WO2018203950A1 - Procédés et systèmes pour la conversion d'hydrocarbures acycliques - Google Patents

Procédés et systèmes pour la conversion d'hydrocarbures acycliques Download PDF

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WO2018203950A1
WO2018203950A1 PCT/US2018/017562 US2018017562W WO2018203950A1 WO 2018203950 A1 WO2018203950 A1 WO 2018203950A1 US 2018017562 W US2018017562 W US 2018017562W WO 2018203950 A1 WO2018203950 A1 WO 2018203950A1
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catalyst material
reaction zone
psia
reactor
feedstock
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Neeraj Sangar
Larry L. Iaccino
Christopher L. Becker
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Exxonmobil Chemical Patents Inc.
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Priority to CN201880026575.7A priority Critical patent/CN110536878B/zh
Priority to EP18795006.8A priority patent/EP3619184A4/fr
Priority to BR112019021037-7A priority patent/BR112019021037A2/pt
Priority to CA3059556A priority patent/CA3059556C/fr
Publication of WO2018203950A1 publication Critical patent/WO2018203950A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/02—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils characterised by the catalyst used
    • C10G11/04—Oxides
    • C10G11/05—Crystalline alumino-silicates, e.g. molecular sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
    • B01J29/42—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing iron group metals, noble metals or copper
    • B01J29/44—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/60—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the type L, as exemplified by patent document US3216789
    • B01J29/61—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the type L, as exemplified by patent document US3216789 containing iron group metals, noble metals or copper
    • B01J29/62—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/90—Regeneration or reactivation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J38/00—Regeneration or reactivation of catalysts, in general
    • B01J38/04—Gas or vapour treating; Treating by using liquids vaporisable upon contacting spent catalyst
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
    • C07C5/373—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen with simultaneous isomerisation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/28—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • C07C2521/08—Silica
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals
    • C07C2523/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals of the platinum group metals
    • C07C2523/42—Platinum
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00—Catalysts comprising molecular sieves
    • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • C07C2529/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
    • C07C2529/42—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11 containing iron group metals, noble metals or copper
    • C07C2529/44—Noble metals
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00—Catalysts comprising molecular sieves
    • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • C07C2529/60—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the type L
    • C07C2529/61—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the type L containing iron group metals, noble metals or copper
    • C07C2529/62—Noble metals
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2601/00—Systems containing only non-condensed rings
    • C07C2601/06—Systems containing only non-condensed rings with a five-membered ring
    • C07C2601/10—Systems containing only non-condensed rings with a five-membered ring the ring being unsaturated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/584—Recycling of catalysts

Definitions

  • This invention relates to processes and reactor systems for the conversion of acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics.
  • Cyclic hydrocarbons, alkenes and aromatics, such as cyclopentadiene (“CPD”) and its dimer dicyclopentadiene (“DCPD”), ethylene, propylene, and benzene, are highly desired raw materials used throughout the chemical industry in a wide range of products, for example, polymeric materials, polyester resins, synthetic rubbers, solvents, fuels, fuel additives, etc. These compounds are typically derived from various streams produced during refinery processing of petroleum.
  • CPD is currently a minor byproduct of liquid feed steam cracking (e.g. , naphtha, and heavier feed). As existing and new steam cracking facilities shift to lighter feeds, less CPD is produced while demand for CPD is rising.
  • Cyclopentane and cyclopentene can have high value as solvents while cyclopentene may be used as a comonomer to produce polymers and as a starting material for other high value chemicals.
  • Linear hydrocarbon skeletal structure is preferred over branched hydrocarbon skeletal structures due to both reaction chemistry and the lower value of linear hydrocarbon relative to branched hydrocarbon (due to octane differences). Further, an abundance of hydrocarbons, such as C 5 hydrocarbons, are available from unconventional gas and shale oil, as well as reduced use in motor fuels due to stringent environmental regulations. Various hydrocarbon feedstocks, such as C 5 feedstock, may also be derived from bio-feeds.
  • Still another common process uses Pt/Sn supported on Zn and/or Ca aluminate to dehydrogenate propane. While these processes are successful in dehydrogenating alkanes, they do not perform cyclization, which is critical to producing CPD. Pt-Sn alumina and Pt- Sn aluminate catalysts exhibit moderate conversion of n-pentane, but such catalyst have poor selectivity and yield to cyclic C5 products.
  • Pt supported on chlorided alumina catalysts are used to reform low octane naphtha to aromatics such as benzene and toluene. See, US 3,953,368 (Sinfelt), "Polymetallic Cluster Compositions Useful as Hydrocarbon Conversion Catalysts.” While these catalysts are effective in dehydrogenating and cyclizing C 6 and higher alkanes to form C 6 aromatic rings, they are less effective in converting acyclic C 5 s to cyclic C 5 s. These Pt supported on chlorided alumina catalysts exhibit low yields of cyclic C5 and exhibit deactivation within the first two hours of time on stream.
  • Cyclization of C 6 and C7 alkanes is aided by the formation of an aromatic ring, which does not occur in C5 cyclization. This effect may be due in part to the much higher heat of formation for CPD, a cyclic C5, as compared to benzene, a cyclic C 6 , and toluene, a cyclic C 7 . This is also exhibited by Pt/Ir and Pt/Sn supported on chlorided alumina. Although these alumina catalysts perform both dehydrogenation and cyclization of C 6+ species to form Ce aromatic rings, a different catalyst will be needed to convert acyclic C5 to cyclic C5.
  • Ga-containing ZSM-5 catalysts are used in a process to produce aromatics from light paraffins.
  • a study by Kanazirev et al. showed n-pentane is readily converted over Ga203/H- ZSM-5. See Kanazirev Price et al., "Conversion of Cs aromatics and n-pentane over Ga203/H- ZSM-5 mechanically mixed catalysts," Catalysis Letters, vol. 9, pp. 35-42, 1991. No production of cyclic C5 was reported while upwards of 6 wt% aromatics were produced at 440°C and 1.8 hr 1 WHSV. Mo/ZSM-5 catalysts have also been shown to dehydrogenate and/or cyclize paraffins, especially methane.
  • U.S. Patent No. 5,254,787 introduced the NU-87 catalyst used in the dehydrogenation of paraffins. This catalyst was shown to dehydrogenate C2-C6+ to produce their unsaturated analogs. A distinction between C2-5 and C 6+ alkanes was made explicit in this patent: dehydrogenation of C2-5 alkanes produced linear or branched mono-olefins or di-olefins, whereas dehydrogenation of C 6+ alkanes yielded aromatics.
  • U.S. Patent No. 5,192,728 (Dessau) involves similar chemistry, but with a tin-containing crystalline microporous material. As with the NU- 87 catalyst, C5 dehydrogenation was only shown to produce linear or branched, mono-olefins or di-olefins and not CPD.
  • U.S. Patent No. 5,284,986 (Dessau) introduced a dual-stage process for the production of cyclopentane and cyclopentene from n-pentane.
  • An example was conducted wherein the first stage involved dehydrogenation and dehydrocyclization of n-pentane to a mix of paraffins, mono-olefins and di-olefins, and naphthenes over a Pt/Sn-ZSM-5 catalyst.
  • This mixture was then introduced to a second-stage reactor consisting of Pd/Sn-ZSM-5 catalyst where dienes, especially CPD, were converted to olefins and saturates. Cyclopentene was the desired product in this process, whereas CPD was an unwanted byproduct.
  • U.S. Patent Nos. 2,438,398; 2,438,399; 2,438,400; 2,438,401 ; 2,438,402; 2,438,403; and 2,438,404 disclosed production of CPD from 1,3-pentadiene over various catalysts. Low operating pressures, low per pass conversion, and low selectivity make this process undesirable. Additionally, 1,3-pentadiene is not a readily available feedstock, unlike n-pentane. See also, Kennedy et al., "Formation of Cyclopentadiene from 1,3-Pentadiene," Industrial & Engineering Chemistry, vol. 42, pp. 547-552, 1950.
  • U.S. Patent No. 5,633,421 discloses a process for dehydrogenating C2-C5 paraffins to obtain corresponding olefins.
  • U.S. Patent No. 2,982,798 discloses a process for dehydrogenating an aliphatic hydrocarbon containing 3 to 6, inclusive, carbon atoms.
  • neither U.S. Patent No. 5,633,421 nor U.S. Patent No. 2,982,798 disclose production of CPD from acyclic C5 hydrocarbons, which are desirable as feedstock because they are plentiful and low cost.
  • Additional challenges may include loss of catalyst activity due to coking during the process and further processing needed to remove coke from the catalyst, and the inability to use oxygen-containing gas to directly provide the heat input necessary to counter the endothermic nature of the reaction without damaging the catalyst.
  • non-uniform catalyst aging can also occur, which can impact resulting product selectivity and catalyst life.
  • this invention relates to a process for converting acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics in a reactor system, wherein the process comprises: contacting a feedstock comprising acyclic hydrocarbons and optionally hydrogen with a catalyst material in at least one reaction zone under reaction conditions to convert at least a portion of the acyclic hydrocarbons to a first effluent comprising alkenes, cyclic hydrocarbons and/or aromatics, wherein the feedstock enters the at least one reaction zone at a temperature of 300°C to 700°C; and providing a co-feed comprising hydrogen, alkanes (e.g.
  • C1-C4 alkanes C1-C4 alkanes
  • alkenes e.g. , C1-C4 alkenes
  • the feedstock and the co-feed may be provided to the at least one reaction zone simultaneously or not.
  • the feedstock and the co-feed are provided to the at least one reaction zone simultaneously.
  • this invention also relates to a reaction system for converting acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics, wherein the reaction system comprises a feedstock stream comprising acyclic hydrocarbons and optionally hydrogen having a temperature of 300°C to 700°C; a co-feed stream comprising hydrogen, alkanes (e.g. , C1-C4 alkanes) and/or alkenes (e.g.
  • C1-C4 alkenes having a temperature of 600°C to 1100°C; an effluent stream comprising alkenes, cyclic hydrocarbons and/or aromatics; a separated catalyst material stream; and a substantially catalyst-free effluent stream; at least one reactor operated under reaction conditions to convert at least a portion of the acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics, wherein the at least one reactor comprises: a feedstock stream inlet; a co-feed stream inlet; a catalyst material stream inlet; and an effluent stream outlet; and a separator for separating catalyst material from the effluent stream to produce the separated catalyst material stream and the second effluent stream, wherein the separator is in fluid connection with the at least one reactor and comprises an effluent stream inlet, a separated catalyst material stream outlet and a substantially catalyst- free effluent stream outlet.
  • the Figure is a diagram of a reactor system according to an embodiment of the invention.
  • the term "about” refers to a range of values of plus or minus 10% of a specified value.
  • the phrase “200” includes plus or minus 10% of 200, or from 180 to 220.
  • hydrocarbon means a class of compounds containing hydrogen bound to carbon, and encompasses (i) saturated hydrocarbon compounds, (ii) unsaturated hydrocarbon compounds, and (iii) mixtures of hydrocarbon compounds (saturated and/or unsaturated), including mixtures of hydrocarbon compounds having different values of n.
  • C n means hydrocarbon(s) having n carbon atom(s) per molecule, wherein n is a positive integer.
  • light hydrocarbon means light paraffinic and/or olefinic hydrocarbons comprised substantially of hydrogen and carbon only and has one to no more than 4 carbon atoms.
  • saturated includes, but is not limited to, alkanes and cycloalkanes.
  • non-saturates includes, but is not limited to, alkenes, dialkenes, alkynes, cyclo-alkenes, and cyclo-dialkenes.
  • cyclic hydrocarbon denotes groups such as the cyclopropane, cyclopropene, cyclobutane, cyclobutadiene etc., and substituted analogues of these structures. These cyclic hydrocarbons can be single- or multi-ring structures. Preferably, the term “cyclic hydrocarbon” refers to non-aromatics.
  • cyclics C5" or “cCs” includes, but is not limited to, cyclopentane, cyclopentene, cyclopentadiene, and mixtures of two or more thereof.
