Process for producing olefin compounds using regenerator

Abstract

A method of producing an olefin compound can include contacting a feed stream comprising one or more hydrocarbons with a particulate solid catalyst in a reactor. In the reactor, the one or more hydrocarbons may be dehydrogenated to form one or more products comprising one or more olefin compounds, and at least a portion of the particulate solid catalyst may be inactivated. The method may also include passing at least a portion of the deactivated particulate solid catalyst to the combustor. In the combustor, a supplemental fuel stream may enter the combustor through a supplemental fuel distributor, and the supplemental fuel stream may react to heat at least a portion of the deactivated particulate solid catalyst. The method may also include passing at least a portion of the heated deactivated particulate solid catalyst to an oxygen treatment zone to produce a reactivated particulate solid catalyst. The method may also include passing at least a portion of the reactivated particulate solid catalyst back to the combustor. In the combustor, the reactivated particulate solid catalyst may enter the combustor downstream of the make-up fuel stream with respect to a flow direction of the make-up fuel stream, and the deactivated particulate solid catalyst may enter the combustor upstream of the make-up fuel stream with respect to the flow direction of the make-up fuel stream. The method may also include passing at least a portion of the reactivated particulate solid catalyst to the reactor.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 428,528, filed on November 29, 2022, the entire disclosure of which is hereby incorporated by reference herein. Technical Field

[0003] The embodiments described herein generally relate to chemical processing, and more particularly, to methods and systems for producing olefin compounds. Background Art

[0004] Olefin compounds can be used as base materials to produce many types of goods and materials. For example, propylene can be used to manufacture polypropylene, propylene oxide, and acrylonitrile. Such products can be used in product packaging, chemical manufacturing, textiles, etc. Thus, there is an industrial need for olefin compounds such as ethylene, propylene, butene, and styrene, as well as methods for producing such materials. Summary of the Invention

[0005] One method for producing olefin compounds is by dehydrogenating hydrocarbons. In some embodiments, the dehydrogenation reaction can use a particulate solid (e.g., a catalyst) to facilitate the dehydrogenation reaction. Additionally, due to the endothermic nature of the dehydrogenation reaction, the reaction can also utilize an external heat source to facilitate the reaction. In such embodiments, the particulate solid can be passed to a burner where a supplementary fuel is reacted to heat the particulate solid. The heated particulate solid can provide some or all of the heat for continuing the dehydrogenation reaction. However, reacting the supplementary fuel in the presence of the particulate solid may reduce the activity of the particulate solid in facilitating the dehydrogenation reaction. Thus, it is desirable to limit the amount of particulate solid exposed to the supplementary fuel while still providing sufficient heat source for the dehydrogenation reaction. The methods of the present disclosure can help limit the amount of particulate solid exposed to the supplementary fuel by delivering both deactivated particulate solid and reactivated particulate solid to the burner in a specific distribution pattern. Specifically, the embodiments described herein utilize a method whereby the deactivated particulate solid catalyst is delivered upstream of the supplementary fuel to the burner, and whereby the reactivated particulate solid catalyst is delivered downstream of the supplementary fuel to the burner. Such an arrangement can be beneficial by allowing an increased residence time of the deactivated catalyst in the burner, thus allowing for more complete coke burnout, while the recycled regenerated catalyst typically contains less coke and can benefit from a reduced residence time of exposure to the supplementary fuel, which can deactivate the catalyst.

[0006] According to one or more embodiments of the present disclosure, a method for producing olefin compounds may include contacting a feed stream comprising one or more hydrocarbons with a particulate solid catalyst in a reactor. In the reactor, the one or more hydrocarbons may be dehydrogenated to form one or more products comprising one or more olefin compounds, and at least a portion of the particulate solid catalyst may be deactivated. The method may further include transferring at least a portion of the deactivated particulate solid catalyst to a burner. In the burner, a supplemental fuel stream may enter the burner through a supplemental fuel dispenser, and the supplemental fuel stream may react to heat at least a portion of the deactivated particulate solid catalyst. The method may further include transferring at least a portion of the heated deactivated particulate solid catalyst to an oxygen treatment zone to produce a reactivated particulate solid catalyst. The method may further include transferring at least a portion of the reactivated particulate solid catalyst back to the burner. In the burner, the reactivated particulate solid catalyst may enter the burner downstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream, and the deactivated particulate solid catalyst may enter the burner upstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream. The method may further include transferring at least a portion of the reactivated particulate solid catalyst to the reactor.

[0007] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. Additional features and advantages of the embodiments will be set forth in the detailed description, and in part, will be readily apparent to those of ordinary skill in the art from the description including the drawings and the claims, or may be recognized by practicing the described embodiments. The drawings are included to provide a further understanding of the embodiments and, together with the detailed description, serve to explain the principles and operations of the claimed subject matter. However, the embodiments depicted in the drawings are illustrative and exemplary in nature and are not intended to limit the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following detailed description can be better understood when read in conjunction with the following drawings, in which:

[0009] Figure 1 schematically depicts a reactor system according to one or more embodiments of the present disclosure; and

[0010] Figure 2 schematically depicts a burner according to one or more embodiments of the present disclosure.

[0011] When describing Figure 1 and Figure 2When presenting simplified schematic illustrations, many valves, temperature sensors, electronic controllers, etc. that can be used and are well-known to those of ordinary skill in the art are not included. In addition, accompanying components that are typically included in such reactor systems, such as air supplies, heat exchangers, buffer tanks, etc., are not included. However, it should be understood that these components are within the scope of the present disclosure.

[0012] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. Detailed Description

[0013] Specific embodiments of the present application will now be described. However, the present disclosure may be implemented in different forms and should not be construed as limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art.

[0014] As described herein, a method for producing an olefin compound may include reactivating a catalyst in a burner by exposure to a supplemental fuel. In the embodiments described herein, the deactivated particulate solid catalyst and the recycled reactivated particulate solid catalyst may be separately delivered to different regions of the burner in the burner. As used herein, "particulate solid catalyst" refers to a particulate solid that may have a catalytic function for dehydrogenation reactions and / or fuel combustion reactions. When the term "particulate solid" is described herein, it may equivalently refer to "particulate solid catalyst".

