurrent flow using a catalyst composition comprising a molecular sieve and at least one metal oxide having an uptake of carbon dioxide at 100&#xb0; C. of at least 0.03 mg/mof the metal oxide.

Conversion of oxygenates to olefins

A process is described for converting an oxygenate-containing feedstock into one or more olefins in a reactor system including a plurality of fixed bed reactors each containing a catalyst composition comprising a molecular sieve and at least one metal oxide having an uptake of carbon dioxide at 100&#xb0; C. of at least 0.03 mg/mof the metal oxide. Each reactor is sequentially rotated between at least one operating mode, wherein the catalyst composition in the reactor is contacted with the oxygenate-containing feedstock, and a regeneration mode, wherein the catalyst composition in the reactor is contacted with a regeneration medium.

A process is described for converting an oxygenate-containing feedstock into one or more olefins in which the feedstock is contacted in a reaction zone with a fluidized bed of a particulate catalyst composition comprising a molecular sieve and at least one metal oxide having an uptake of carbon dioxide at 100&#xb0; C. of at least 0.03 mg/mof the metal oxide whereby at least part of the feedstock is converted into a product stream comprising one or more olefins and a carbonaceous material is deposited on the catalyst composition to produce a coked catalyst composition. The coked catalyst composition is separated from the product stream and divided into at least first and second portions. The first portion of the coked catalyst composition is contacted with a regeneration medium in a regeneration zone under conditions to remove at least part of the carbonaceous material from the coked catalyst composition and produce a regenerated catalyst composition, which is subsequently recycled to the reaction zone. The second portion of the coked catalyst composition is also recycled to the reaction zone but without being initially contacted with a regeneration medium.

Hydrocarbon or oxygenate conversion process in which a feedstock is contacted with a non zeolitic molecular sieve which has been treated 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&#xb0; C. to 1000&#xb0; C. The hydrocarbon or oxygenate 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.

Hydrocarbon conversion processes using non-zeolitic molecular sieve catalysts

The present invention provides a process for making an olefin product from an oxygenate feedstock which comprises: a) contacting the feedstock in a reaction zone with a catalyst comprising i) a molecular sieve having defined pore openings and ii) a CO oxidation metal, under conditions effective to convert the feedstock into an olefin product stream comprising C&#x2013;Colefins and to form carbonaceous deposits on the catalyst so as to provide a carbon-containing catalyst; b) contacting at least a portion of the carbon-containing catalyst with a regeneration medium comprising oxygen in a regeneration zone comprising a fluid bed regenerator having a dense fluid phase and a dilute fluid phase under conditions effective to obtain a regenerated catalyst portion, wherein the difference between the temperature of the dilute phase and the temperature of the dense phase is no greater than 100&#xb0; C.; c) introducing said regenerated catalyst portion into said reaction zone; and d) repeating steps a)&#x2013;c).

Reducing temperature differences within the regenerator of an oxygenate to olefin process

Method for using stabilizing catalyst activity during MTO unit operation

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.

Heat treating a molecular sieve and catalyst

Disclosed is a method of protecting the loss of catalytic activity of metalloaluminophosphate molecular sieve, particularly a SAPO molecular sieve, from contact with moisture. The method involves heating the metalloaluminophosphate molecular sieve so as to remove template, and provide a molecular sieve in sufficiently dry form for storage.

Method of protecting SAPO molecular sieve from loss of catalytic activity

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Bridgewater, NJ, United States of America

Shun Chong Fung