  • cyclic C5" or “cC 5” also includes alkylated analogs of any of the foregoing, e.g., methyl cyclopentane, methyl cyclopentene, and methyl cyclopentadiene. It should be recognized for purposes of the invention that cyclopentadiene spontaneously dimerizes over time to form dicyclopentadiene via Diels- Alder condensation over a range of conditions, including ambient temperature and pressure.
  • acyclics includes, but is not limited to, linear and branched saturates and non- saturates.
  • alkane refers to non-aromatic saturated hydrocarbons with the general formula C n H(2 n +2), where n is 1 or greater.
  • An alkane may be straight chained or branched. Examples of alkanes include, but are not limited to methane, ethane, propane, butane, pentane, hexane, heptane and octane.
  • Alkane is intended to embrace all structural isomeric forms of an alkane. For example, butane encompasses n-butane and isobutane; pentane encompasses n- pentane, isopentane and neopentane.
  • alkene refers to a branched or unbranched unsaturated hydrocarbon having one or more carbon-carbon double bonds.
  • a simple alkene comprises the general formula CnEhn, where n is 2 or greater. Examples of alkenes include, but are not limited to ethylene, propylene, butylene, pentene, hexene and heptene.
  • Alkene is intended to embrace all structural isomeric forms of an alkene. For example, butylene encompasses but-l-ene, (Z)-but-2-ene, etc.
  • aromatic means a planar cyclic hydrocarbyl with conjugated double bonds, such as benzene.
  • aromatic encompasses compounds containing one or more aromatic rings, including, but not limited to, benzene, toluene, and xylene, and polynuclear aromatics (PNAs), which include naphthalene, anthracene, chrysene, and their alkylated versions.
  • C 6 + aromatics includes compounds based upon an aromatic ring having six or more ring atoms, including, but not limited to, benzene, toluene, and xylene, and polynuclear aromatics (PNAs), which include naphthalene, anthracene, chrysene, and their alkylated versions.
  • PNAs polynuclear aromatics
  • BTX includes, but is not limited to, a mixture of benzene, toluene, and xylene (ortho and/or meta and/or para).
  • catalyst composition includes, but is not limited to, a low hydrogen content hydrocarbon that is adsorbed on the catalyst composition.
  • C n+ means hydrocarbon(s) having at least n carbon atom(s) per molecule.
  • C n means hydrocarbon(s) having no more than n carbon atom(s) per molecule.
  • C5 feedstock includes a feedstock containing n-pentane, such as a feedstock which is predominately normal pentane and isopentane (also referred to as methylbutane), with smaller fractions of cyclopentane and neopentane (also referred to as 2,2-dimethylpropane).
  • n-pentane such as a feedstock which is predominately normal pentane and isopentane (also referred to as methylbutane), with smaller fractions of cyclopentane and neopentane (also referred to as 2,2-dimethylpropane).
  • Group 10 metal means an element in Group 10 of the Periodic Table and includes, but is not limited to, Ni, Pd, and Pt, and a mixture of two or more thereof.
  • Group 11 metal means an element in Group 11 of the Periodic Table and includes, but is not limited to, Cu, Ag, Au, and a mixture of two or more thereof.
  • Group 1 alkali metal means an element in Group 1 of the Periodic Table and includes, but is not limited to, Li, Na, K, Rb, Cs, and a mixture of two or more thereof, and excludes hydrogen.
  • Group 2 alkaline earth metal means an element in Group 2 of the Periodic Table and includes, but is not limited to, Be, Mg, Ca, Sr, Ba, and a mixture of two or more thereof.
  • rare earth metal means an element in the Lanthanide series of the Periodic Table, as well as scandium and yttrium.
  • the term rare earth metal includes, but is not limited to, lanthanum, praseodymium, neodymium, cerium, yttrium, and a mixture of two or more thereof.
  • oxygen includes air, O2, H2O, CO, and CO2.
  • molecular sieve of the MCM-22 family includes one or more of: • molecular sieves made from a common first degree crystalline building block unit cell, which unit cell has the MWW framework topology.
  • a unit cell is a spatial arrangement of atoms, which if tiled in three-dimensional space describes the crystal structure. Such crystal structures are discussed in the "Atlas of Zeolite Framework Types", Fifth edition, 2001, the entire content of which is incorporated as reference);
  • molecular sieves made from a common second degree building block, being a 2- dimensional tiling of such MWW framework topology unit cells, forming a monolayer of one unit cell thickness, preferably one c-unit cell thickness;
  • molecular sieves made from common second degree building blocks, being layers of one or more than one unit cell thickness, wherein the layer of more than one unit cell thickness is made from stacking, packing, or binding of at least two monolayers of one unit cell thickness.
  • the stacking of such second degree building blocks may be in a regular fashion, an irregular fashion, a random fashion, or any combination thereof;
  • molecular sieves made by any regular or random 2-dimensional or 3-dimensional combination of unit cells having the MWW framework topology.
  • the MCM-22 family includes those molecular sieves having an X-ray diffraction pattern including d-spacing maxima at 12.4+0.25, 6.9+0.15, 3.57+0.07, and 3.42+0.07 Angstrom.
  • the X-ray diffraction data used to characterize the material are obtained by standard techniques using the K-alpha doublet of copper as incident radiation and a diffractometer equipped with a scintillation counter and associated computer as the collection system.
  • molecular sieve is used synonymously with the term “microporous crystalline material” or "zeolite.”
  • the term “selectivity” means the moles of carbon in the respective cyclic C 5 , CPD, Ci, and C 2-4 formed divided by total moles of carbon in the pentane converted.
  • carbon selectivity to cyclic C 5 of at least 30% means that at least 30 moles of carbon in the cyclic C 5 is formed per 100 moles of carbon in the pentane converted.
  • conversion means the moles of carbon in the acyclic C 5 feedstock that is converted to a product.
  • a conversion of at least 70% of said acyclic Cs feedstock to said product means that at least 70% of the moles of said acyclic Cs feedstock was converted to a product.
  • Alpha Value is used as a measure of the cracking activity of a catalyst and is described in U.S. Patent No. 3,354,078 and in the Journal of Catalysis, Vol. 4, p. 527 (1965); Vol. 6, p. 278, (1966) and Vol. 61 , p. 395, (1980), each incorporated herein by reference.
  • the experimental conditions of the test used herein included a constant temperature of 538°C and a variable flow rate as described in detail in the Journal of Catalysis, Vol. 61, p. 395, (1980).
  • reactor system refers to a system including one or more reactors and all necessary and optional equipment used in the production of cyclopentadiene.
  • reactor refers to any vessel(s) in which a chemical reaction occurs. Reactor includes both distinct reactors, as well as reaction zones within a single reactor apparatus and, as applicable, reactions zones across multiple reactors. In other words, and as is common, a single reactor may have multiple reaction zones. Where the description refers to a first and second reactor, the person of ordinary skill in the art will readily recognize such reference includes two reactors, as well as a single reactor vessel having first and second reaction zones. Likewise, a first reactor effluent and a second reactor effluent will be recognized to include the effluent from the first reaction zone and the second reaction zone of a single reactor, respectively.
  • a reactor/reaction zone may be an adiabatic reactor/reaction zone or a diabatic reactor/reaction zone.
  • adiabatic refers to a reaction zone for which there is essentially no heat input into the system other than by a flowing process fluid.
  • a reaction zone that has unavoidable losses due to conduction and/or radiation may also be considered adiabatic for the purpose of this invention.
  • diabatic refers to a reactor/reaction zone to which heat is supplied by a means in addition to that provided by the flowing process fluid.
  • the term "moving bed” reactor refers to a zone or vessel with contacting of solids (e.g. , catalyst particles) and gas flows such that the superficial gas velocity (U) is below the velocity required for dilute-phase pneumatic conveying of solid particles in order to maintain a solids bed with void fraction below 95%.
  • the solids e.g., catalyst material
  • the solids may slowly travel through the reactor and may be removed from the bottom of the reactor and added to the top of the reactor.
  • a moving bed reactor may operate under several flow regimes including settling or moving packed-bed regime (U ⁇ U m f), bubbling regime (Umf ⁇ U ⁇ Umb), slugging regime (U m b ⁇ U ⁇ U c ), transition to and turbulent fluidization regime (Uc ⁇ U ⁇ Utr), and fast-fluidization regime (U>Utr), where Umf is minimum fluidizing velocity, Umb is minimum bubbling velocity, Uc is the velocity at which fluctuation in pressure peaks, and tr is transport velocity.
  • These different fluidization regimes have been described in, for example, Kunii, D., Levenspiel, O., Chapter 3 of Fluidization Engineering, 2 nd Edition, Butterworth-Heinemann, Boston, 1991 and Walas, S. M., Chapter 6 of Chemical Process Equipment, Revised 2 nd Edition, Butterworth-Heinemann, Boston, 2010, which are incorporated by reference.
  • the term "settling bed” reactor refers to a zone or vessel wherein particulates contact with gas flows such that the superficial gas velocity (U) is below the minimum velocity required to fluidize the solid particles (e.g. , catalyst particles), the minimum fluidization velocity (U m f), U ⁇ U m f, in at least a portion of the reaction zone, and/or operating at a velocity higher than the minimum fluidization velocity while maintaining a gradient in gas and/or solid property (such as, temperature, gas, or solid composition, etc.) axially up the reactor bed by using reactor internals to minimize gas-solid back-mixing.
  • U superficial gas velocity
  • U m f minimum fluidization velocity
  • U m f minimum fluidization velocity
  • a settling bed reactor may be a "circulating settling bed reactor,” which refers to a settling bed with a movement of solids (e.g. , catalyst material) through the reactor and at least a partial recirculation of the solids (e.g. , catalyst material).
  • the solids e.g. , catalyst material
  • the solids may have been removed from the reactor, regenerated, reheated, and/or separated from the product stream and then returned back to the reactor.
  • the term "fluidized bed” reactor refers to a zone or vessel with contacting of solids (e.g., catalyst particles) and gas flows such that the superficial gas velocity (U) is sufficient to fluidize solid particles (i.e., above the minimum fluidization velocity U m f) and is below the velocity required for dilute-phase pneumatic conveying of solid particles in order to maintain a solids bed with void fraction below 95%.
  • solids e.g., catalyst particles
  • U superficial gas velocity
  • cascaded fluid- beds means a series arrangement of individual fluid-beds such that there can be a gradient in gas and/or solid property (such as, temperature, gas, or solid composition, pressure, etc.) as the solid or gas cascades from one fluid-bed to another.
  • a fluidized bed reactor may be a moving fluidized bed reactor, such as a "circulating fluidized bed reactor,” which refers to a fluidized bed with a movement of solids (e.g. , catalyst material) through the reactor and at least a partial recirculation of the solids (e.g. , catalyst material).
  • solids e.g. , catalyst material
  • the solids e.g.
  • a fluidized bed reactor may be a "captive fluidized bed reactor" wherein solids (e.g., catalyst material) may circulate between reaction zones but are not circulated, on a continuous flow basis, between the reactor and a separate vessel (e.g., to perform re-heating and/or regeneration). Solids (e.g., catalyst material) may be withdrawn from the reactor and returned (along with any fresh solids addition) to the reactor after batchwise regeneration performed in a separate vessel.
  • solids e.g., catalyst material
  • an external cyclone or any similar device to separate solids from the reactor effluent stream
  • its return standpipe is considered part of the captive fluidized bed reactor, i.e., does not constitute a separate vessel for the purpose of defining a captive fluidized bed reactor.
  • the term "riser” reactor also known as a transport reactor refers to a zone or vessel (such as, vertical cylindrical pipe) used for net upwards transport of solids (e.g. , catalyst particles) in fast-fluidization or pneumatic conveying fluidization regimes.
  • Fast fluidization and pneumatic conveying fluidization regimes are characterized by superficial gas velocities (U) greater than the transport velocity (Utr).
  • U superficial gas velocities
  • Utr transport velocity
  • Fast fluidization and pneumatic conveying fluidization regimes are also described in Kunii, D., Levenspiel, O., Chapter 3 of Fluidization Engineering, 2 nd Edition, Butterworth-Heinemann, Boston, 1991 and Walas, S.
  • a fluidized bed reactor such as a circulating fluidized bed reactor, may be operated as a riser reactor.
  • Average diameter for particles in the range of 3 mm to 50 mm is determined using a micrometer on a representative sample of 100 particles.