[0015] Now, the present disclosure will be described in detail in the context of Figure 1 a reactor system and Figure 2 a burner of Figure 1 which operate as a circulating fluidized bed to dehydrogenate hydrocarbons. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems utilizing different system components oriented in different ways. For example, the concepts described herein may equivalently apply to other systems having alternative reactor units and regeneration units, such as those operating under non-fluidized conditions, or those including downcomers instead of risers, and vice versa. It should also be understood that not all parts of Figure 2 the reactor system and Figure 1 the burner of Figure 2 should be construed as necessary for the claimed subject matter. In addition, although the method steps recited in the appended claims are described in the context of

[0016] Now refer to Figure 1, schematically depicts an example reactor system 103 that can be applicable to the methods and / or apparatuses described herein. The reactor system 103 generally includes a plurality of system components, such as a reactor section 206 and a regeneration unit 306. As described herein, a "system component" refers to a part of the reactor system 103, such as a reactor, a separator, a transfer line, a combination thereof, etc. As used herein in the Figure 1 context of, the reactor section 206 generally refers to the part of the reactor system 103 where the main process reaction (e.g., dehydrogenation) occurs to form a product stream. A feed stream enters the reactor section 206, is converted into a product stream (containing products and unreacted feed), and exits the reactor section 206. The reactor section 206 includes a reactor 202, which may include an upstream reactor section 254 and a downstream reactor section 232. According to one or more embodiments, as Figure 1 depicted, the reactor section 206 may additionally include a particulate solid separation section 216, which is used to separate the particulate solid catalyst from the chemical products formed in the reactor 202. Additionally, as used herein, the regeneration unit 306 generally refers to the part of the reactor system 103 where the particulate solid is treated in some manner, such as by combustion, to, for example, improve the catalytic activity and / or heat the particulate solid. The regeneration unit 306 may include a burner 350 and a riser 330, and may additionally include a particulate solid separation section 316. In one or more embodiments, the particulate solid separation section 216 may be in fluid communication with the burner 350 (e.g., via line 426), and the particulate solid separation section 316 may be in fluid communication with the upstream reactor section 254 (e.g., via lines 424 and transfer riser 430).

[0017] Generally as described herein, in the Figure 1 embodiment shown, a portion of the particulate solid is circulated between the reactor section 206 and the regeneration unit 306. It should be understood that when referring to particulate solids herein, they may refer to solid materials that are catalytically active for the desired reaction (i.e., catalysts), or may equally refer to reference Figure 1Other particulate solids that are mentioned in the context of the system may not necessarily be catalytically active but affect the reaction, such as oxygen carrier materials. The terms "catalytic activity" and "catalyst activity" refer to the extent to which a catalyst is able to catalyze the reactions occurring in the reactor system 103. The particulate solids exiting the reactor section 206 can be deactivated particulate solids. As used herein, "deactivated" can refer to particulate solids having a reduced catalytic activity or cooler particulate solids compared to the particulate solids entering the reactor section 206. However, the deactivated particulate solids can retain some catalytic activity. The reduced catalytic activity can be caused by contamination with substances such as coke. Reactivation (sometimes referred to herein as "regeneration") can remove contaminants such as coke, raise the temperature of the particulate solids, or both. In an embodiment, the deactivated particulate solids can be reactivated by reactivating the particulate solids in the regeneration unit 306. The deactivated particulate solids can be reactivated by, but not limited to, removing coke by combustion, restoring catalyst acidity, oxidizing the particulate solids, heating the particulate solids, other reactivation processes, or combinations thereof. In one or more embodiments, the particulate solids can be heated during reactivation by combusting a supplemental fuel such as hydrogen, methane, ethane, propane, natural gas, or combinations thereof. Without being bound by theory, it is believed that when the particulate solids are heated by combusting a supplemental fuel during reactivation, exposure of the particulate solids to the fuel gas can deactivate the particulate solids while still heating the particulate solids. As used herein, the term "heated deactivated particulate solid catalyst" refers to a particulate solid catalyst that has been heated by combusting a supplemental fuel but may still have a reduced catalytic activity. The regenerated particulate solids from the regeneration unit 306 can then be transferred back to the reactor section 206.

[0018] A feed stream can enter through the feed inlet 434, enter the reactor 202, and a product stream can exit the reactor system 103 via the tube 420. According to one or more embodiments, the reactor system 103 can be operated by feeding a chemical feed (e.g., in the feed stream) and particulate solids into the upstream reactor section 254. The chemical feed contacts the particulate solids in the upstream reactor section 254, and each chemical feed flows upward and through the downstream reactor section 232 to produce a chemical product.

[0019] Now referring in detail to Figure 1 , the reactor section 206 can include an upstream reactor section 254, a transition section 258, and a downstream reactor section 232, such as a riser. The transition section 258 can connect the upstream reactor section 254 to the downstream reactor section 232. As Figure 1As depicted, the upstream reactor section 254 can be positioned below the downstream reactor section 232. Such a configuration can be referred to as an upflow configuration in the reactor 202. The upstream reactor section 254 can include a vessel, a drum, a barrel, a tank, or other container suitable for a given chemical reaction. As Figure 1 depicted, the upstream reactor section 254 can be connected to the downstream reactor section 232 via a transition section 258. The upstream reactor section 254 can generally have a larger cross-sectional area than the downstream reactor section 232. The transition section 258 can taper from the size of the cross-section of the upstream reactor section 254 to the size of the cross-section of the downstream reactor section 232 such that the transition section 258 projects inward from the upstream reactor section 254 into the downstream reactor section 232. For example, the transition section 258 can be a frustum.

[0020] The upstream reactor section 254 can be connected to a transport riser 430 that can, in operation, provide regenerated particulate solids in a feed stream to the reactor section 206. The particulate solids entering the upstream reactor section 254 via the transport riser 430 can be transferred to the transport riser 430 via line 424 and thus arrive from the regeneration unit 306. The particulate solids can come directly from the particulate solid separation section 216 via the standpipe 422 and enter the transport riser 430, where the particulate solids enter the upstream reactor section 254. This particulate solid can be slightly deactivated but can still be suitable for reaction in the upstream reactor section 254 in some embodiments, particularly when used in combination with regenerated / reactivated particulate solids.

