Processes for improving the efficiency of hydrocarbon production

Patent metadata

Field	Value
Publication number	US-11220469-B2
Application number	US-201816754162-A
Country	US
Kind code	B2
Filing date	Oct 9, 2018
Priority date	Oct 10, 2017
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

A process for converting a feed stream having carbon to C2 to C5 olefins, includes introducing a feed stream including methane and oxygen to a first reaction zone, reacting the methane and oxygen in the first reaction zone to form a first reaction zone product stream having a mixture of C2 to C5 alkanes, transporting the mixture of C2 to C5 alkanes to a second reaction zone, introducing a fresh stream of at least one of ethane and propane to the second reaction zone, converting the C2 to C5 alkanes to C2 to C5 olefins in the second reaction zone, producing one or more product streams in the second reaction zone, where a sum of the one or more product streams includes C2 to C5 olefins, and producing a recycle stream comprising hydrogen in the second reaction zone, where the recycle stream is transported to the first reaction zone.

First claim

The invention claimed is:

1. A process for converting a feed stream comprising carbon to C 2 to C 5 olefins, comprising:
introducing a feed stream comprising methane and oxygen to a first reaction zone;
reacting the methane and oxygen in the first reaction zone to form a first reaction zone product stream comprising a mixture of C 2 to C 5 alkanes;
transporting the mixture of C 2 to C 5 alkanes to a second reaction zone;
introducing a fresh stream of at least one of ethane and propane to the second reaction zone;
converting the mixture of C 2 to C 5 alkanes to C 2 to C 5 olefins in the second reaction zone;
producing one or more product streams in the second reaction zone, wherein a sum of the one or more product streams comprises C 2 to C 5 olefins; and
producing a recycle stream comprising hydrogen in the second reaction zone, wherein the recycle stream is transported directly from the second reaction zone to the first reaction zone.

2. The process of claim 1 , wherein the second reaction zone comprises a cracker.

3. The process of claim 2 , wherein introducing a fresh stream of at least one of ethane and propane to the second reaction zone comprises introducing a fresh stream of ethane into the cracker.

4. The process of claim 2 , wherein the second reaction zone comprises a propane dehydrogenation reactor.

5. The process of claim 4 , wherein introducing a fresh stream of at least one of ethane and propane to the second reaction zone comprises introducing propane into the propane dehydrogenation reactor.

6. The process of claim 5 , wherein the second reaction zone comprises a cracker and introducing a fresh stream of at least one of ethane and propane to the second reaction zone comprises introducing propane into the propane dehydrogenation reactor and introducing ethane to the cracker.

7. The process of claim 1 , wherein the recycle stream further comprises methane.

8. The process of claim 1 , wherein the first reaction zone product stream does not comprise carbon dioxide.

9. The process of claim 1 , wherein the first reaction zone comprises a hybrid catalyst.

10. The process of claim 9 , wherein the hybrid catalyst comprises a methanol synthesis component and a solid microporous acid component having 8-MR access.

11. The process of claim 1 , wherein a CH 4 /alkanes ratio is less than 1.17.

12. The process of claim 1 , wherein a CH 4 /alkanes ratio is less than or equal to 1.14.

13. The process of claim 1 , wherein an O 2 /alkanes ratio is less than or equal to 1.10.

14. The process of claim 1 , wherein a carbon efficiency is greater than 0.93.

15. The process of claim 1 , wherein a carbon efficiency is greater than or equal to 0.96.

16. The process of claim 1 , wherein the first reaction zone comprises a reformer, a partial oxidation reactor, and a hybrid reactor, wherein the outlet stream of the reformer is introduced into the partial oxidation reactor, and wherein the outlet stream of the partial oxidation reactor is introduced to a hybrid reactor where the outlet stream from the partial oxidation reactor contacts a hybrid catalyst, and wherein the hybrid catalyst converts syngas into oxygenated hydrocarbons and the oxygenated hydrocarbons into C 2 to C 5 alkanes.

Assignees

• Dow Global Technologies Llc

Inventors

• Fish Barry B
• Groenendijk Peter E
• Nieskens Davy L S
• Malek Andrzej
• Stears Brien A

Classifications

• C07C4/02

  by cracking a single hydrocarbon or a mixture of individually defined hydrocarbons or a normally gaseous hydrocarbon fraction · CPC title

• C01B2203/0283

  containing a CO-shift step, i.e. a water gas shift step · CPC title

• C07C2529/70

  of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65 · CPC title

• C07C1/0485 Primary

  Set-up of reactors or accessories; Multi-step processes · CPC title

• C01B3/38

  using catalysts · CPC title