  • 1 psi is equivalent to 6.895 kPa.
  • 1 psia is equivalent to 1 kPa absolute (kPa-a).
  • 1 psig is equivalent to 6.895 kPa gauge (kPa-g).
  • this invention relates to a process for converting acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics in a reactor system.
  • the process may comprise contacting a feedstock comprising acyclic hydrocarbons and optionally hydrogen with a catalyst material in at least one reaction zone under reaction conditions to convert at least a portion of the acyclic hydrocarbons to a first effluent comprising alkenes, cyclic hydrocarbons and/or aromatics and providing a co-feed comprising hydrogen, alkanes (e.g. , C1-C4 alkanes) and/or alkenes (e.g.
  • the feedstock enters the at least one reaction zone at a temperature of 300°C to 700°C.
  • the feedstock and the co-feed may be provided to the at least one reaction zone at different locations via different inlets.
  • this invention relates to a process for conversion of an acyclic C5 feedstock to a product comprising cyclic C5 compounds (e.g. , cyclopentadiene).
  • the process comprises contacting said feedstock and, optionally, hydrogen under acyclic C5 conversion conditions in the presence of one or more catalyst compositions, including but not limited to the catalyst compositions described herein, and providing a co-feed as described herein to form said product.
  • the product of the process for conversion of an acyclic C5 feedstock comprises cyclic C5 compounds.
  • the cyclic C5 compounds comprise one or more of cyclopentane, cyclopentene, cyclopentadiene, and includes mixtures thereof.
  • the cyclic C5 compounds comprise at least 20 wt%, or 30 wt%, or 40 wt%, or 70 wt% cyclopentadiene, or in the range of from 10 wt% to 80 wt%, alternately 20 wt% to 70 wt%.
  • the acyclic C5 conversion conditions include at least a temperature, an n-pentane partial pressure, and a weight hourly space velocity (WHSV).
  • the temperature is in the range of 400°C to 700°C, or in the range from 450°C to 650°C, preferably, in the range from 500°C to 600°C.
  • the n-pentane partial pressure is in the range of 3 to 100 psia at the reactor inlet, or in the range from 3 to 50 psia, preferably, in the range from 3 psia to 20 psia.
  • the weight hourly space velocity is in the range from 1 to 50 hr 1 , or in the range from 1 to 20 hr 1 .
  • Such conditions include a molar ratio of the optional hydrogen co-feed to the acyclic C5 feedstock in the range of 0 to 3, or in the range from 1 to 2.
  • Such conditions may also include co-feed Ci - C 4 hydrocarbons with the acyclic C5 feed.
  • this invention relates to a process for conversion of n- pentane to cyclopentadiene comprising the steps of contacting n-pentane and, optionally, hydrogen (if present, typically 3 ⁇ 4 is present at a ratio to n-pentane of 0.01 to 3.0) with one or more catalyst compositions, including but not limited to the catalyst compositions described herein, and providing a co-feed as described herein to form cyclopentadiene at a temperature of 400°C to 700°C, an n-pentane partial pressure of 3 to 100 psia at the reactor inlet, and a weight hourly space velocity of 1 to 50 hr 1 .
  • a feedstock comprising acyclic hydrocarbons preferably acyclic C2-C10 hydrocarbons are provided to a reactor system comprising a catalyst material and an inert material.
  • Acyclic C2-C10 hydrocarbons include, but are not limited to alkanes (e.g. , ethane, propane, butane, pentane, hexane, etc.), alkenes (e.g. , ethylene, propylene, butylene, etc.), alkynes (e.g. , ethyne, propyne, 1-butyne, 2-butyne, etc.), dialkenes (e.g.
  • An acyclic C2-C10 hydrocarbon feedstock useful herein, is obtainable from crude oil or natural gas condensate.
  • hydrogen may be present in the feedstock as well.
  • the molar ratio of optional hydrogen to acyclic hydrocarbon is preferably between 0 to 3, or in the range of 1 to 2.
  • Hydrogen may be included in the feedstock in order to minimize production of coke material on the particulate material and/or to fluidize the particulate material in the at least one reaction zone.
  • the acyclic C5 feedstock comprises at least 50 wt%, or 60 wt%, or 75 wt%, or 90 wt% acyclic hydrocarbons, or in the range from 50 wt% to 100 wt% n-pentane.
  • an amount of the acyclic hydrocarbons in the feedstock converted to alkenes e.g., propylene
  • alkenes e.g., propylene
  • cyclic hydrocarbons e.g., cyclopentadiene
  • aromatics e.g., benzene
  • an amount of the acyclic hydrocarbons in the feedstock converted to alkenes e.g., propylene
  • cyclic hydrocarbons e.g., cyclopentadiene
  • aromatics e.g., benzene
  • the feedstock may preferably be an acyclic C5 feedstock and can include cracked C5 (in various degrees of unsaturation: alkenes, dialkenes, alkynes) produced by refining and chemical processes, such as fluid catalytic cracking (FCC), reforming, hydrocracking, hydrotreating, coking, and steam cracking.
  • FCC fluid catalytic cracking
  • the acyclic C5 feedstock useful in the process of this invention comprises pentane, pentene, pentadiene and mixtures of two or more thereof.
  • the acyclic C5 feedstock comprises at least 50 wt%, or 60 wt%, or 75 wt%, or 90 wt% n-pentane, or in the range from 50 wt% to 100 wt% n-pentane.
  • the acyclic hydrocarbon feedstock optionally does not comprise C 6 aromatic compounds, such as benzene.
  • C 6 aromatic compounds are present at less than 5 wt%, preferably less than 1 wt%, preferably less than 0.01 wt%, and preferably at zero wt%.
  • the acyclic hydrocarbon feedstock optionally does not comprise benzene, toluene, or xylene (ortho, meta, or para).
  • any benzene, toluene, or xylene (ortho, meta, or para) compounds are present at less than 5 wt%, preferably less than 1 wt%, preferably less than 0.01 wt%, and preferably at zero wt%.
  • the acyclic hydrocarbon feedstock optionally does not comprise C 6+ aromatic compounds.
  • C 6+ aromatic compounds are present at less than 5 wt%, preferably less than 1 wt%, preferably less than 0.01 wt%, and preferably at zero wt%.
  • an amount of the C 5 hydrocarbons (e.g. , acyclic C 5 hydrocarbons) in the feedstock converted to cyclopentadiene is > 5.0 wt%, > 10.0 wt%, > 20.0 wt%, > 30.0 wt%, > 40.0 wt%, > 50.0 wt%, > 60.0 wt%, > 70.0 wt%, > 80.0 wt%, or > 90.0 wt%.
  • at least 30.0 wt% or at least 60.0 wt% of the Cs hydrocarbons is converted to cyclopentadiene.
  • Ranges expressly disclosed include combinations of any of the above-enumerated values; e.g., 5.0% to 90.0 wt%, 10.0 wt% to 80.0 wt%, 20.0 wt% to 70.0 wt%, 20.0 wt% to 60.0 wt%, etc.
  • 20.0 wt% to 90.0 wt% of the C 5 hydrocarbons e.g.
  • acyclic Cs hydrocarbons is converted to cyclopentadiene, more preferably 30.0 wt% to 85.0 wt%, more preferably 40.0 wt% to 80.0 wt%, more preferably 45.0 wt% to 75.0 wt%, and more preferably 50.0 wt% to 70.0 wt%.
  • a co-feed comprising hydrogen and/or light hydrocarbons, such as Ci-C 8 hydrocarbons, preferably C1-C4 hydrocarbons, such as C1-C4 alkenes and/or C1-C4 alkanes, are also fed into the at least one reaction zone (discussed herein).
  • the co-feed comprises at least 50 wt%, or 60 wt%, or 75 wt%, or 90 wt% hydrogen, or in the range from 50 wt% to 100 wt% hydrogen.
  • the co-feed comprises at least 50 wt%, or 60 wt%, or 75 wt%, or 90 wt% light hydrocarbons, or in the range from 50 wt% to 100 wt% light hydrocarbons.
  • the co-feed may comprise hydrogen, ethane, methane and/or a mixture of ethane and ethylene.
  • the feedstock and co-feed are substantially free of oxygen, e.g., less than 1.0 wt%, less than 0.1 wt%, less than 0.01 wt%, less than 0.001 wt%, less than 0.0001 wt%, less than 0.00001 wt%, etc.
  • the feedstock and the co-feed may be provided to the at least one reaction zone at different locations via different inlets. Additionally, the feedstock and the co-feed may be provided to the at least one reaction zone simultaneously or not, preferably simultaneously. It is contemplated herein that co-feed and the feedstock are provided to the at least one reaction zone in different horizontal and/or vertical planes. For example, the co-feed may be provided to the at least one reaction zone at a lower position in the at least one reaction zone with respect to where the feedstock is provided, i.e. , the feedstock may be provided to the at least one reaction zone at a position above (or higher than) where the co-feed is provided.
  • the co-feed and the feedstock may be provided to the at least one reaction zone at different horizontal planes, preferably where the co-feed is provided at a horizontal plane at a lower position in the at least one reaction zone with respect to horizontal plane where the feedstock is provided, and optionally, the co-feed and the feedstock may be provided along the same or different vertical plane.
  • the co-feed may be provided to the at least one reaction zone at a position above (or higher than) where the feedstock is provided in the at least one reaction zone.
  • the co-feed and the feedstock may be provided to the at least one reaction zone at different horizontal planes, preferably where the co-feed is provided at a horizontal plane above (or higher than) a horizontal plane where the feedstock is provided, and optionally, the co-feed and the feedstock may be provided along the same or different vertical plane. Additionally, it is contemplated herein that the feedstock and the co-feed may be provided to the at least one reaction zone at substantially the same locations via the same or different inlet. Hydrogen may be provided to the reactor via the feedstock, the co-feed, or a combination of both. Preferably, hydrogen is included in both the feedstock and the co-feed.
  • the presence of hydrogen in the feed mixture at or near the inlet location, where the feed first comes into contact with the catalyst can prevent or reduce the formation of coke on the catalyst particles. Additionally, the presence of hydrogen in the co-feed can prevent or reduce the formation of coke in co-feed pre-heating furnaces.
  • the feedstock is fed into a reactor system and contacted with a catalyst material in at least one reaction zone under reaction conditions to convert at least a portion of the acyclic hydrocarbons (e.g. , acyclic C 5 hydrocarbons) to a first effluent comprising alkenes (e.g. , propylene), cyclic hydrocarbons (e.g. , cyclopentadiene) and/or aromatics (e.g., benzene).
  • the at least one reaction zone may be a circulating fluidized bed reactor or a captive fluidized bed reactor.
  • the circulating fluidized bed reactor may be operated in a bubbling or turbulent fluidization regime; and a fast fluidization or transport regime, both as described in Kunii, D., Levenspiel, O., Chapter 3 of Fluidization Engineering, 2 nd Edition, Butterworth- Heinemann, Boston, 1991 and Walas, S. M., Chapter 6 of Chemical Process Equipment, Revised 2 nd Edition, Butterworth-Heinemann, Boston, 2010. Additionally, or alternatively, the at least one reaction zone is not a radial-flow reactor or a cross-flow reactor.
  • the at least one reaction zone may comprise at least a first reaction zone, a second reaction zone, a third reaction zone, a fourth reaction zone, a fifth reaction zone, a sixth reaction zone, a seventh reaction zone, and/or an eighth reaction zone, etc.
  • each reaction zone may be an individual reactor or a reactor may comprise one or more of the reaction zones.
  • the reactor system includes 1 to 20 reaction zones, more preferably 1 to 15 reaction zones, more preferably 2 to 10 reaction zones, more preferably 2 to 8 reaction zones.
  • the at least one reaction zone includes a first and a second reaction zone, the reaction zones may be arranged in any suitable configuration, preferably in series.
  • Each reaction zone independently may be a circulating fluidized bed or a captive fluidized bed, preferably each reaction zone is a captive fluidized bed. Additionally, or alternatively, the process described herein may further comprise moving a bulk of a partially converted feedstock from the first reaction zone to the second reaction zone and/or moving a bulk of a particulate material (e.g. , catalyst material and/or inert material) from the second reaction zone to the first reaction zone.