[0021] Still referring to Figure 1 , in one or more embodiments, based on the shape, size, and other processing conditions (such as temperature and pressure) in the upstream reactor section 254 and the downstream reactor section 232, the upstream reactor section 254 can operate as a fluidized bed, such as in a fast fluidized, turbulent, or bubbling bed upflow reactor, while the downstream reactor section 232 can operate in a more plug flow manner, such as in a riser reactor. For example, Figure 1The reactor 202 may include an upstream reactor section 254 operating as a fast fluidized, turbulent, or bubbling bed reactor and a downstream reactor section 232 operating as a dilute phase riser reactor, such that an average granular solid and gas flow move upward simultaneously. As used herein, the term "average flow" refers to the net flow, i.e., the total upward flow minus the reverse or counter flow, which is typically characteristic of fluidized particles. As described herein, a "fast fluidized" reactor may refer to a reactor utilizing a fluidization scheme where the superficial velocity of the gas phase is greater than the choking velocity and may be semi-dense in operation. As described herein, a "turbulent" reactor may refer to a fluidization scheme where the superficial velocity is less than the choking velocity and is denser than the fast fluidization scheme. As described herein, a "bubbling bed" reactor may refer to a fluidization morphology where distinct bubbles exist in a highly dense bed in two distinct phases. The "choking velocity" is the minimum velocity required to maintain solids in a dilute phase mode in a vertical transport line. As described herein, a "dilute phase riser" may refer to a riser reactor operating at a transport velocity where the gas and granular solids have approximately the same velocity in the dilute phase.

[0022] In one or more embodiments, the granular solids may be capable of fluidizing. In some embodiments, the granular solids may exhibit characteristics referred to industrially as "Geldart A" or "Geldart B" characteristics. According to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), pp. 34-37; and D. Geldart, "Types of Gas Fluidization", Powder Technol. 7 (1973) 285-292, which are hereby incorporated by reference in their entirety, the particles may be classified as "Group A" or "Group B".

[0023] Group A is understood by those skilled in the art to represent an aeratable powder having fluidization with a range of no bubbles; high bed expansion; slow and linear degassing rate; bubble characteristics which may include the advantage of splitting / recoalescing bubbles, having a maximum bubble size and a large wake; a high level of solid mixing and gas backmixing, assuming U - umf are equal (U is the velocity of the carrier gas and Umf is the minimum fluidization velocity, typically but not necessarily measured in meters per second (m / s), i.e., there is an excessive gas velocity); axisymmetric slug characteristics; and no spouting except in very shallow beds. The listed characteristics tend to improve with decreasing mean particle size, assuming cfp is equal; or with increasing proportion < 45 micrometers (μm); or with increasing gas pressure, temperature, viscosity, and density. Generally, the particles may exhibit a small mean particle size and / or a low particle density (< 1.4 grams per cubic centimeter, g / cm 3 ); are easily fluidized, where they fluidize smoothly at low gas velocities; and may exhibit controlled bubbling with small bubbles at higher gas velocities.

[0024] Group B is understood by those skilled in the art to represent "sand-like" powders which start to bubble at Umf; which exhibit moderate bed expansion; rapid degassing; no limitation on bubble size; a moderate level of solid mixing and gas backmixing, assuming U - umf are equal; both axisymmetric and non-axisymmetric slugs; and spouting only in shallow beds. These characteristics tend to improve with decreasing mean particle size, but the particle size distribution and certain uncertainties in the gas, pressure, temperature, viscosity, or density do not seem to have much effect on improving these characteristics. Generally, when the density (pp) is 1.4 < pp < 4 g / cm 3 , the particle size (cfp) of most particles is 40 μm < cfp < 500 μm, and preferably, when the density (pp) is 4 g / cm 3 , the particle size of most particles is 60 μm < cfp < 500 μm, and when the density (pp) is 1 g / cm 3 , the particle size of most particles is 250 μm < cfp < 100 μm.

[0025] According to an embodiment, the chemical product and the particulate solid can be transferred from the downstream reactor section 232 to the separation device 226 in the particulate solid separation section 216, where the particulate solid is separated from the chemical product, and the chemical product is conveyed out of the particulate solid separation section 216. According to one or more embodiments, after separating the particulate solid from the vapor in the separation device 226, the particulate solid can generally move through the stripping zone 224 to the particulate solid outlet port 222, where the particulate solid is transferred out of the reactor section 206 via the pipeline 426 and into the regeneration unit 306.

[0026] Now return to referenceFigure 1 , according to one or more embodiments, the separation device 226 can be a cyclone separation system, which can include two or more cyclone separation stages. In embodiments where the separation device 226 includes more than one cyclone separation stage, the first separation device into which the fluidized stream enters is referred to as the primary cyclone separation device. The fluidized effluent from the primary cyclone separation device can enter a secondary cyclone separation device for further separation. The primary cyclone separation device can include, for example, a primary cyclone separator and systems that can be commercially obtained under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster), and RS2 (commercially available from Stone and Webster). The primary cyclone separator is described, for example, in U.S. Pat. Nos. 4,579,716, 5,190,650, and 5,275,641, each of which is incorporated herein by reference in its entirety. In some separation systems that utilize a primary cyclone separator as the primary cyclone separation device, one or more additional sets of cyclone separators, such as secondary and tertiary cyclone separators, are used to further separate particulate solids from the product gas. It should be understood that any primary cyclone separation device can be used in the embodiments of the present invention.

[0027] Still referring to Figure 1 , the separated particulate solids are transferred from the particulate solid separation section 216 to the combustor 350 via line 426. In the combustor 350, the particulate solids can be treated, for example, by burning with one or both of oxygen and supplemental fuel. For example but not limited to, the particulate solids can be decoked and / or a combustible fuel to heat the particulate solids. Then, the particulate solids are transferred out of the combustor 350 and through the riser 330 to the riser termination separator 378, where the gas and solid components from the riser 330 are at least partially separated. The vapor and remaining solids are transported to a secondary separation device 326 in the particulate solid separation section 316, where the remaining particulate solids are separated from the gas from the particulate solid treatment (e.g., the gas emitted by burning the used particulate solids or fuel, referred to herein as flue gas). The flue gas can be transferred out of the regeneration unit 306 via the outlet pipe 432. Then, the separated particulate solids are transferred via line 424 and the transport riser 430 through the oxygen treatment zone 312 within the particulate solid separation section 316 to the upstream reactor section 254, where the particulate solids are further used for catalytic reactions. In one or more embodiments, at least a portion of the particulate solids can be transferred from the oxygen treatment zone 312 to the combustor 350. Thus, in operation, the particulate solids can be cycled between the reactor section 206 and the regeneration unit 306. Generally, the processed chemical stream, including the feed stream and the product stream, can be gaseous, and the particulate solids can be fluidized particulate solids.

