Processes and apparatuses for production of polypropylene

Patent metadata

Field	Value
Publication number	US-9919983-B2
Application number	US-201715609465-A
Country	US
Kind code	B2
Filing date	May 31, 2017
Priority date	Jun 22, 2016
Publication date	Mar 20, 2018
Grant date	Mar 20, 2018

Abstract

Processes and apparatuses for the production of propylene are provided. In an embodiment, a process is provided for production of propylene from an oxygenate feed comprising passing the oxygenate feed to an oxygenate-to-olefin reactor to contact the oxygenate feed with a catalyst to provide an effluent stream comprising olefins comprising ethylene, propylene and butylene. The effluent stream is separated in a product separation zone to generate a propylene product stream, an ethylene stream and a C 4 + stream. The ethylene stream is reacted in an ethylene dimerization or oligomerization reactor in presence of a dimerization or oligomerization catalyst to provide a first process stream. The C 4 + stream and the first process stream are cracked in a cracking reactor under cracking conditions to provide a cracked stream comprising additional amounts of ethylene and propylene. Finally, the cracked stream is passed to the product separation zone to recover additional amounts of propylene.

First claim

The invention claimed is:

1. An integrated process for the production of propylene from an oxygenate feed, comprising:
(a) passing the oxygenate feed to an oxygenate-to-olefin reactor to contact the oxygenate feed with a catalyst comprising a silicoaluminophosphate (SAPO) to provide an effluent stream comprising light olefins comprising ethylene, propylene and butylene;
(b) separating the effluent stream in a product separation zone to generate a propylene product stream, an ethylene stream and a C 4 + stream;
(c) reacting the ethylene stream in an ethylene dimerization or oligomerization reactor in presence of a dimerization or oligomerization catalyst to provide a first process stream;
(d) cracking the C 4 + stream and the first process stream in a cracking reactor under cracking conditions to provide a cracked stream comprising additional amounts of ethylene and propylene; and
(e) passing the cracked stream to the product separation zone to recover additional amounts of propylene.

2. The process of claim 1 , wherein the SAPO catalyst is selected from the group consisting of SAPO-34, SAPO-18, SAPO-5 and mixtures thereof.

3. The process of claim 1 , wherein the oxygenate feed comprise at least one of alcohols, aldehydes and ethers.

4. The process of claim 1 further comprising introducing an additional stream comprising at least one of paraffins and olefins, to the cracking reactor.

5. The process of claim 1 , wherein the C 4 + stream comprises at least one of C 4 + olefins and C 4 + paraffins and the step of cracking comprises cracking at least one of the C 4 + olefins and C 4 + paraffins.

6. The process of claim 5 , wherein the cracking conditions comprise a temperature in the range of about 475° C. to about 650° C.

7. The process of claim 1 , wherein the dimerization or oligomerization catalyst comprises a solid phosphoric acid catalyst.

8. The process of claim 1 , wherein the dimerization or oligomerization catalyst comprises a zeolite, wherein the zeolite has a structure selected from the group consisting of MFI, MEL, ITH, IMF, TUN, FER, BEA, FAU, BPH, MEI, MSE, MWW, UZM-8, MOR, OFF, MTW, TON, MTT, AFO, ATO, and AEL, and mixtures thereof.

9. The process of claim 1 , wherein the dimerization or oligomerization reactor is an oligomerization reactor.

10. The process of claim 1 further comprising:
separating the C 4 + stream to a C 4 stream and a C 5 + stream; and
passing the C 5 + stream to the cracking reactor.

11. The process of claim 10 further comprising recovering at least one of butene-1 and butadiene from the C 4 stream.

12. The process of claim 11 , wherein the step of recovering butadiene comprises contacting a first portion of the C 4 stream with a dehydrogenation catalyst in a dehydrogenation reaction zone under dehydrogenation conditions to form butadiene.

13. The process of claim 11 , wherein the step of recovering butene-1 comprising separating a second portion of the C 4 stream to generate a butene-1 stream and a 2-butene stream.

14. The process of claim 13 further comprising passing the 2-butene stream to the dehydrogenation reactor.

15. An integrated process for the production of propylene from an oxygenate feed, comprising:
(a) passing the oxygenate feed to an oxygenate-to-olefin reactor to contact the oxygenate feed with a catalyst comprising a silicoaluminophosphate (SAPO) to provide an effluent stream comprising light olefins comprising ethylene, propylene and butylene;
(b) separating the effluent stream in a product separation zone to provide a propylene product stream, an ethylene stream, C 4 olefin stream and a C 5 + olefin stream;
(c) reacting the ethylene stream in an ethylene dimerization or oligomerization reactor in presence of a dimerization or oligomerization catalyst to provide a first process stream;
(d) cracking the C 5 + olefin stream in a cracking reactor under cracking conditions to provide a cracked stream comprising additional amounts of ethylene and propylene;
(e) passing the cracked stream to the product separation zone to recover additional amounts of propylene; and
(f) recovering at least one of butene-1 and butadiene from the C 4 olefin stream.

16. The process of claim 15 further comprising passing the first process stream to the cracking reactor.

17. The process of claim 15 further comprising passing a first portion of the first process stream to the product separation zone and a second portion of the first process stream to the cracking reactor, wherein the first portion is between 1% and 99%, and the second portion is the remainder of the first process stream.

18. The process of claim 15 , wherein the step of recovering comprises contacting a first portion of the C 4 olefin stream with a dehydrogenation catalyst in a dehydrogenation reaction zone under dehydrogenation conditions to form butadiene.

19. The process of claim 15 , wherein the step of recovering comprising separating a second portion of the C 4 olefin stream to generate a butene-1 stream and a 2-butene stream and passing the 2-butene stream to the dehydrogenation reactor.

20. An integrated process for the production of propylene from an oxygenate feed, comprising:
(a) passing the oxygenate feed to an oxygenate-to-olefin reactor to contact the oxygenate feed with a catalyst comprising a silicoaluminophosphate (SAPO) to provide an effluent stream comprising light olefins comprising ethylene, propylene and butylene and paraffins;
(b) separating the effluent stream in a product separation zone to provide a propylene product stream, an ethylene stream, a C 4 + olefin stream and a C 4 + paraffin stream;
(c) reacting the ethylene stream in an ethylene dimerization or oligomerization reactor in presence of a dimerization or oligomerization catalyst to provide a first process stream;
(d) cracking the C 4 + olefin stream, the C 4 + paraffin stream and the first process stream in a cracking reactor under cracking conditions to provide a cracked stream comprising additional amounts of ethylene and propylene; and
(e) passing the cracked stream to the product separation zone to recover additional amounts of propylene.

Assignees

• Uop Llc

Inventors

• Vora Bipin V
• Abrevaya Hayim

Classifications

• C07C4/04

  Thermal processes {(C07C4/025 takes precedence)} · CPC title

• C07C5/333

  Catalytic processes · CPC title

• C07C2529/85

  Silicoaluminophosphates (SAPO compounds) · CPC title

• C07C1/20 Primary

  starting from organic compounds containing only oxygen atoms as heteroatoms · CPC title

• C07C2527/173

  Phosphoric acid or other acids with the formula Hn+2PnO3n+1 · CPC title