  • a particulate material e.g. , catalyst material and/or inert material
  • the at least one reaction zone may include at least one internal structure, preferably a plurality of internal structures (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, etc.) to influence a velocity vector of the particulate material and/or gas flow.
  • the internal structure(s) can ensure movement of particulate material while minimizing the degree of gas back- mixing.
  • the at least one reaction zone may include a plurality of internal structures. Examples of suitable internal structures include a plurality of baffles, sheds, trays, tubes, tube bundles, tube coils, rods, and/or distributors.
  • the at least one reaction zone is operated under reaction conditions sufficient to convert at least a portion of the acyclic hydrocarbons feedstock, preferably acyclic C 5 hydrocarbons, to a first effluent comprising alkene, cyclic hydrocarbons, and aromatics, preferably cyclopentadiene.
  • the feedstock e.g., acyclic hydrocarbons
  • co-feed may be fed to the reaction system at a weight hourly space velocity (WHSV, mass of acyclic hydrocarbons/mass of catalyst/hour) in the range of from 1.0 to 1000.0 hr 1 .
  • the WHSV may be 1.0 to 900.0 hr 1 , 1.0 to 800.0 hr 1 , 1.0 to 700.0 hr 1 , 1.0 to 600.0 hr 1 , 1.0 to 500.0 hr 1 , 1.0 to 400.0 hr 1 , 1.0 to 300.0 hr 1 , 1.0 to 200.0 hr 1 , 1.0 to 100.0 hr 1 , 1.0 to 90.0 hr 1 , 1.0 to 80.0 hr 1 , 1.0 to 70.0 hr 1 , 1.0 to 60.0 hr 1 , 1.0 to 50.0 hr 1 , 1.0 to 40.0 hr 1 , 1.0 to 30.0 hr 1 , 1.0 to 20.0 hr 1 , 1.0 to 10.0 hr 1 , 1.0 to 5.0 hr 1 , 2.0 to 1000.0 hr 1 , 2.0 to 900.0 hr 1 , 2.0 to 800.0 hr 1 , 2.0 to 700.0 hr 1
  • the heated co-feed may provide the endothermic heat of reaction for the conversion process within the at least one reaction zone.
  • the co-feed may contact the catalyst present in the at least one reaction zone and heat the catalyst, for example, where the co-feed is provided to the at least one reaction zone at a position lower than where the feedstock is provided.
  • the feedstock may contact the heated catalyst and at least a portion of the acyclic hydrocarbons may be converted to alkenes, cyclic hydrocarbons and/or aromatics.
  • the co-feed provided to the at least one reaction may provide > 10%, > 20%,
  • the co-feed may provide > 25% of the required heat for converting at least a portion of the acyclic C 5 hydrocarbons to the first effluent comprising cyclopentadiene.
  • Ranges expressly disclosed include combinations of any of the above-enumerated values; e.g. , 20% to 100%, 40% to 95%, 50% to 90%, etc.
  • the co-feed may provide 20% to 100% of the required heat, more preferably 40% to 100% of the required heat, or more preferably 50% to 100% of the required heat.
  • the co-feed may enter the at least one reaction zone at a temperature of > 450°C, > 500°C, > 550°C, > 600°C, > 650°C, > 700°C, > 750°C, > 800°C,
  • the co-feed may enter the at least one reaction zone at a temperature of > 600°C, more preferably > 750°C, or more preferably > 900°C. Ranges of temperatures expressly disclosed include combinations of any of the above-enumerated values, e.g., 450°C to 1500°C, 550°C to 1400°C, 600°C to 1250°C, 700°C to 1150°C, etc.
  • the temperature of the co-feed entering the reaction system is 550°C to 1150°C more preferably 600°C to 1100°C, more preferably 650°C to 1050°C, and more preferably 700°C to 1000°C.
  • the feedstock may be heated to a lower temperature than the co-feed to avoid cracking in the feed and coking of the catalyst.
  • the temperature of the feedstock (e.g., acyclic hydrocarbons) entering the reactor system at a feedstock inlet may be ⁇ 750°C, ⁇ 725 °C, ⁇ 700°C, ⁇ 675°C, ⁇ 650°C, ⁇ 625°C, ⁇ 600°C, ⁇ 575°C, ⁇ 550°C, ⁇ 525°C, ⁇ 500°C, ⁇ 475°C, ⁇ 450°C, ⁇ 425°C, ⁇ 400°C, ⁇ 375°C, ⁇ 350°C, ⁇ 325°C, ⁇ or 300°C.
  • the temperature of the feedstock (e.g., acyclic hydrocarbons) entering the reactor system is ⁇ 700°C, more preferably ⁇ 650°C, or more preferably ⁇ 625 °C.
  • Ranges of temperatures expressly disclosed include combinations of any of the above-enumerated values, e.g. , 300°C to 750°C, 350°C to 700°C, 450°C to 650°C, 475°C to 600°C, etc.
  • the temperature of the feedstock (e.g., acyclic hydrocarbons) entering the reaction system is 300°C to 750°C, more preferably 300°C to 700°C, more preferably 400°C to 700°C, and more preferably 575 °C to 675 °C.
  • Providing the feedstock (e.g., acyclic C 5 hydrocarbons) at the above-described temperatures may advantageously minimize undesirable cracking of the Cs hydrocarbons (e.g. , acyclic Cs hydrocarbons) before they can react in the presence of the catalyst material.
  • the feedstock may be heated via any suitable means, for example a furnace, such as a fired-tube furnace and/or heat exchanger, prior to entering the at least one reaction zone.
  • an isothermal or substantially isothermal temperature profile be maintained in the at least one reaction zone.
  • a substantially isothermal temperature profile has the advantages of maximizing the effective utilization of the catalyst and minimizing the production of undesirable C4- byproducts.
  • isothermal temperature profile means that the temperature at each point within the reaction zone between the reactor inlet and reactor outlet as measured along the tube centerline of the reactor is kept essentially constant, e.g., at the same temperature or within the same narrow temperature range wherein the difference between an upper temperature and a lower temperature is no more than 40°C; more preferably no more than 20°C.
  • the isothermal temperature profile is one where the temperature along the length of the reaction zone(s) within the reactor does not vary by more than 40°C as compared to the average temperature within the reactor, alternately not more than 20°C, alternately not more than 10°C, alternately not more than 5°C.
  • the isothermal temperature profile is one where the temperature along the length of the reaction zone(s) within the reactor is within 20% of the average temperature within the reactor, alternately within 10%, alternately within 5%, alternately within 1% of the average temperature within the reactor.
  • the temperature of a first effluent exiting the at least one reaction zone at an effluent outlet may be > 400°C, > 425°C, > 450°C, > 475°C, > 500°C, > 525°C, > 550°C, > 575 °C, > 600°C, > 625 °C, > 650°C, > 675 °C, or > 700°C.
  • the temperature of a first effluent exiting the at least one reaction zone is > 550°C, more preferably > 575°C, more preferably > 600°C. Ranges of temperatures expressly disclosed include combinations of any of the above-enumerated values, e.g.
  • the temperature of a first effluent exiting the at least one reaction zone is 475°C to 700°C, more preferably 500°C to 650°C, more preferably 550°C to 625°C.
  • reaction conditions in the at least one reaction zone may include a temperature of > 300°C, > 325°C, > 350°C, > 375°C, > 400°C, > 425°C, > 450°C, > 475°C, > 500°C, > 525°C, > 550°C, > 575°C, > 600°C > 625°C, > 650°C, > 675°C, or > 700°C.
  • Ranges of temperatures expressly disclosed include combinations of any of the above- enumerated values, e.g. , 300°C to 700°C, 350°C to 675°C, and 400°C to 700°C, etc.
  • the temperature may be 350°C to 700°C, more preferably 500°C to 700°C, or more preferably 500°C to 650°C.
  • the at least one reaction zone may include one or more means for heating the at least one reaction zone in order to maintain a temperature therein.
  • suitable heating means include, but are not limited to a fired tube, heat transfer tubes, a heated coil with a high temperature heat transfer fluid, an electrical heater, and/or a microwave emitter.
  • coil refers to a structure placed within a vessel through which a heat transfer fluid flows to transfer heat to the vessel contents.
  • a coil may have any suitable cross-sectional shape and may be straight, include u-bends, include loops, etc.
  • reaction conditions at the effluent outlet of the at least one reaction zone may include a pressure of > 1.0 psia, > 2.0 psia, > 3.0 psia, > 4.0 psia, > 5.0 psia, > 10.0 psia, > 15.0 psia, > 20.0 psia, > 25.0 psia, > 30.0 psia, > 35.0 psia, > 40.0 psia, > 45.0 psia, > 50.0 psia, > 55.0 psia, > 60.0 psia, > 65.0 psia, > 70.0 psia, > 75.0 psia, > 80.0 psia, > 85.0 psia, > 90.0 psia, > 95.0 psia, > 100.0 psia, > 125.0 psia, > 150.0
  • Ranges and combinations of temperatures and pressures expressly disclosed include combinations of any of the above-enumerated values, e.g. , 1.0 psia to 200.0 psia, 2.0 psia to 175.0 psia, 5.0 psia to 95.0 psia, etc.
  • the pressure may be 3.0 psia to 100.0 psia, more preferably 3.0 psia to 50.0 psia, more preferably 3.0 psia to 30.0 psia.
  • the reaction conditions may comprise a temperature of 500°C to 700°C and a pressure of 3.0 psia to 100 psia.
  • a delta pressure (or pressure drop) across the at least one reaction zone may be > 0.5 psia, > 1.0 psia, > 2.0 psia, > 3.0 psia, > 4.0 psia, > 5.0 psia, > 10.0 psia, > 14.0 psia, > 15.0, psia, > 20.0 psia, > 24.0 psia, > 25.0 psia, > 30.0 psia, > 35.0 psia, > 40.0 psia, > 45.0 psia, > 50.0 psia, > 55.0 psia, > 60.0 psia, > 65.0 psia, > 70.0 psia, > 75.0 psia, > 80.0 psia, > 85.0 psi
  • a delta pressure (or pressure drop) across the at least one reaction zone may be ⁇ 2.0 psia, ⁇ 3.0 psia, ⁇ 4.0 psia, ⁇ 5.0 psia, ⁇ 10.0 psia, ⁇ 14.0 psia, ⁇ 15.0 psia, ⁇ 20.0 psia, ⁇ 24.0 psia, ⁇ 25.0 psia, ⁇ 30.0 psia, ⁇ 35.0 psia, ⁇ 40.0 psia, ⁇ 45.0 psia, ⁇ 50.0 psia, ⁇ 55.0 psia, ⁇ 60.0
  • Ranges of delta pressures expressly disclosed include combinations of any of the above- enumerated values, e.g. , 10 psia to 70.0 psia, 20.0 psia to 60.0 psia, 30.0 psia to 50.0 psia, etc.
  • the pressure substantially at an inlet of a feedstock e.g., acyclic C 5 hydrocarbons
  • a feedstock e.g., acyclic C 5 hydrocarbons
  • a feedstock e.g., acyclic C 5 hydrocarbons
  • the pressure substantially at an outlet of at least a first effluent may be 1.0 psia to 60.0 psia, preferably 5 psia to 40.0 psia, more preferably 10.0 psia to 30.0 psia.
  • the at least one reaction zone comprises particulate material including a catalyst material.
  • the catalyst material also referred to as a "catalyst composition,” is present in the reaction system for promoting conversion of at least a portion of the acyclic hydrocarbons to alkenes, cyclic hydrocarbons and/or aromatics, in particular conversion of acyclic C 5 hydrocarbons to cyclopentadiene.
  • Catalyst compositions useful herein include microporous crystalline metallosilicates, such as crystalline aluminosilicates, crystalline ferrosilicates, or other metal-containing crystalline silicates (such as those where the metal or metal-containing compound is dispersed within the crystalline silicate structure and may or may not be a part of the crystalline framework).
  • microporous crystalline metallosilicate framework types useful as catalyst compositions herein include, but are not limited to, MWW, MFI, LTL, MOR, BEA, TON, MTW, MTT, FER, MRE, MFS, MEL, DDR, EUO, and FAU.