[0028] Now referring to the regeneration unit 306, as Figure 1 depicted, the burner 350 of the regeneration unit 306 can be in fluid communication with the riser 330. An oxygen-containing gas (such as air) can be transferred through the pipe 358 into the burner 350. The burner 350 can be in fluid communication with the granular solid separation section 216 via the pipeline 426, and this pipeline can supply the deactivated granular solids from the reactor section 206 to the regeneration unit 306 for regeneration. The burner 350 can also be in fluid communication with the oxygen treatment zone 312, and this oxygen treatment zone can supply the reactivated granular solids to the reactor section 206 and the burner 350. The burner 350 and the riser 330 can be operated in a fluidization manner similar to or the same as that disclosed for the upstream reactor section 254 and the downstream reactor section 232 of the reactor section 206. That is to say, the burner 350 can operate as a fluidized bed, for example, in a fast fluidization, turbulent or bubbling bed upflow reactor, while the riser 330 can be operated in a more plug flow manner, for example, in a riser reactor. The geometries described for the upstream reactor section 254 and the downstream reactor section 232 can equally apply to the burner 350 and the riser 330. Additionally, the burner 350 can further include a supplementary fuel distributor 354, and this supplementary fuel distributor can supply fuels such as a hydrocarbon stream, hydrogen or a combination thereof to the burner 350.

[0029] The granular solids and the flue gas generated in the burner 350 can travel through the riser 330 to the granular solid separation section 316. In the granular solid separation section 316, the flue gas and the granular solids can be first separated by the riser terminal separator 378 and then by the secondary separation device 326. As described in one or more embodiments, after separating the flue gas from the granular solids in the riser terminal separator 378 and the secondary separation device 326, the processed granular solids are treated with an oxygen-containing gas in the oxygen treatment zone 312. In some embodiments, the oxygen treatment zone 312 includes a fluid-solid contact device. The fluid-solid contact device can include a baffle or grid structure to promote the contact between the processed catalyst and the oxygen-containing gas. Examples of the fluid-solid contact device are further described in detail in U.S. Patent Nos. 9,827,543 and 9,815,040. The fluidization scheme in the oxygen treatment zone can be of the bubbling bed type.

[0030] In one or more embodiments, the particulate solid can be exposed to an oxygen-containing gas in the oxygen treatment zone 312 for 30 seconds to 20 minutes. For example, the particulate solid can be exposed to the oxygen-containing gas in the oxygen treatment zone 312 for 30 seconds to 18 minutes, such as 30 seconds to 16 minutes, 30 seconds to 14 minutes, 30 seconds to 12 minutes, 30 seconds to 10 minutes, 30 seconds to 8 minutes, 30 seconds to 6 minutes, 30 seconds to 4 minutes, 30 seconds to 2 minutes, 2 minutes to 20 minutes, 2 minutes to 18 minutes, 2 minutes to 16 minutes, 2 minutes to 14 minutes, 2 minutes to 12 minutes, 2 minutes to 10 minutes, 2 minutes to 8 minutes, 2 minutes to 6 minutes, 2 minutes to 4 minutes, 4 minutes to 20 minutes, 4 minutes to 18 minutes, 4 minutes to 16 minutes, 4 minutes to 14 minutes, 4 minutes to 12 minutes, 4 minutes to 10 minutes, 4 minutes to 8 minutes, 4 minutes to 6 minutes, 6 minutes to 20 minutes, 6 minutes to 18 minutes, 6 minutes to 16 minutes, 6 minutes to 14 minutes, 6 minutes to 12 minutes, 6 minutes to 10 minutes, 6 minutes to 8 minutes, 8 minutes to 20 minutes, 8 minutes to 18 minutes, 8 minutes to 16 minutes, 8 minutes to 14 minutes, 8 minutes to 12 minutes, 8 minutes to 10 minutes, 10 minutes to 20 minutes, 10 minutes to 18 minutes, 10 minutes to 16 minutes, 10 minutes to 14 minutes, 10 minutes to 12 minutes, 12 minutes to 20 minutes, 12 minutes to 18 minutes, 12 minutes to 16 minutes, 12 minutes to 14 minutes, 14 minutes to 20 minutes, 14 minutes to 18 minutes, 14 minutes to 16 minutes, 16 minutes to 20 minutes, 16 minutes to 18 minutes, or 18 minutes to 20 minutes.

[0031] In one or more embodiments, a portion of the particulate solid can be passed through the oxygen treatment zone 312 and returned to the reactor section 206 via line 424. In one or more embodiments, a portion of the particulate solid can be passed through the oxygen treatment zone 312 and returned to the burner 350 via line 356 and pipe 428. Pipe 428 can individually convey this portion of the particulate solid coming from the oxygen treatment zone 312 via line 356 and this portion of the particulate solid coming from the particulate solid separation section 216 via line 426 to the particulate solid distributor 100, which can be operable to individually convey the two portions of the particulate solid to the burner 350.

[0032] In one or more embodiments, at least a portion of the particulate solid can be removed from the oxygen treatment zone 312 after being passed through only a portion of the oxygen treatment zone. For example, if the oxygen treatment zone 312 exposes the particulate solid to an oxygen-containing gas for 5 minutes, a portion of the particulate solid can be removed from the oxygen treatment zone after having been exposed to the oxygen-containing gas for only 1 minute. In one or more embodiments, this portion of the particulate solid that is removed from the oxygen treatment zone 312 without being passed through the entire oxygen treatment zone 312 can be passed to the burner 350 as reactivated particulate solid ( Figure 1 not shown in

[0033] Now referring to Figure 2 , an example burner 350 that can be adapted for use with the methods described herein is schematically depicted. Figure 2 The burner 350 is shown as a fluidized fuel gas burner system for use in a dehydrogenation process. However, as will be understood by those skilled in the art, the methods described herein can be used with a variety of burner systems. The burner 350 can include a lower portion 351 that is generally cylindrical in shape and an upper portion that includes a frustum 353. The angle between the frustum 353 and an internal horizontal imaginary line drawn at the intersection of the frustum 353 and the lower portion 351 can be in the range of 10 degrees to 80 degrees. All individual values and subranges from 10 wt% to 80 wt% are included and disclosed herein; for example, the range of the angle between the tubular member and the frustum 353 member can range from a lower limit of 10 degrees, 40 degrees, or 60 degrees to an upper limit of 30 degrees, 50 degrees, 70 degrees, or 80 degrees. For example, the angle can be from 10 degrees to 80 degrees; or in an alternative, from 30 degrees to 60 degrees; or in an alternative, from 10 degrees to 50 degrees; or in an alternative, from 40 degrees to 80 degrees. Additionally, in an alternative embodiment, the angle can change continuously or discontinuously along the height of the frustum 353. In some embodiments, the burner 350 can be lined or can be unlined with refractory material.

