Alkyl halides conversion into ethylene and propylene

Patent metadata

Field	Value
Publication number	US-11643371-B2
Application number	US-202017777787-A
Country	US
Kind code	B2
Filing date	Nov 20, 2020
Priority date	Nov 22, 2019
Publication date	May 9, 2023
Grant date	May 9, 2023

Abstract

The present disclosure concerns a process for converting alkyl halides to ethylene and propylene, said process comprising the steps of (a) providing a feedstream comprising alkyl halides; (b) providing a first and second catalyst composition, said second catalyst composition comprising a cracking catalyst; (c) contacting said feedstream with said first catalyst composition in a first reaction zone under first reaction conditions to provide a first product stream, and (d) subjecting at least a part of said first product stream to an Olefin Catalytic Cracking with said second catalyst composition in a second reaction zone under second reaction conditions to provide a second product steam. The process is remarkable in that it further comprises a step of steaming said first catalyst composition before the step (c) and in that said first catalyst composition comprises zeolites and a binder, wherein said zeolites comprise at least one 10-membered ring channel.

First claim

The invention claimed is:

1. Process for converting one or more alkyl halides to ethylene and propylene, said process comprising the following steps:
a) providing a feedstream comprising one or more alkyl halides; optionally, diluted in at least one diluent;
b) providing a first catalyst composition and a second catalyst composition, said second catalyst composition comprising a cracking catalyst;
c) contacting said feedstream with said first catalyst composition in a first reaction zone under first reaction conditions to provide a first product stream; and
d) subjecting at least a part of said first product stream to an Olefin Catalytic Cracking with said second catalyst composition in a second reaction zone under second reaction conditions to provide a second product stream,

the process is characterized in that it further comprises a step of steaming said first catalyst composition before the step (c), and in that said first catalyst composition comprises one or more zeolites and a binder, wherein said one or more zeolites comprise at least one 10-membered ring channel.

2. The process according to claim 1 , characterized in that said step of steaming is followed by an extraction step.

3. The process according to claim 1 , characterized in that the one or more zeolites in the first catalyst composition are selected from the group of MFI, MEL, FER, MTT, MWW, TON, EUO and MRE families, said one or more zeolites having a Si/Al molar ratio in the framework of the zeolite of at least 10 as determined by TPD before the step of steaming.

4. The process according to claim 1 , characterized in that said binder in said first catalyst composition is selected from silica, clays, calcium phosphates, magnesium phosphates and mullite.

5. The process according to claim 1 , characterized in that said binder in said first catalyst composition is present in an amount of at least 10 wt. % as based on the total weight of the first catalyst composition, preferably of at least 40 wt. %.

6. The process according to claim 1 , characterized in that said one or more zeolites in the first catalyst composition have Bronsted acid sites in a concentration inferior to 100 μmol/g-cat as determined by NH 3 -Temperature Programmed Desorption.

7. The process according to claim 1 , characterized in that said first catalyst composition further comprises at least 0.1 wt. % of phosphorous based on the total weight of the first catalyst composition.

8. The process according to claim 1 , characterized in that said first catalyst composition further comprises phosphoric acid and magnesium nitrate.

9. The process according to claim 1 , characterized in that said first catalyst composition is blended with at least one metal-containing material.

10. The process according to claim 9 , characterized in that the at least one metal-containing material is an alkaline earth metal-containing material which comprises at least one alkaline earth metal is selected from beryllium, magnesium, calcium, strontium, barium and any mixtures thereof.

11. The process according to claim 9 , characterized in that the at least one metal-containing material has an anion selected from the group of oxides, silicates, aluminates, titanates, phosphates, borates and borosilicates.

12. The process according to claim 1 , characterized in that said one or more zeolites of the first catalyst composition contain less than 1000 wt. ppm of alkali metals as determined by XRF based on the total weight one or more zeolites of the first catalyst composition.

13. The process according to claim 1 , characterized in that said one or more zeolites of the first catalyst composition contain less than 5000 wt. ppm of transition metals as determined by XRF as based on the total weight one or more zeolites of the first catalyst composition.

14. The process according to claim 1 , characterized in that said cracking catalyst comprises one or more zeolites and/or one or more clays.

15. The process according to claim 14 , characterized in that said cracking catalyst comprises one or more zeolites selected from silicalites from the MFI family, crystalline silicate from the MFI family with a Si/Al atomic ratio of at least 180, crystalline silicate from the MEL family with a Si/Al atomic ratio ranging between 150 and 800, and/or phosphorous-modified zeolite from the MFI, MEL, FER, or MOR family.

16. The process according to claim 1 , characterized in that the second reaction conditions of step (d) include a reaction temperature ranging from 500° C. to 600° C.

17. The process according to claim 1 , characterized in that the second reaction conditions of step (d) include a weight hourly space velocity comprised between 0.1 h −1 and 100 h −1 .

18. The process according to claim 1 , characterized in that step (c) further comprises separating from the first product stream a C4+ stream and the step (d) comprises subjecting said C4+ stream to an Olefin Catalytic Cracking with said second catalyst composition in a second reaction zone under second reaction conditions to provide a second product stream.

19. The process according to claim 1 , characterized in that said step (d) of contacting said first product stream with said second catalyst composition is followed by a step (e) of performing a separation of ethylene and propylene from said second product stream.

20. The process according to claim 1 , characterized in that said process further comprises one or more of the following sub-steps:
i. removing hydrogen halide from said first product stream before the step (d) or from said second product stream after the step (d);
ii. recovering at least a part of the unreacted one or more alkyl halides before or after the step (d), followed by a step of reinjecting said at least a part of unreacted one or more alkyl halides into the feedstream of step (a);
iii. removing aromatics from said first product stream before the step (d) or from said second product stream after the step (d).

Assignees

• Totalenergies Onetech
• Sulzer Management Ag

Inventors

• Nesterenko Nikolai
• Veryasov Gleb
• Dethier Raoul

Classifications

• B01J29/40 Primary

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C07C1/26 Primary

  starting from organic compounds containing only halogen atoms as hetero-atoms · CPC title

• B01J29/18

  of the mordenite type · CPC title

• B01J37/28

  Phosphorising · CPC title