  • microporous metallosilicates for use herein, include those of framework type MWW, MFI, LTL, MOR, BEA, TON, MTW, MTT, FER, MRE, MFS, MEL, DDR, EUO, and FAU (such as zeolite beta, mordenite, faujasite, Zeolite L, ZSM-5, ZSM-11, ZSM-22, ZSM-23, ZSM-35, ZSM-48, ZSM-50, ZSM-57, ZSM-58, and MCM-22 family materials) where one or more metals from groups 8, 11, and 13 of the Periodic Table of the Elements (preferably one or more of Fe, Cu, Ag, Au, B, Al, Ga, and/or In) are incorporated in the crystal structure during synthesis or impregnated post crystallization.
  • framework type MWW such as framework type MWW, MFI, LTL, MOR, BEA, TON, MTW, MTT, FER, MRE, MFS, MEL, D
  • a metallosilicate may have one of more metals present and, for example, a material may be referred to as a ferrosilicate, but it will most likely still contain small amounts of aluminum.
  • the microporous crystalline metallosilicates preferably have a constraint index of less than 12, alternately from 1 to 12, alternately from 3 to 12.
  • Aluminosilicates useful herein have a constraint index of less than 12, such as 1 to 12, alternately 3 to 12, and include, but are not limited to Zeolite beta, mordenite, faujasite, Zeolite L, ZSM-5, ZSM-11, ZSM-22, ZSM-23, ZSM-35, ZSM-48, ZSM-50, ZSM-57, ZSM-58, MCM-22 family materials, and mixtures of two or more thereof.
  • the crystalline aluminosilicate has a constraint index of 3 to 12 and is ZSM-5.
  • ZSM-5 is described in U.S. Patent No. 3,702,886.
  • ZSM-11 is described in U.S. Patent No. 3,709,979.
  • ZSM-22 is described in U.S. Patent No. 5,336,478.
  • ZSM-23 is described in U.S. Patent No. 4,076,842.
  • ZSM-35 is described in U.S. Patent No. 4,016,245.
  • ZSM-48 is described in U.S. Patent No. 4,375,573.
  • ZSM-50 is described in U.S. Patent No. 4,640,829.
  • ZSM-57 is described in U.S. Patent No. 4,873,067.
  • ZSM-58 is described in U.S. Patent No. 4,698,217.
  • the MCM-22 family material is selected from the group consisting of MCM-22, PSH-3, SSZ-25, MCM-36, MCM-49, MCM-56, ERB-1, EMM- 10, EMM-10-P, EMM-12, EMM- 13, UZM-8, UZM-8HS, ITQ-1, ITQ-2, ITQ-30, and mixtures of two or more thereof.
  • MCM-22 Materials of the MCM-22 family include MCM-22 (described in U.S. Patent No. 4,954,325), PSH-3 (described in U.S. Patent No. 4,439,409), SSZ-25 (described in U.S. Patent No. 4,826,667), ERB-1 (described in EP 0 293 032), ITQ-1 (described in U.S. Patent No. 6,077,498), and ITQ-2 (described in WO 97/17290), MCM-36 (described in U.S. Patent No. 5,250,277), MCM-49 (described in U.S. Patent No. 5,236,575), MCM-56 (described in U.S. Patent No.
  • zeolites to be included in the MCM-22 family are UZM-8 (described in U.S. Patent No. 6,756,030) and UZM-8HS (described in U.S. Patent No. 7,713,513), both of which are also suitable for use as the molecular sieve of the MCM-22 family.
  • the crystalline metallosilicate has an Si/M molar ratio
  • M is a group 8, 11, or 13 metal
  • the crystalline aluminosilicate has an S1O2/AI2O3 molar ratio greater than 3, or greater than 25, or greater than 50, or greater than 100, or greater than 400, or greater than 1,000, or in the range from 100 to 400, or from 100 to 500, or from 25 to 2,000, or from 50 to 1,500, or from 100 to 1,200, or from 50 to 1,000.
  • the microporous crystalline metallosilicate (such as an aluminosilicate) is combined with a Group 10 metal or metal compound and, optionally, one, two, three, or more additional metals selected from Groups 8, 9, 11, and 13 of the Periodic Table of the Elements and the rare earth metals, such as Ga, In, Zn, Cu, Re, Mo, W, La, Fe, Ag, Rh, Pr, La, and/or oxides, sulfides, nitrides, and/or carbides of these metals.
  • the Group 10 metal is present in combination with a Group I alkali metal and/or a Group 2 alkaline earth metal.
  • the Group 10 metal includes, or is selected from the group consisting of, Ni, Pd, and Pt, preferably Pt.
  • the Group 10 metal content of said catalyst composition is at least 0.005 wt%, based on the weight of the catalyst composition. In one or more embodiments, the Group 10 content is in the range from 0.005 wt% to 10 wt%, or from 0.005 wt% up to 1.5 wt%, based on the weight of the catalyst composition.
  • the Group 1 alkali metal is generally present as an oxide and the metal is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and mixtures of two or more thereof.
  • the Group 2 alkaline earth metal is generally present as an oxide and the metal is selected from the group consisting of beryllium, magnesium, calcium, strontium, barium, and mixtures of two or more thereof.
  • the Group 11 metal includes, or is selected from the group consisting of, silver, gold, copper, preferably silver or copper.
  • the Group 11 metal content of said catalyst composition is at least 0.005 wt%, based on the weight of the catalyst composition. In one or more embodiments, the Group 11 content is in the range from 0.005 wt% to 10 wt%, or from 0.005 wt% up to 1.5 wt%, based on the weight of the catalyst composition.
  • the molar ratio of said Group 11 metal to Group 10 metal is at least 0.1, or from at least 0.1 up to 10, preferably at least 0.5, more preferably at least 1. In one or more embodiments, the Group 11 metal is present as an oxide.
  • a preferred Group 9 metal is Rh, which may form an alloy with the Group 10 metal.
  • the molar ratio of Rh to Group 10 metal is in the range from 0.1 to 5.
  • the rare earth metal is selected from the group consisting of yttrium, lanthanum, cerium, praseodymium, and mixtures or combinations thereof.
  • the molar ratio of rare earth metal to Group 10 metal is in the range from 1 to 10.
  • the rare earth metal may be added to the catalyst composition during or after synthesis of the microporous crystalline molecular sieve as any suitable rare earth metal compound.
  • the molar ratio of said Group 1 alkali metal to Al is at least 0.5, or from at least 0.5 up to 3, preferably at least 1, more preferably at least 2.
  • the molar ratio of said Group 2 alkaline earth metal to Al is at least 0.5, or from at least 0.5 up to 3, preferably at least 1, more preferably at least 2.
  • the catalyst composition has an Alpha Value (as measured prior to the addition of the Group 10 metal, preferably platinum) of less than 25, alternately less than 15, alternately from 1 to 25, alternately from 1.1 to 15.
  • Alpha Value is determined as described in US 3,354,078; The Journal of Catalysis, v. 4, p. 527 (1965); v. 6, p. 278 (1966); and v. 61, p. 395 (1980) using a constant temperature of 538°C and a variable flow rate, as described in detail in The Journal of Catalysis, v. 61 , p. 395, (1980).
  • any one of the catalyst compositions of this invention provides a conversion of at least 70%, or at least 75%, or at least 80%, or in the range from 60% to 80%, of said acyclic Cs feedstock under acyclic Cs conversion conditions.
  • any one of the catalyst compositions of this invention provides a carbon selectivity to cyclic C 5 compounds of at least 30%, or at least 40%, or at least 50%, or in the range from 30% to 80%, under acyclic C 5 conversion conditions.
  • This includes an n-pentane feedstock with equimolar 3 ⁇ 4, a temperature in the range of 550°C to 600°C, an n-pentane partial pressure between 3 and 10 psia, and an n-pentane weight hourly space velocity between 10 and 20 hr 1 .
  • any one of the catalyst compositions of this invention provides a carbon selectivity to cyclopentadiene of at least 30%, or at least 40%, or at least 50%, or in the range from 30% to 80%, under acyclic C 5 conversion conditions.
  • This includes an n-pentane feedstock with equimolar 3 ⁇ 4, a temperature in the range of 550°C to 600°C, an n-pentane partial pressure between 3 and 10 psia, and an n-pentane weight hourly space velocity between 10 and 20 hr 1 .
  • the catalyst compositions of this invention can be combined with a matrix or binder material to render them attrition resistant and more resistant to the severity of the conditions to which they will be exposed during use in hydrocarbon conversion applications.
  • the combined compositions can contain 1 to 99 wt% of the materials of the invention based on the combined weight of the matrix (binder) and material of the invention.
  • the relative proportions of microcrystalline material and matrix may vary widely, with the crystal content ranging from 1 to 90 wt% and, more usually, particularly when the composite is prepared in the form of beads, extrudates, pills, oil drop formed particles, spray dried particles, etc., in the range of 2 to 80 wt% of the composite.
  • Preferred binder materials comprise one or more of silica, titania, zirconia, metal silicates of Group 1 or Group 13 of the Periodic Table, carbides, nitrides, aluminum phosphate, aluminum molybdate, aluminate, surface passivated alumina, and mixtures thereof.
  • suitable binder materials have a lower affinity for Group 10 metal particles, e.g. Pt, in comparison with the crystalline metallosilicate, e.g. aluminosilicate.
  • Useful catalyst compositions comprise a crystalline aluminosilicate or ferrosilicate, which is optionally combined with one, two, or more additional metals or metal compounds. Preferred combinations include:
  • a crystalline aluminosilicate such as ZSM-5 or Zeolite L
  • a Group 10 metal such as Pt
  • a Group 1 alkali metal such as sodium or potassium
  • a crystalline aluminosilicate such as ZSM-5 or Zeolite L
  • a Group 10 metal such as Pt
  • a Group 1 alkali metal such as sodium or potassium
  • a crystalline aluminosilicate such as a ferrosilicate or an iron treated ZSM-5 combined with a Group 10 metal (such as Pt) and a Group 1 alkali metal (such as sodium or potassium);
  • a crystalline aluminosilicate (Zeolite L) combined with a Group 10 metal (such as Pt) and a Group 1 alkali metal (such as potassium); and
  • a crystalline aluminosilicate such as ZSM-5 combined with a Group 10 metal (such as Pt), a Group 1 alkali metal (such as sodium), and a Group 11 metal (such as silver or copper).
  • Another useful catalyst composition is a Group 10 metal (such as Ni, Pd, and Pt, preferably Pt) supported on silica (e.g., silicon dioxide) modified by a Group 1 alkali metal silicate (such as Li, Na, K, Rb, and/or Cs silicates) and/or a Group 2 alkaline earth metal silicate (such as Mg, Ca, Sr, and/or Ba silicates), preferably potassium silicate, sodium silicate, calcium silicate, and/or magnesium silicate, preferably potassium silicate and/or sodium silicate.
  • a Group 1 alkali metal silicate such as Li, Na, K, Rb, and/or Cs silicates
  • a Group 2 alkaline earth metal silicate such as Mg, Ca, Sr, and/or Ba silicates
  • the Group 10 metal content of the catalyst composition is at least 0.005 wt%, based on the weight of the catalyst composition, preferably, in the range from 0.005 wt% to 10 wt%, or from 0.005 wt% up to 1.5 wt%, based on the weight of the catalyst composition.
  • the silica (SiC ) may be any silica typically used as catalyst support such as those marketed under the tradenames of DAVISIL 646 (Sigma Aldrich), DAVISON 952, DAVISON 948 or DAVISON 955 (Davison Chemical Division of W.R. Grace and Company).
  • Catalyst composition shape and design are preferably configured to minimize pressure drop, increase heat transfer, and minimize mass transport phenomena. Suitable catalyst shape and design are described in WO 2014/053553, which is incorporated by reference in its entirety.
  • the catalyst composition may be an extrudate with a diameter of 2 mm to 20 mm.
  • the catalyst composition cross section may be shaped with one or more lobes and/or concave sections. Additionally, the catalyst composition lobes and/or concave sections may be spiraled.
  • the catalyst composition may be an extrudate with a diameter of 2 mm to 20 mm; and the catalyst composition cross section may be shaped with one or more lobes and/or concave sections; and the catalyst composition lobes and/or concave sections may be spiraled.