[0034] In one or more embodiments, a supplemental fuel stream can enter the burner 350 through a supplemental fuel dispenser 354. In one or more embodiments, the supplemental fuel stream can include hydrogen, methane, ethane, propane, natural gas, or a combination thereof. In the burner 350, the supplemental fuel can react with oxygen and / or with the particulate solid. Without being bound by theory, it is believed that the combustion of the supplemental fuel in the burner 350 can heat the particulate solid. However, it is also believed that contacting the particulate solid with the supplemental fuel stream can reduce the dehydrogenation activity of the particulate solid. In addition to the combustion of the supplemental fuel, coke from the particulate solid can also burn in the burner 350, which can heat the particulate solid and also reactivate the particulate solid.

[0035] The reactivated particulate solid 104 and the deactivated particulate solid 105 (described below) can enter the combustor 350 via the particulate solid dispenser 100. The reactivated particulate solid 104 can be a portion of the particulate solid transferred from the Figure 1 oxygen treatment zone 312 to the combustor via line 356, and the deactivated particulate solid 105 can be a portion of the particulate solid transferred from the particulate solid separation section 216 to the combustor 350 via line 426. The reactivated particulate solid 104 and the deactivated particulate solid 105 can be transferred separately through the particulate solid dispenser 100 and into the combustor 350. In an embodiment, the deactivated particulate solid 104 and the reactivated particulate solid 105 are not mixed before entering the combustor 350. In one or more embodiments, the reactivated particulate solid 104 can enter the combustor 350 downstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream, and the deactivated particulate solid 105 can enter the combustor upstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream. In such embodiments, the supplemental fuel stream can contact the deactivated particulate solid 105 before any remaining (unburned) supplemental fuel can contact the reactivated particulate solid 104. Generally, if any residual supplemental fuel contacts the reactivated particulate solid 104, its concentration is much lower than when it contacts the deactivated particulate solid 105.

[0036] As Figure 2 shown, in one or more embodiments, the particulate solid dispenser 100 can extend into the combustor 350 through the bottom end of the combustor 350. In one or more embodiments, the particulate solid dispenser 100 can transfer the reactivated particulate solid 104 into the combustor 350 above the supplemental fuel dispenser 354, and can transfer the deactivated particulate solid 105 into the combustor 350 below the supplemental fuel dispenser 354.

[0037] Figure 2 A contemplated particulate solid dispenser is depicted. However, other solid dispensers may also be suitable, and the embodiments described herein should not be construed as being limited by the design, shape, size, construction, etc. of the one or more dispensers for transferring particulate solids into the combustor 350. For example, a tube dispenser as disclosed in U.S. Patent No. 9,360,759 (incorporated herein by reference in its entirety) may be suitable for use with the embodiments described herein.

[0038] As Figure 2As shown, in one or more embodiments, the granular solid dispenser 100 may include an inner conduit 200 and an outer conduit 300. The inner conduit 200 may extend from an inner conduit inlet 210 to an inner conduit outlet 220. The inner conduit 200 may be at least partially defined by an inner wall 260. The inner wall 260 may be arranged around a central axis. The outer conduit 300 may extend from an outer conduit inlet 310 to an outer conduit outlet 320. The outer conduit 300 may be at least partially defined by the inner wall 260 and an outer wall 360. The outer wall 360 may be arranged around the central axis, and the cross-section of the outer wall 360 may surround the cross-section of the inner wall 260 in a plane perpendicular to the central axis. The granular solid dispenser 100 may further include a first solid guide 240 and a second solid guide 340. In some embodiments, as Figure 2 shown, the first solid guide 240 and the second solid guide 340 may be a first deflector plate and a second deflector plate.

[0039] The reactivated granular solid 104 may be passed through the inner conduit inlet 210 into the inner conduit 200, and may pass through the inner conduit 200 and exit the inner conduit outlet 220 to reach the first solid guide 240, which may direct the reactivated granular solid 104 into the burner 350. The deactivated granular solid 105 may be passed through the outer conduit inlet 310 into the outer conduit 300, and may pass through the outer conduit 300 and exit the outer conduit outlet 320 to reach the second solid guide 340, which may direct the deactivated granular solid 105 into the burner 350.

[0040] Still referring to Figure 2, when make-up fuel enters the burner 350 via the make-up fuel dispenser 354, it contacts an oxygen-containing gas that enters the burner upstream of the make-up fuel stream via the tube 358 relative to the flow direction of the make-up fuel stream, thereby causing combustion of the make-up fuel. The burner 350 may include a grid dispenser 352 that evenly distributes the oxygen-containing gas over the surface of the grid dispenser 352. In one or more embodiments, the grid dispenser 352 is not connected to the outer wall 360 of the granular solid dispenser 100. Since the make-up fuel dispenser 354 is downstream of the tube 358, the make-up fuel entering the burner 350 contacts the oxygen-containing gas when entering the burner 350. Thus, as the make-up fuel travels upward through the burner 350 and away from the make-up fuel dispenser 354 toward the frustum 353, the concentration of the make-up fuel in the burner 350 decreases. In one or more embodiments, the concentration of the make-up fuel in the burner 350 can be lower in the region where the reactivated granular solid 104 enters the burner 350 compared to the concentration of the make-up fuel in the region where the deactivated granular solid 105 enters the burner 350. In some embodiments, greater than or equal to 80% of the make-up fuel can be burned in the region below the location where the reactivated granular solid 104 enters the burner. For example, greater than or equal to 85% of the make-up fuel can be burned before the reactivated granular solid 104 enters the burner, such as greater than or equal to 90%, greater than or equal to 95%, or even greater than or equal to 99% of the make-up fuel in the make-up fuel stream.

[0041] Without being bound by theory, it is believed that by adding the reactivated granular solid 104 to the burner 350 downstream of the make-up fuel stream relative to the flow direction of the make-up fuel stream and adding the deactivated granular solid 105 to the burner 350 upstream of the make-up fuel stream relative to the flow direction of the make-up fuel stream, the amount of specific particles of the granular solid contacting the make-up fuel can be reduced. It is believed that exposing the granular solid to the make-up fuel can reduce the dehydrogenation activity of the granular solid and can reduce the stability of the granular solid, thus shortening the lifespan of the granular solid. It is believed that the heat generated by the combustion of the make-up fuel can heat the particles of the granular solid closer to the combustion to a high enough temperature to have a negative impact on the stability of the granular solid compared to the particles of the granular solid farther from the make-up fuel combustion. Therefore, by adding the deactivated granular solid 105 to the burner at a location upstream of the reactivated granular solid 104, the deactivated granular solid 104 can be exposed to more make-up fuel combustion than the reactivated granular solid 104, such that the amount of heating of the reactivated granular solid 104 is reduced, thereby improving the stability of the reactivated granular solid 104 compared to the granular solid exposed to more make-up fuel combustion.

[0042] Without being bound by theory, it is also believed that since a portion of the reactivated particulate solid 104 can be transferred back to the combustor 350, the particles of the reactivated particulate solid 104 can cycle through the combustor 350 multiple times before being transferred to the reactor section 206. Thus, if the reactivated particulate solid 104 is transferred back to the combustor 350 at the same location or more upstream than the deactivated particulate solid 105, the particles that have undergone multiple combustion cycles can be exposed to more supplemental fuel combustion compared to the particles that have been utilized in the methods of the present disclosure. When the deactivated particulate solid 105 comes from the reactor section 206, exposing the deactivated particulate solid 105 to a supplemental fuel stream such that the concentration of the supplemental fuel is higher than that of the reactivated particulate solid 104 can reduce the amount of supplemental fuel combustion experienced by an individual particle of the particulate solid because the highest fuel concentration and thus combustion is experienced by the particles that have been transferred back to the reactor and then to the combustor rather than the particles that have been repeatedly transferred from the oxygen treatment zone 312 to the combustor.

[0043] In one or more embodiments, the deactivated particulate solid 105 transferred from the reactor section 206 to the combustor 350 can have a temperature of from 580 °C to 800 °C. For example, the deactivated particulate solid 105 transferred from the reactor section to the combustor 350 can have a temperature of from 580 °C to 775 °C, such as from 580 °C to 750 °C, from 580 °C to 725 °C, from 580 °C to 700 °C, from 580 °C to 675 °C, from 580 °C to 650 °C, from 580 °C to 625 °C, from 580 °C to 600 °C, from 600 °C to 800 °C, from 600 °C to 775 °C, from 600 °C to 750 °C, from 600 °C to 725 °C, from 600 °C to 700 °C, from 600 °C to 675 °C, from 600 °C to 650 °C, from 600 °C to 625 °C, from 625 °C to 800 °C, from 625 °C to 775 °C, from 625 °C to 750 °C, from 625 °C to 725 °C, from 625 °C to 700 °C, from 625 °C to 675 °C, from 625 °C to 650 °C, from 650 °C to 800 °C, from 650 °C to 775 °C, from 650 °C to 750 °C, from 650 °C to 725 °C, from 650 °C to 700 °C, from 650 °C to 675 °C, from 675 °C to 800 °C, from 675 °C to 775 °C, from 675 °C to 750 °C, from 675 °C to 725 °C, from 675 °C to 700 °C, from 700 °C to 800 °C, from 700 °C to 775 °C, from 700 °C to 750 °C, from 700 °C to 725 °C, from 725 °C to 800 °C, from 725 °C to 775 °C, from 725 °C to 750 °C, from 750 °C to 800 °C, from 750 °C to 775 °C, from 775 °C to 800 °C, or any combination of these ranges.

[0044] In one or more embodiments, the reactivated particulate solid 104 transferred from the oxygen treatment zone 312 to the burner 350 can have a temperature of 680 °C to 900 °C. For example, the reactivated particulate solid 104 transferred from the reactor section to the burner 350 can have a temperature of 680 °C to 875 °C, such as 680 °C to 850 °C, 680 °C to 825 °C, 680 °C to 800 °C, 680 °C to 775 °C, 680 °C to 750 °C, 680 °C to 725 °C, 680 °C to 700 °C, 700 °C to 900 °C, 700 °C to 875 °C, 700 °C to 850 °C, 700 °C to 825 °C, 700 °C to 800 °C, 700 °C to 775 °C, 700 °C to 750 °C, 700 °C to 725 °C, 725 °C to 900 °C, 725 °C to 875 °C, 725 °C to 850 °C, 725 °C to 825 °C, 725 °C to 800 °C, 725 °C to 775 °C, 725 °C to 750 °C, 750 °C to 900 °C, 750 °C to 875 °C, 750 °C to 850 °C, 750 °C to 825 °C, 750 °C to 800 °C, 750 °C to 775 °C, 775 °C to 900 °C, 775 °C to 875 °C, 775 °C to 850 °C, 775 °C to 825 °C, 775 °C to 800 °C, 800 °C to 900 °C, 800 °C to 875 °C, 800 °C to 850 °C, 800 °C to 825 °C, 825 °C to 900 °C, 825 °C to 875 °C, 825 °C to 850 °C, 850 °C to 900 °C, 850 °C to 875 °C, 875 °C to 900 °C, or any combination of these ranges.

[0045] Combustion of the supplemental fuel can heat the particulate solid. It is believed that because heat transfer from one particle of the particulate solid to another particle of the particulate solid is rapid, the heat obtained by combustion of the supplemental fuel can be transferred throughout the mass of the particulate solid in the burner without each particle of the particulate solid being close to the combustion of the supplemental fuel. This can allow only a portion of the particulate solid to be directly exposed to the heat of the supplemental fuel combustion while still heating the total mass of the particulate solid for the dehydrogenation reaction. Additionally, when two portions of particulate solid enter the burner 350, the reactivated particulate solid 104 may be hotter than the deactivated particulate solid 105, which means that it may be desirable to heat the deactivated particulate solid 105 more than the reactivated particulate solid 104. Thus, initially exposing the deactivated particulate solid 105 to the supplemental fuel stream can allow more fuel combustion to occur near the deactivated particulate solid 105 than near the reactivated particulate solid 104, thereby heating the deactivated particulate solid 105 more than the reactivated particulate solid 104.

[0046] Without being bound by theory, it is believed that by introducing the deactivated particulate solid 105 upstream of the make-up fuel stream into the combustor 350, the deactivated particulate solid 105 may have a longer residence time in the combustor 350 than if it were introduced downstream of the make-up fuel stream. This increased residence time in the combustor 350 can allow for a greater portion of the coke to be removed from the deactivated particulate solid 105 compared to a lower residence time in the combustor. It may be desirable to remove as much of the coke formed on the deactivated particulate solid 105 in the reactor section 206 as possible to reactivate the deactivated particulate solid 105, and a longer residence time in the combustor 350 can remove more coke compared to a shorter residence time in the combustor 350.

[0047] As described herein, in one or more embodiments, the oxygen-containing gas can enter the combustor 350 through line 358 and the lower gas distribution plate 352. In some embodiments, the oxygen in the oxygen-containing gas can react with the coke formed on the particulate solid, which can remove at least a portion of the coke from the particulate solid.