  • the formulated catalyst composition may be made into a particle, such as, for example, a spray dried particle, an oil drop particle, a mulled particle, or a spherical particle.
  • the formulated catalyst composition may be made into a slurry.
  • Such slurry materials typically contain the microporous crystalline metallosilicate, such as zeolite, and a filler such as a silicate.
  • spherical particle shapes are particularly useful.
  • the catalyst material comprises platinum on ZSM-5, platinum on zeolite L, and/or platinum on silica.
  • inert material may also be present in the at least one reaction zone.
  • the inert material is understood to include materials which promote a negligible amount promote a negligible amount (e.g. , ⁇ 3%, ⁇ 2%, ⁇ 1%, etc.) of conversion of the feedstock, intermediate products, or final products under the reaction conditions described herein.
  • the catalyst material and/or the inert material may have an average diameter of > 10 ⁇ > 25 ⁇ , > 50 ⁇ , > 100 ⁇ , > 200 ⁇ , > 300 ⁇ , > 400 ⁇ , > 500 ⁇ , > 600 ⁇ , > 700 ⁇ , > 800 ⁇ , > 900 ⁇ , > 1000 ⁇ .
  • the catalyst material and/or the inert material may have an average diameter of ⁇ 50 ⁇ , ⁇ 100 ⁇ , ⁇ 200 ⁇ , ⁇ 300 ⁇ , ⁇ 400 ⁇ , ⁇ 500 ⁇ , ⁇ 600 ⁇ , ⁇ 700 ⁇ , ⁇ 800 ⁇ , ⁇ 900 ⁇ , ⁇ 1000 ⁇ .
  • Ranges expressly disclosed include combinations of any of the above- enumerated values, e.g. , 10 ⁇ to 1,000 ⁇ , 50 ⁇ to 500 ⁇ , 100 ⁇ to 750 ⁇ , 200 ⁇ to 500 ⁇ , etc.
  • the catalyst material and/or the inert material may have an average diameter of 20 ⁇ to 300 ⁇ , more preferably 20 ⁇ to 100 ⁇ , more preferably 40 ⁇ to 90 ⁇ , more preferably 50 ⁇ to 80 ⁇ .
  • the catalyst material and the inert material may be combined as portions of the same particles and/or may be separate particles.
  • the catalyst material and the inert material are separate particles.
  • the catalyst material and/or inert material may be essentially spherical (i.e. , ⁇ 20%, ⁇ 30%, ⁇ 40%, or ⁇ 50% aberration in diameter).
  • suitable inert materials include, but are not limited to metal carbides (e.g. , silicon carbide, tungsten carbide, etc.), metal oxides (e.g. , silica, zirconia, titania, alumina, etc. ), clays, metal phosphates (e.g. , aluminum phosphates, nickel phosphates, zirconium phosphates, etc.), and combinations thereof.
  • the inert material may comprise silicon carbide, silica, and a combination thereof.
  • An effluent exiting the at least one reaction zone may comprise a variety of hydrocarbon compositions produced from the reaction of the acyclic hydrocarbons (e.g. , acyclic C 5 hydrocarbons) in the at least one reaction zone.
  • acyclic hydrocarbons e.g. , acyclic C 5 hydrocarbons
  • the hydrocarbon compositions typically have mixtures of hydrocarbon compounds, such as alkenes, cyclic hydrocarbons, and aromatics, having from 1 to 30 carbon atoms (C1-C30 hydrocarbons), from 1 to 24 carbon atoms (C1-C24 hydrocarbons), from 1 to 18 carbon atoms (C1-C18 hydrocarbons), from 1 to 10 carbon atoms (C1-C10 hydrocarbons), from 1 to 8 carbon atoms (Ci-Cs hydrocarbons), and from 1 to 6 carbon atoms (Ci-C 6 hydrocarbons).
  • the first effluent comprises cyclopentadiene.
  • the cyclopentadiene may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of > 20.0 wt%, > 25.0 wt%, > 30.0 wt%, > 35.0 wt%, > 40.0 wt%, > 45.0 wt%, > 50.0 wt%, > 55.0 wt%, > 60.0 wt%, > 65.0 wt%, > 70.0 wt%, > 75.0 wt%, or > 80.0 wt%.
  • the cyclopentadiene may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of ⁇ 20.0 wt%, ⁇ 25.0 wt%, ⁇ 30.0 wt%, ⁇ 35.0 wt%, ⁇ 40.0 wt%, ⁇ 45.0 wt%, ⁇ 50.0 wt%, ⁇ 55.0 wt%, ⁇ 60.0 wt%, ⁇ 65.0 wt%, ⁇ 70.0 wt%, ⁇ 75.0 wt%, ⁇ 80.0 wt%, or ⁇ 85.0 wt%.
  • Ranges expressly disclosed include combinations of any of the above- enumerated values, e.g., 20.0 wt% to 85.0 wt%, 30.0 wt% to 75.0 wt%, 40.0 wt% to 85.0 wt%, 50.0 wt% to 85.0 wt%, etc.
  • the cyclopentadiene may be present in a hydrocarbon portion of an effluent (e.g. , first effluent, second effluent) in an amount of 10.0 wt% to 85.0 wt%, more preferably 25.0 wt% to 80.0 wt%, more preferably 40.0 wt% to 75.0 wt%.
  • an effluent may comprise one or more other C5 hydrocarbons in addition to cyclopentadiene.
  • examples of other C5 hydrocarbons include, but are not limited to cyclopentane and cyclopentene.
  • the one or more other C5 hydrocarbons may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount > 10.0 wt%, > 15.0 wt%, > 20.0 wt%, > 25.0 wt%, > 30.0 wt%, > 35.0 wt%, > 40.0 wt%, > 45.0 wt%, > 50.0 wt%, > 55.0 wt%, > 60.0 wt%, > 65.0 wt%, or > 70.0 wt%.
  • the one or more other C5 hydrocarbons may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of ⁇ 15.0 wt%, ⁇ 20.0 wt%, ⁇ 25.0 wt%, ⁇ 30.0 wt%, ⁇ 35.0 wt%, ⁇ 40.0 wt%, ⁇ 45.0 wt%, ⁇ 50.0 wt%,
  • Ranges expressly disclosed include combinations of any of the above-enumerated values, e.g., 10.0 wt% to 70.0 wt%, 10.0 wt% to 55.0 wt%, 15.0 wt% to 60.0 wt%, 25.0 wt% to 65.0 wt%, ⁇ ?ic.
  • the one or more other C 5 hydrocarbons may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of 30.0 wt% to 65.0 wt%, more preferably 20.0 wt% to 40.0 wt%, more preferably 10.0 wt% to 25.0 wt%.
  • an effluent (e.g. , first effluent, second effluent) may also comprise one or more aromatics, e.g. , having 6 to 30 carbon atoms, particularly 6 to 18 carbon atoms.
  • the one or more aromatics may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of > 1.0 wt%, > 5.0 wt%, > 10.0 wt%, > 15.0 wt%, > 20.0 wt%, > 25.0 wt%, > 30.0 wt%, > 35.0 wt%, > 40.0 wt%, > 45.0 wt%, > 50.0 wt%, > 55.0 wt%, > 60.0 wt%, or > 65.0 wt%.
  • the one or more aromatics may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of ⁇ 1.0 wt%, ⁇ 5.0 wt%, ⁇ 10.0 wt%, ⁇ 15.0 wt%, ⁇ 20.0 wt%, ⁇ 25.0 wt%, ⁇ 30.0 wt%, ⁇ 35.0 wt%,
  • Ranges expressly disclosed include combinations of any of the above- enumerated values, e.g., 1.0 wt% to 65.0 wt%, 10.0 wt% to 50.0 wt%, 15.0 wt% to 60.0 wt%, 25.0 wt% to 40.0 wt%, eic.
  • the one or more aromatics may be present in a hydrocarbon portion of an effluent (e.g.
  • first effluent, second effluent in an amount of 1.0 wt% to 15.0 wt%, more preferably 1.0 wt% to 10 wt%, more preferably 1.0 wt% to 5.0 wt%.
  • catalyst material and/or inert material may become entrained with hydrocarbons (e.g., cyclopentadiene) in the effluent (e.g., first effluent, second effluent) as the effluent travels through and/or exits the at least one reaction zone.
  • the process may further comprise separating catalyst material and/or inert material, which may be entrained with hydrocarbons (e.g., cyclopentadiene) in the effluent (e.g., first effluent, second effluent). This separating may comprise removal of the catalyst material and/or inert material from the hydrocarbons (e.g.
  • cyclopentadiene by any suitable means, such as, but not limited to cyclones, filter, electrostatic precipitators, heavy liquid contacting, and/or other gas solid separation equipment, which may be inside and/or outside the at least one reaction zone.
  • suitable means such as, but not limited to cyclones, filter, electrostatic precipitators, heavy liquid contacting, and/or other gas solid separation equipment, which may be inside and/or outside the at least one reaction zone.
  • the effluent substantially free of particulate material may then travel to a product recovery system.
  • the separated catalyst material and/or inert material may then be fed back into the at least one reaction zone at any desirable location.
  • a separated catalyst material stream may be introduced into the at least one reaction zone at a position above where feedstock and co-feed are provided to the at least one reaction.
  • co-feed may also be separated from the effluent (e.g., first effluent, second effluent) via any suitable means or combinations thereof such as distillation, adsorption (pressure- swing or temperature-swing), membrane separation, liquid/solvent absorption, condensation, etc. and the separated co-feed may be recycled back to the at least one reaction zone.
  • the separated co-feed is heated as described above before being reintroduced into the at least one reaction zone.
  • the separated material with reduced level of hydrocarbons may then travel to a rejuvenation zone, and/or regeneration zone, and the hydrocarbons stripped from the particulate material may be directed to the product recovery system or to the reactor system.
  • coke material may form on the particulate material, particularly on the catalyst material, which may reduce the activity of the catalyst material. Additionally, or alternatively, the particulate material may cool as the reaction occurs.
  • the catalyst material exiting the at least one reaction zone is referred to as "spent catalyst material.”
  • the effluent and the separate catalyst material can comprise spent catalyst material.
  • This spent catalyst material may not necessarily be a homogenous mix of particles as individual particles may have had a distribution of total aging in the system, time since last regeneration and/or rejuvenation, and/or ratio of times spent in reaction zones relative to in the regeneration and/or rejuvenation zones.
  • At least a portion of the particulate material may be transferred from the at least one reaction zone to a rejuvenation zone to produce rejuvenated catalyst material.
  • the transferring of the particulate material (e.g. , spent catalyst material) from the at least one reaction zone to a reheating zone may occur after the catalyst material has been stripped and/or separated from the hydrocarbons after exiting the at least one reaction zone.
  • catalyst (e.g. , spent catalyst material) material may be transferred directly from the at least one reaction zone to a reheating zone.
  • the reheating zone may include one more heating devices, such as but not limited to direct contacting, a heating coil, and/or a fired tube.
  • the particulate material e.g. , spent catalyst material
  • a gaseous stream comprising hydrogen and substantially free of reactive oxygen-containing compounds to remove at least a portion of incrementally deposited coke material on the catalyst material thereby forming a rejuvenated catalyst material and a volatile hydrocarbon, such as, but not limited to methane.
  • the term "incrementally deposited" coke material refers to an amount of coke material that is deposited on the catalyst material during each pass of the catalyst material through the at least one reaction zone as opposed to a cumulative amount of coke material deposited on the catalyst material during multiple passes through the at least one reaction zone.
  • substantially free used in this context means the rejuvenation gas comprises less than 1.0 wt%, based upon the weight of the gaseous stream, e.g., less than 0.1 wt%, less than 0.01 wt%, less than 0.001 wt%, less than 0.0001 wt%, less than 0.00001 wt% oxygen-containing compounds.
  • the gaseous stream may comprise > 50 wt% 3 ⁇ 4, such as > 60 wt%, > 70 wt%, preferably > 90 wt% 3 ⁇ 4.
  • the gaseous stream may further comprise an inert substance (e.g., N 2 ), and/or methane.