[0048] In a non-limiting example, the reactor system 103 described herein can be used to produce olefinic compounds from a hydrocarbon feed stream. As used herein, the term "olefinic compound" refers to a hydrocarbon having one or more carbon-carbon double bonds other than the formal double bonds in aromatic compounds. For example, ethylene and styrene are olefinic compounds, but ethylbenzene is not an olefinic compound because the only double bond present in ethylbenzene is a formal double bond that is part of an aromatic structure. Olefinic compounds can be produced from various hydrocarbon feed streams using different reaction mechanisms. For example, olefinic compounds can be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefins reactions. These reaction types can use different feed streams and different particulate solid catalysts to produce olefinic compounds. It should be understood that when "catalyst" is referred to herein, these catalysts can equally refer to the particulate solid catalysts mentioned with respect to Figure 1 the systems mentioned.

[0049] According to one or more embodiments, the reaction can be a dehydrogenation reaction. According to such embodiments, one or more hydrocarbons can be a hydrocarbon feed stream, which can include one or more of ethylbenzene, ethane, propane, n-butane, and isobutane. In one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of ethylbenzene. In one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of ethane. In additional embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of propane. In additional embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of n-butane. In additional embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of isobutane. In additional embodiments, the hydrocarbon feed stream can contain at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of the sum of ethylbenzene, ethane, propane, n-butane, and isobutane.

[0050] In one or more embodiments, the dehydrogenation reaction can utilize gallium and / or platinum particulate solids as catalysts. In such embodiments, the particulate solids can include gallium and / or platinum catalysts. As described herein, the gallium and / or platinum catalysts contain gallium, platinum, or both. The gallium and / or platinum catalysts can be supported on an alumina or alumina-silica support and can optionally contain potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Patent No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts can be utilized for the dehydrogenation reaction.

[0051] In one or more embodiments, the reaction mechanism can be dehydrogenation followed by combustion (in the same chamber). In such embodiments, the dehydrogenation reaction can produce hydrogen as a byproduct, and the oxygen carrier material can contact the hydrogen and promote its combustion to form water. Examples of such reaction mechanisms are disclosed in WO 2020 / 046978 and U.S. Patent Publication No. 2021 / 0292259, which are considered to be possible reaction mechanisms for the systems and methods described herein, and the teachings of these documents are incorporated herein by reference in their entirety.

[0052] In one or more embodiments, the particulate solid catalyst can comprise an oxygen carrier material and a dehydrogenation catalyst material. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst material can be separate particles of the particulate solid. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst can be comprised within the same particle of the particulate solid.

[0053] In some embodiments, the particulate solid catalyst can comprise a “dual-use material” that can serve as both a dehydrogenation catalyst and an oxygen carrier material. It should be understood that in at least the embodiments where the oxygen carrier material and the dehydrogenation catalyst described herein are used in the same reaction vessel (such as Figure 1 the reaction vessel), this dual-use material can be used in place of or in combination with the particulate solid oxygen carrier material and the particulate solid dehydrogenation catalyst.

[0054] In one or more embodiments, an olefinic compound can be present in a “product stream” sometimes referred to as an “olefin-containing effluent”. This stream exits Figure 1The reactor system can then be processed. In one or more embodiments, the olefinic compound can include one or more of ethylene, propylene, butene, or styrene. The term butene includes any butene isomer, such as α-butene, cis-β-butene, trans-β-butene, and isobutene. In some embodiments, the olefin-containing effluent can contain at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% ethylene. In additional embodiments, the olefin-containing effluent can contain at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% propylene. In additional embodiments, the olefin-containing effluent can contain at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% butene. In additional embodiments, the olefin-containing effluent can contain at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% styrene. In additional embodiments, the olefin-containing effluent can contain at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% of the sum of one or more of ethylene, propylene, butene, and styrene. The olefin-containing effluent can also contain unreacted components of the feed stream and other reaction products that are not considered light olefins. The olefinic compound can be separated from the unreacted components in a subsequent separation step.

[0055] In a first aspect of the present disclosure, a method for producing an olefinic compound can include contacting a feed stream comprising one or more hydrocarbons with a particulate solid catalyst in a reactor. In the reactor, the one or more hydrocarbons can be dehydrogenated to form one or more products comprising one or more olefinic compounds, and at least a portion of the particulate solid catalyst can be deactivated. The method can also include transferring at least a portion of the deactivated particulate solid catalyst to a combustor. In the combustor, a supplemental fuel stream can enter the combustor through a supplemental fuel distributor, and the supplemental fuel stream can react to heat at least a portion of the deactivated particulate solid catalyst. The method can also include transferring at least a portion of the heated deactivated particulate solid catalyst to an oxygen treatment zone to produce a reactivated particulate solid catalyst. The method can also include transferring at least a portion of the reactivated particulate solid catalyst back to the combustor. In the combustor, the reactivated particulate solid catalyst can enter the combustor downstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream, and the deactivated particulate solid catalyst can enter the combustor upstream of the supplemental fuel stream with respect to the flow direction of the supplemental fuel stream. The method can also include transferring at least a portion of the reactivated particulate solid catalyst to the reactor.

[0056] The second aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the reactivated particulate solid catalyst and the deactivated particulate solid catalyst are delivered to the combustor via a particulate solid dispenser that delivers the reactivated particulate solid catalyst and the deactivated particulate solid catalyst separately into the combustor.

[0057] The third aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the particulate solid dispenser extends into the reactor through the bottom end of the reactor.

[0058] The fourth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the particulate solid dispenser delivers the reactivated particulate solid catalyst into the combustor above the supplementary fuel dispenser and delivers the deactivated particulate solid catalyst into the combustor below the supplementary fuel dispenser.

[0059] The fifth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the combustor operates as a fast fluidized bed, a turbulent bed, or a bubbling bed.

[0060] The sixth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the temperature of the deactivated particulate solid catalyst delivered to the combustor is from 580 °C to 800 °C.

[0061] The seventh aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the temperature of the reactivated particulate solid catalyst delivered to the combustor is from 680 °C to 900 °C.

[0062] The eighth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the deactivated catalyst heated in the oxygen treatment zone is exposed to an oxygen-containing gas.

[0063] The ninth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the heated deactivated particulate solid catalyst is exposed to the oxygen-containing gas for 30 seconds to 20 minutes.

[0064] The tenth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the particulate solid catalyst comprises one or both of a dehydrogenation catalyst material and an oxygen carrier material.

[0065] The eleventh aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the dehydrogenation catalyst material and the oxygen carrier material are contained in the same particles of the particulate solid catalyst.

[0066] The twelfth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the supplementary fuel stream comprises hydrogen, methane, ethane, propane, natural gas, or a combination thereof.

[0067] The thirteenth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein coke is formed on a deactivated particulate solid catalyst in a reactor, and at least a portion of the coke on the deactivated particulate solid catalyst reacts in a burner.

[0068] The fourteenth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the particulate solid catalyst is a Geldart A or Geldart B particle.

[0069] The fifteenth aspect of the present disclosure includes any of the foregoing aspects or combinations of aspects, wherein the one or more hydrocarbons comprise propane and the one or more olefinic compounds comprise propylene.

[0070] It will be apparent to those skilled in the art that various modifications and variations can be made to the technology disclosed in this invention without departing from the essence and scope of the technology. Since those skilled in the art can make modifications, combinations, sub - combinations, and variations of the disclosed embodiments that incorporate the spirit and essence of the technology disclosed in this invention, this technology should be construed to include all things within the scope of the appended claims and their equivalents. Additionally, although some aspects of the present disclosure may be identified herein as preferred or particularly advantageous, upon consideration, the present disclosure is not limited to these aspects.

[0071] It should be noted that the various details described in this disclosure should not be taken to imply that these details relate to elements that are essential components of each of the embodiments described in this disclosure, even in cases where a particular element is shown in each of the figures attached to this specification. Unless so expressly stated, none of the features disclosed and described herein should be construed as "essential". The contemplated embodiments of this technology include those that include some or all of the features of the appended claims.

[0072] For the purposes of describing and defining the present disclosure, it should be noted that the term "about" is used in this disclosure to represent the inherent uncertainty that can be attributed to any quantitative comparison, value, measurement, or other representation. The term "about" is also utilized in this disclosure to represent the degree to which a quantitative representation can vary from a specified reference without causing a fundamental change in the basic function of the subject matter of concern.

[0073] In relevant cases, where a composition is described as "comprising" one or more elements, embodiments of the composition "consisting of" or "consisting essentially of" those one or more elements are contemplated herein.

[0074] It should be understood that, in some embodiments, the composition range of chemical components in a stream or reactor should be understood to contain a mixture of isomers of the component. For example, a specified composition range of butene can include a mixture of various isomers of butene. It should be understood that the examples provide composition ranges of various streams, and the total amount of isomers of a specific chemical composition can constitute a range.

[0075] It should be noted that one or more of the following claims and detailed description utilize the terms "where" or "wherein" as transitional phrases. For the purpose of defining the present technology, it should be noted that this term is introduced in the claims as an open transitional phrase, which is used to introduce a recitation of a series of characteristics of a structure and should be interpreted in a manner similar to the more commonly used open preamble term "comprising".

[0076] It should be understood that any two quantitative values assigned to a characteristic can constitute a range of that characteristic, and all combinations of ranges formed by all the recited quantitative values of a given characteristic are contemplated in the present disclosure. In cases where multiple ranges of quantitative values are provided, these ranges can be combined to form a broader range, which is contemplated in the embodiments described herein.

[0077] As understood in the context of the terms used herein, the term "transfer" can include directly transferring a substance between two parts of the disclosed system and, in some cases, means indirectly transferring a substance between two parts of the disclosed system. For example, indirect transfer can include steps in which the substance is transferred through intermediate operating units, valves, sensors, etc.

Claims

1. A method for producing an olefin compound, the method comprising: Contact a feed stream comprising one or more hydrocarbons with a particulate solid catalyst in a reactor, wherein in the reactor: The one or more hydrocarbons are dehydrogenated to form one or more products comprising one or more olefinic compounds; and At least a portion of the particulate solid catalyst is deactivated; Transfer at least a portion of the deactivated particulate solid catalyst to a burner, wherein in the burner: A make-up fuel stream enters the burner through a make-up fuel distributor; and The make-up fuel stream is combusted to heat at least a portion of the particulate solid catalyst; Transfer at least a portion of the heated deactivated particulate solid catalyst to an oxygen treatment zone to produce a reactivated particulate solid catalyst; Transfer at least a portion of the reactivated particulate solid catalyst back to the burner, wherein the reactivated particulate solid catalyst enters the burner downstream of the make-up fuel stream with respect to the flow direction of the make-up fuel stream, and the deactivated particulate solid catalyst enters the burner upstream of the make-up fuel stream with respect to the flow direction of the make-up fuel stream; And Transfer at least a portion of the reactivated particulate solid catalyst to the reactor.

2. The method according to claim 1, wherein the reactivated particulate solid catalyst and the deactivated particulate solid catalyst are transferred to the burner through a particulate solid distributor, and the particulate solid distributor transfers the reactivated particulate solid catalyst and the deactivated particulate solid catalyst separately into the burner.

3. The method according to claim 2, wherein the particulate solid distributor extends into the burner through the bottom end of the burner.

4. The method according to claim 3, wherein the particulate solid distributor transfers the reactivated particulate solid catalyst into the burner above the supplementary fuel distributor and transfers the deactivated particulate solid catalyst into the burner below the supplementary fuel distributor.

5. The method according to any one of the preceding claims, wherein the burner operates as a fast fluidized bed, a turbulent bed or a bubbling bed.

6. The method according to any one of the preceding claims, wherein the temperature of the deactivated particulate solid catalyst transferred to the burner is 580 °C to 800 °C.

7. The method according to any one of the preceding claims, wherein the temperature of the reactivated particulate solid catalyst transferred to the burner is 680 °C to 900 °C.

8. The method according to any one of the preceding claims, wherein in the oxygen treatment zone, the heated deactivated particulate solid catalyst is exposed to an oxygen-containing gas.

9. The method according to claim 8, wherein the heated deactivated particulate solid catalyst is exposed to the oxygen-containing gas for 30 seconds to 20 minutes.

10. The method according to any one of the preceding claims, wherein the particulate solid catalyst comprises one or both of a dehydrogenation catalyst material and an oxygen carrier material.

11. The method according to claim 10, wherein the dehydrogenation catalyst material and the oxygen carrier material are included in the same particles of the particulate solid catalyst.

12. The method according to any one of the preceding claims, wherein the supplementary fuel stream comprises hydrogen, methane, ethane, propane, natural gas or a combination thereof.

13. The method according to any one of the preceding claims, wherein coke is formed on the deactivated particulate solid catalyst in the reactor, and at least a portion of the coke on the deactivated particulate solid catalyst reacts in the burner.

14. The method according to any one of the preceding claims, wherein the particulate solid catalyst is Geldart A or Geldart B particles.

15. The method according to any one of the preceding claims, wherein the one or more hydrocarbons comprise propane and the one or more olefinic compounds comprise propylene.

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