  • Contacting the spent catalyst material with the gaseous stream may occur at a temperature of 500°C to 900°C, preferably 575°C to 750°C and/or at a pressure between 5.0 psia to 250 psia, preferably 25 psia to 250 psia.
  • the particulate material e.g. , spent catalyst material
  • a mild oxidation procedure comprising contacting the particulate material with an oxygen-containing gaseous stream under conditions effective to remove at least a portion of incrementally deposited coke material on the catalyst material thereby forming a rejuvenated catalyst material.
  • these conditions include a temperature range of 250°C to 500°C, and a total pressure of 0.1 bar to 100 bar, preferably at atmospheric pressure.
  • the oxygen-containing gaseous stream is typically supplied to the rejuvenation zone at a total WHSV in the range of 1 to 10,000.
  • purge gas is generally reintroduced to purge oxidants from the catalyst composition using a purge gas, for example, N 2 .
  • a purge gas for example, N 2 .
  • This purging step may be omitted if CO2 is the oxidant as it will not produce a flammable mixture.
  • rejuvenation via mild oxidation further comprises one or more hydrogen treatment steps.
  • the rejuvenated catalyst material may then be returned to the at least one reaction zone.
  • rejuvenation is generally effective at removing at least 10 wt% (> 10 wt%) of incrementally deposited coke material. Between 10 wt% to 100 wt%, preferably between 60 wt% to 100 wt%, more preferably between 90 wt% to 100 wt% of incrementally deposited coke material is removed.
  • Rejuvenation advantageously may have a time duration of ⁇ 90 mins, e.g., ⁇ 60 mins, ⁇ 30 mins, ⁇ 10 mins, such as ⁇ 1 min, or ⁇ 10 seconds.
  • Rejuvenation may be advantageously performed > 10 minutes, e.g., > 30 minutes, > 2 hours, > 5 hours, > 24 hours, > 2 days, > 5 days, > 20 days, after beginning the specified conversion process.
  • Rejuvenation effluent exiting the rejuvenation zone and comprising, unreacted hydrogen, coke particulate, and optionally light hydrocarbon may be further processed.
  • the rejuvenation effluent may be sent to a compression device and then sent to a separation apparatus wherein a light hydrocarbon enriched gas and light hydrocarbon depleted gas is produced.
  • the light hydrocarbon gas may be carried away, e.g., for use as fuel gas.
  • the light hydrocarbon depleted stream may be combined with make-up hydrogen and make up at least a portion of the gaseous stream provided to the rejuvenation zone.
  • the separation apparatus may be a membrane system, adsorption system (e.g., pressure swing or temperature swing), or other known system for separation of hydrogen from light hydrocarbons.
  • a particulate separation device e.g., a cyclonic separation drum, may be provided wherein coke particulate is separated from the rejuvenation effluent.
  • the process may further comprise a regeneration step to recapture catalyst activity lost due to the accumulation of coke material and/or agglomeration of metal on the catalyst material during the reaction.
  • This regeneration step may be carried out when there has not been sufficient removal of the coke material from the particulate material (e.g. , spent catalyst material) in the rejuvenation zone.
  • At least a portion of the spent catalyst material from the at least one reaction zone, from the separated catalyst material following stripping from the effluent, and/or from the rejuvenation zone may be transferred to a regeneration zone and regenerated by methods known in the art.
  • an oxidative regeneration may be used to remove at least a portion of coke material from the spent catalyst material.
  • a regeneration gas comprising an oxidizing material such as oxygen, for example, air, may contact the spent catalyst material. The regeneration gas may oxidatively remove at least 10 wt% (> 10 wt%) of the total amount of coke material deposited on the catalyst composition at the start of regeneration.
  • an oxychlorination step is performed following coke removal comprising contacting the catalyst composition with a gaseous stream comprising a chlorine source and an oxygen source under conditions effective for dispersing at least a portion of metal, e.g., Group 10 metal, particles on the surface of the catalyst and to produce a metal chlorohydrate, e.g., a Group 10 metal chlorohydrate.
  • a chlorine stripping step is typically performed following oxychlorination comprising contacting the catalyst composition with a gaseous stream comprising an oxygen source, and optionally a chlorine source, under conditions effective for increasing the O/Cl ratio of the metal chlorohydrate.
  • a reduction step, and optionally a sulfidation step may also be performed in the regeneration step.
  • regeneration is effective at removing between 10 wt% to 100 wt%, preferably between 90 wt% to 100 wt% of coke material is removed.
  • the catalyst material may also be contacted with a purge gas, e.g. , N 2 .
  • Regeneration including purging before and after coke oxidation, requires less than 10 days, preferably less than 3 days to complete.
  • Catalyst may be continuously withdrawn from and returned to the reaction zone and/or the rejuvenation zone or may be periodically withdrawn from and returned to the reaction zone and/or regeneration zone.
  • the regeneration times between when withdrawals are made for coke burn, oxychlorination, chlorine stripping, purge, reduction, and optional sulfidation occurs are between 24 hours (1 day) to 240 hours (10 days), preferably between 36 hours (1.5 days) to 120 hours (5 days).
  • the removal/addition of particulate material rate may vary between 0.0 wt% to 100 wt% (e.g., 0.01 wt% to 100 wt%) per day of the particulate material inventory, and preferably between 0.25 wt% to 30.0 wt% per day of the particulate material inventory where there is balanced addition/removal of particulate material.
  • Regeneration of the catalyst material may occur as a continuous process or may be done batch wise in both cases intermediate vessels for inventory accumulation and/or inventory discharge may be required.
  • the removal and addition of the particulate material may occur at the same or different location in the reactor system.
  • the particulate material e.g., fresh catalyst material, fresh inert material, rejuvenated catalyst material, regenerated catalyst material
  • the particulate material may be added after or before the rejuvenation zone, while the removal of the particulate material (e.g. , spent catalyst material) may be done before or after the particulate material (e.g. , spent catalyst material) is passed through the rejuvenation zone.
  • At least a portion of the regenerated catalyst material may be recycled to the at least one reaction zone or at least one rejuvenation zone.
  • the regenerated catalyst material and/or fresh particulate material are provided to the rejuvenation zone to minimize any loss in heat input and to remove any remaining species that may be carried by the regenerated catalyst material from the regeneration zone.
  • separators inside or outside of the regeneration zone may be used to separate the inert material from the catalyst material prior to regeneration so that just the catalyst material is regenerated. This separation may be carried out on the basis of size, magnetic, and/or density property differences between the inert material and the regenerated catalyst material using any suitable means.
  • standpipes well known by those skilled in the art with the particle size and operating conditions described above, may be used to provide the means of transporting the particulate material between the at least one reaction zone, rejuvenation zone, and/or regeneration zone.
  • Slide valves and lifting gas known by those skilled in the art, may also be used to help circulate the particulate material and/or build the necessary pressure profile inside the regeneration zone.
  • the lifting gas may be the same as the fluidizing gas used in the rejuvenation zone, e.g. , a hydrogen stream that may contribute in minimizing the hydrogen usage in the reaction system, while also reducing the coke material formation.
  • a reaction system 1 for converting acyclic hydrocarbons e.g. , acyclic C 5 hydrocarbons
  • the reaction system 1 may comprise a feedstock stream 2, a co-feed stream 3, at least one reactor 10, and an effluent stream 11.
  • the feedstock stream 2 may comprise an acyclic hydrocarbon (e.g. , acyclic C 5 hydrocarbons, such as pentane) stream 2a as described above, and optionally, a first hydrogen stream 2b.
  • the co-feed stream 3 may comprise a light hydrocarbon (e.g.
  • the co-feed stream 3 may comprise hydrogen, ethane, methane and/or a mixture of ethane and ethylene.
  • the reaction system 1 may further comprise a first furnace 4 for heating the feedstock stream 2 to produce a heated feedstock stream 5, which may be provided to the least one reactor 10 at feedstock temperatures as described herein (e.g. , 300°C to 700°C).
  • a first fuel gas stream 6 may be provided to the first furnace 4 for heating the feedstock stream 2.
  • reaction system 1 may further comprise a second furnace 7 for heating the co-feed stream 3 to produce a heated co-feed stream 8, which may be provided to at least one reactor 10 at co-feed temperatures as described herein (e.g. , 600°C to 1100°C) and which may heat catalyst material present in the at least one reactor 10.
  • a second fuel gas stream 9 may be provided to the second furnace 7 for heating the co-feed stream 3.
  • the at least one reactor 10 may comprise a feedstock stream inlet (not shown) for providing the heated feedstock stream 5 to the reaction system, a co-feed stream inlet (not shown) for providing the heated co-feed stream 8, and an effluent stream outlet (not shown) for removal of the effluent stream 11.
  • the feedstock stream inlet (not shown) is a position in the at least one reactor 10 above the co-feed stream inlet (not shown).
  • the at least one reactor 10 may be a circulating fluidized bed reactor or a captive fluidized bed reactor, preferably a captive fluidized bed reactor. Additionally, or alternatively, the at least one reactor is not a radial-flow reactor or a cross-flow reactor.
  • the reaction system 1 may comprise at least a first reactor, a second reactor, a third reactor, a fourth reactor, a fifth reactor, a sixth reactor, a seventh reactor, etc.
  • each "reactor" may be individual vessels or individual reaction zones within a single vessel.
  • the reaction system includes 1 to 20 reactors, more preferably 1 to 15 reactors, more preferably 2 to 10 reactors, more preferably 3 to 8 reactors.
  • a circulating fluidized bed reactor may include multiple reaction zones (e.g. , 3-8) within a single vessel or multiple vessels (e.g. , 3-8).
  • the reactors may be arranged in any suitable configuration, preferably in series, wherein a bulk of the feedstock moves from the first reactor to the second reactor and/or a bulk of the particulate material moves from the second reactor to the first reactor, and so on.
  • Each reactor independently, may be a circulating fluidized bed reactor or a captive fluidized bed reactor.
  • the at least one reactor 10 may include at least one or more internal structures 8, as described above.
  • the at least one reactor 10 may include a plurality of internal structures (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, etc.), such as, baffles, sheds, trays, tubes, tube bundles, tube coils, rods, and/or distributors.
  • the at least one reactor 10 is operated under reaction conditions as described above to convert at least a portion of the acyclic hydrocarbons (e.g., acyclic C 5 hydrocarbons) to alkenes, cyclic hydrocarbons (e.g. , cyclopentadiene), and/or aromatics.
  • the reaction conditions may comprise a temperature of 500°C to 700°C and/or a pressure of 3.0 psia to 100 psia.
  • at least 30 wt% of the acyclic C 5 hydrocarbons is converted to cyclopentadiene.
  • the at least one reactor 10 may include one or more heating means (e.g. , fired tube, heated coil, heat transfer tubes) (not shown) as described herein in order to maintain temperature therein.
  • the reaction system 1 may further comprise a separator 12, such as a cyclone, (one is shown, but two or more operating in series may be present with one or more operating in parallel) in fluid connection with the at least one reactor 10.
  • the separator 12 may be located externally (as shown) or internally (not shown) within the reactor.
  • the separator 12, may separate the catalyst material, which may be entrained with hydrocarbons (e.g., cyclopentadiene) in the effluent stream 11 to produce a separated catalyst material stream 14 and a substantially catalyst-free effluent stream 13.
  • the substantially catalyst-free effluent stream 13 may comprise a lower amount of catalyst material than the effluent stream 11, preferably the substantially catalyst-free effluent stream 13 comprises a negligible amount (e.g. , ⁇ 5.0 wt%, ⁇ 2.0 wt%, ⁇ 1.0 wt%) of catalyst material or no catalyst material.
  • the substantially catalyst- free effluent stream 13 may optionally travel to a product recovery system. Additionally, the separated catalyst material stream 14 may then be fed back into the at least one reactor 10 (the material may be returned at a position above where the heated feedstock stream 5 enters) via a separated catalyst material inlet (not shown) in the at least one reactor 10.
  • the separator 12 may comprise an effluent stream inlet (not shown), a separated catalyst material stream outlet (not shown), and a substantially catalyst-free effluent stream outlet (not shown).
  • a third hydrogen stream 15 may be present in the reaction system 1, which may be fed to the first separator 12 and/or combined with the separated catalyst material stream 14.
  • the reaction system 1 may further comprise a rejuvenating and/or regenerating apparatus 16 for restoring activity of the spent catalyst material, wherein the rejuvenating and/or regenerating apparatus 16 is in fluid connection with the at least one reactor 10.
  • a spent catalyst stream 17 comprising at least a portion of the separated catalyst material stream 14 may be provided to the rejuvenating and/or regenerating apparatus 16 to produce a rejuvenated and/or regenerated catalyst stream 18 which can be combined with the separated catalyst material stream 14 or alternatively, enter the reactor through a separate outlet (not shown).
  • reaction system 1 may further comprise a fresh catalyst material stream (not shown) in fluid connection with the at least one reactor 10.
  • a first hydrocarbon reactor effluent obtained during the acyclic Cs conversion process containing cyclic, branched and linear C 5 hydrocarbons and, optionally, containing any combination of hydrogen, C 4 and lighter byproducts, or C 6 and heavier byproducts is a valuable product in and of itself.
  • CPD and/or DCPD may be separated from the reactor effluent to obtain purified product streams which are useful in the production of a variety of high value products.
  • a purified product stream containing 50 wt% or greater, or preferably 60 wt% or greater of DCPD is useful for producing hydrocarbon resins, unsaturated polyester resins, and epoxy materials.
  • a purified product stream containing 80 wt% or greater, or preferably 90 wt% or greater of CPD is useful for producing Diels-Alder reaction products formed in accordance with the following reaction Scheme (I):
  • R is a heteroatom or substituted heteroatom, substituted or unsubstituted C1-C50 hydrocarbyl radical (often a hydrocarbyl radical containing double bonds), an aromatic radical, or any combination thereof.
  • substituted radicals or groups contain one or more elements from Groups 13-17, preferably from Groups 15 or 16, more preferably nitrogen, oxygen, or sulfur.
  • a purified product stream containing 80 wt% or greater, or preferably 90 wt% or greater of CPD can be used to form Diels-Alder reaction products of CPD with one or more of the following: another CPD molecule, conjugated dienes, acetylenes, allenes, disubstituted olefins, trisubstituted olefins, cyclic olefins, and substituted versions of the foregoing.
  • Preferred Diels-Alder reaction products include norbornene, ethylidene norbornene, substituted norbornenes (including oxygen-containing norbornenes), norbornadienes, and tetracyclododecene, as illustrated in the followin structures:
  • the foregoing Diels-Alder reaction products are useful for producing polymers and copolymers of cyclic olefins copolymerized with olefins such as ethylene.
  • the resulting cyclic olefin copolymer and cyclic olefin polymer products are useful in a variety of applications, e.g., packaging film.
  • a purified product stream containing 99 wt% or greater of DCPD is useful for producing
  • DCPD polymers using, for example, ring opening metathesis polymerization (ROMP) catalysts.
  • REP ring opening metathesis polymerization
  • the DCPD polymer products are useful in forming articles, particularly molded parts, e.g., wind turbine blades and automobile parts.
  • cyclopentane is useful as a blowing agent and as a solvent.
  • Linear and branched C 5 products are useful for conversion to higher olefins and alcohols.
  • Cyclic and non- cyclic C5 products, optionally after hydrogenation, are useful as octane enhancers and transportation fuel blend components.
  • compositions, an element or a group of elements are preceded with the transitional phrase “comprising,” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.
  • Reactor modeling was performed using Invensys Systems Inc. PRO/II 9.3.4 for the purpose of estimating the performance at various commercially relevant operating conditions.
  • Example 1A Methane Diluent, 20 psia outlet pressure, 10 psia HC partial pressure
  • a 20 psia outlet pressure, 575 °C outlet temperature, fluidized bed reactor is simulated with a feed comprising of n-pentane, which is pre-heated to 621°C prior to feeding into the fluidized bed, and a co-feed comprising of methane and hydrogen, which is separately pre-heated to a temperature required to supply 100% of the heat of reaction.
  • the catalyst is assumed to have a lights selectivity (C4- products) of ⁇ 18%.
  • the residence time within the catalyst bed is assumed to provide for CPD concentration to reach its thermodynamic concentration at the reactor outlet conditions.
  • the hydrogen molar rate in reactor co-feed is set to deliver a molar ratio of hydrogen :n-pentane in feed of 1 : 1.
  • the methane molar rate in reactor co-feed is set to deliver a methane partial pressure at reactor outlet of 10 psia (i.e., combined partial pressure of all other hydrocarbons including hydrogen of 10 psia). Based on the reactor yields, this corresponds to a molar ratio of methane :n-pentane in feed of 4:1.
  • a methane partial pressure at reactor outlet of 10 psia i.e., combined partial pressure of all other hydrocarbons including hydrogen of 10 psia
  • this corresponds to a molar ratio of methane :n-pentane in feed of 4:1.
  • Example IB Methane Diluent, 950°C co-feed preheat, 10 psia outlet HC partial pressure
  • a 575°C outlet temperature, fluidized bed reactor is simulated with a feed comprising of n-pentane, which is pre-heated to 621°C prior to feeding into the fluidized bed, and a co-feed comprising of methane and hydrogen, which is separately pre-heated to 950°C.
  • the catalyst is assumed to have a lights selectivity (C4- products) of ⁇ 18%.
  • the residence time within the catalyst bed is assumed to provide for CPD concentration to reach its thermodynamic concentration at the reactor outlet conditions.
  • the hydrogen molar rate in reactor co-feed is set to deliver a molar ratio of hydrogen: n-pentane in feed of 1:1.
  • the methane molar rate in reactor co-feed is set to deliver 100% of the heat of reaction.
  • the combined outlet pressure of all components including hydrogen, with the exception of methane, is set at 10 psia by adjusting the total outlet pressure.
  • To generate 1 lb- mole of CPD in the fluidized bed reactor effluent it is determined from the simulation that 2.195 lb-moles of n-Pentane and 13.0 lb-moles of methane is required. Additionally, the outlet reactor pressure is determined to be 25 psia.
  • Example 1A As can be seen by comparing the simulation results of Example 1A and Example IB, reducing the methane pre-heat temperature from 1098 to 950°C results in higher methane feed rate (increase from 8.7 to 13.0 lb-mol per lb-mol of CPD produced) in order to provide the same heat of reaction.
  • Example 1C Ethane Diluent, 20 psia outlet pressure, 10 psia HC partial pressure
  • a 20 psia outlet pressure, 575 °C outlet temperature, fluidized bed reactor is simulated with a feed comprising of n-pentane, which is pre-heated to 621°C prior to feeding into the fluidized bed, and a co-feed comprising of methane and hydrogen, which is separately pre-heated to a temperature required to supply 100% of the heat of reaction.
  • the catalyst is assumed to have a lights selectivity (C4- products) of ⁇ 18%.
  • the residence time within the catalyst bed is assumed to provide for CPD concentration to reach its thermodynamic concentration at the reactor outlet conditions.
  • the hydrogen molar rate in reactor co-feed is set to deliver a molar ratio of hydrogen:n-pentane in feed of 1: 1.
  • the ethane molar rate in reactor co-feed is set to deliver an ethane partial pressure at reactor outlet of 10 psia (i.e., combined partial pressure of all other hydrocarbons including hydrogen of 10 psia). Based on the reactor yields, this corresponds to a molar ratio of ethane :n-pentane in feed of 4:1.
  • To generate 1 lb- mole of CPD in the fluidized bed reactor effluent it is determined that 2.195 lb-moles of n- Pentane, 8.741 lb-moles of ethane and a co-feed pre -heat temperature of 911 °C is required.
  • use of ethane as co-feed allows for a lower pre -heat temperature owing to its higher heat capacity relative to methane.
  • a 575 °C outlet temperature, fluidized bed reactor is simulated with a feed comprising of n-pentane, which is pre-heated to 621°C prior to feeding into the fluidized bed, and a co-feed comprising of ethane and hydrogen, which is separately preheated to 732°C.
  • the catalyst is assumed to have a lights selectivity (C4- products) of ⁇ 18%.
  • the residence time within the catalyst bed is assumed to provide for CPD concentration to reach its thermodynamic concentration at the reactor outlet conditions.
  • the hydrogen molar rate in reactor co-feed is set to deliver a molar ratio of hydrogen: n-pentane in feed of 1: 1.
  • the ethane molar rate in reactor co-feed is set to deliver 100% of the heat of reaction.
  • the combined outlet pressure of all components including hydrogen, with the exception of ethane, is set at 10 psia by adjusting the total outlet pressure.
  • To generate 1 lb-mole of CPD in the fluidized bed reactor effluent it is determined from the simulation that 2.195 lb-moles of n- Pentane and 19.35 lb-moles of methane is required. Additionally, the outlet reactor pressure is determined to be 33 psia.
  • Example ID As can be seen by comparing the simulation results of Example ID and Example 1C, reducing the ethane pre -heat temperature from 911 to 732°C results in higher ethane feed rate (increase from 8.7 to 19.4 lb-mol per lb-mol of CPD produced) in order to provide the same heat of reaction.
  • compositions described herein may be free of any component, or composition not expressly recited or disclosed herein. Any method may lack any step not recited or disclosed herein.
  • compositions, element or group of elements are considered synonymous with the term “including.”
  • transitional phrase “comprising” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.

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Abstract

La présente invention concerne des procédés et des systèmes pour convertir des hydrocarbures acycliques en alcènes, en hydrocarbures cycliques et/ou en composés aromatiques, par exemple en convertissant des hydrocarbures acycliques C5 en cyclopentadiène dans un système de réacteur. Le procédé comprend la mise en contact d'une charge d'alimentation comprenant des hydrocarbures acycliques avec un matériau catalyseur dans au moins une zone de réaction pour convertir au moins une partie des hydrocarbures acycliques en un premier effluent comprenant des alcènes, des hydrocarbures cycliques et/ou des composés aromatiques. Une charge d'alimentation supplémentaire comprenant H2, des alcanes en C1-C4 et/ou des alcènes en C1-C4 peut également être fournie à au moins une zone de réaction.
PCT/US2018/017562 2017-05-03 2018-02-09 Procédés et systèmes pour la conversion d'hydrocarbures acycliques WO2018203950A1 (fr)

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CN201880026575.7A CN110536878B (zh) 2017-05-03 2018-02-09 用于转化无环烃的方法和***
EP18795006.8A EP3619184A4 (fr) 2017-05-03 2018-02-09 Procédés et systèmes pour la conversion d'hydrocarbures acycliques
BR112019021037-7A BR112019021037A2 (pt) 2017-05-03 2018-02-09 Processos e sistemas para a conversão de hidrocarbonetos acíclicos
CA3059556A CA3059556C (fr) 2017-05-03 2018-02-09 Procedes et systemes pour la conversion d'hydrocarbures acycliques

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Citations (5)

* Cited by examiner, † Cited by third party
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US2344330A (en) * 1942-03-05 1944-03-14 Universal Oil Prod Co Conversion of hydrocarbons
US2893849A (en) * 1956-05-01 1959-07-07 Standard Oil Co Fluidized solids contacting apparatus
US5284986A (en) * 1988-06-24 1994-02-08 Mobil Oil Corporation Upgrading of normal pentane to cyclopentene
JP2012255149A (ja) * 2011-05-27 2012-12-27 China Petroleum & Chemical Corp ナフサを触媒改質するためのプロセス
US20160152528A1 (en) * 2014-12-01 2016-06-02 Bestrong International Limited Method and system for acetylene (c2h2) or ethylene (c2h4) production

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2344330A (en) * 1942-03-05 1944-03-14 Universal Oil Prod Co Conversion of hydrocarbons
US2893849A (en) * 1956-05-01 1959-07-07 Standard Oil Co Fluidized solids contacting apparatus
US5284986A (en) * 1988-06-24 1994-02-08 Mobil Oil Corporation Upgrading of normal pentane to cyclopentene
JP2012255149A (ja) * 2011-05-27 2012-12-27 China Petroleum & Chemical Corp ナフサを触媒改質するためのプロセス
US20160152528A1 (en) * 2014-12-01 2016-06-02 Bestrong International Limited Method and system for acetylene (c2h2) or ethylene (c2h4) production

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