Fixed bed reactor and process for alcohol dehydration

Abstract

The present disclosure provides a process for converting an alcohol to an olefin. The method includes passing a first fluid comprising the alcohol through a plurality of reactors. Each reactor includes a catalyst bed. During a catalyst operation cycle of at least one reactor of the plurality of reactors, a corresponding catalyst bed includes a catalytically active zone that is at least 90% of the catalyst bed. In addition, the present disclosure provides a system for converting an alcohol to an olefin.

Description

Background Technology

[0001] Ethylene can be produced by dehydrating ethanol using a fixed-bed reactor. While offering good conversion and selectivity, the reactor may not provide efficient catalyst utilization due to the presence of idle layers in the catalyst bed that are not involved in the dehydration process. These idle layers often operate at lower temperatures, leading to increased production of byproducts such as ethane.

[0002] These empty layers can also lead to an increase in pressure drop. Pressure drop can be closely related to the size of the compressor following the reaction and condensation sections. A higher pressure drop in the reactor may mean that once the system is pressurized in the vaporization section and pressure is lost along the equipment and piping until the feed reaches the compressor, the feed can be sent to the compressor suction port at a lower pressure. Suction pressure can be an important factor because, for the same purification process, once the discharge pressure is fixed, the compressor size and compression rate can be calculated based on this pressure. Therefore, a higher pressure drop may result in a lower suction pressure, which may require a higher number of compression stages to reach the compressed pressure. A higher number of compression stages may result in higher capital and operating expenditures.

[0003] US 2013 / 0178674 A1 discloses a reactor design, configuration, and process for the catalytic dehydration of ethanol to ethylene.

[0004] WO 2021 / 247563 A1 discloses a trickle bed reactor comprising multiple catalyst beds connected in series, with the catalyst mass gradually increasing from upstream to downstream.

[0005] Smaller reactors are still needed by eliminating the idle layer and thus reducing the bed height. There is also a need in the art to reduce the consumption of catalyst, medium-pressure steam, and / or power. Summary of the Invention

[0006] In one aspect, this disclosure provides a method for converting an alcohol to an olefin. The method includes passing a first fluid containing an alcohol through a plurality of reactors, each reactor comprising a catalyst bed. During a catalyst campaign of at least one of the plurality of reactors, the corresponding catalyst bed comprises a catalytically active zone, which is at least 90% of the catalyst bed. In one embodiment, the catalytically active zone may be 100% of the catalyst bed during the catalyst campaign. In one embodiment, at least one catalyst bed may further comprise an idle catalyst zone, which may be less than 10% of the catalyst bed during the catalyst campaign. In one embodiment, at least one catalyst bed may not include an idle catalyst zone during the catalyst campaign. In one embodiment, the catalytically active zone may be 280 C to 500 It operates at a temperature of C. In one embodiment, the catalytic active region can be 360°C. C to 470 The system operates at a temperature of C. In one embodiment, the alcohol may comprise at least one of C2, C3, and C4 alcohols. In one embodiment, the olefin may comprise an olefin having the same number of carbon atoms as the alcohol. In one embodiment, the olefin may comprise ethylene, and the catalytically active region may be 360°. C to 470 It operates at a temperature of C.

[0007] In one embodiment, the method may further include contacting the first fluid with a second fluid comprising steam before contacting the first fluid with a plurality of reactors, wherein the ratio of steam to alcohol may be from 1:1 to 3:1; obtaining a third fluid from at least one of the plurality of reactors, wherein the third fluid contains alcohol at a concentration lower than that of the alcohol in the first fluid; contacting the third fluid with the first fluid before contacting the third fluid with another of the plurality of reactors; and obtaining a fourth fluid from the ends of the plurality of reactors, the fourth fluid comprising olefins and alkanes having the same number of carbon atoms. In one embodiment, the amount of olefins in the fourth fluid may be at least 1,000 ppm greater than the amount of alkanes on a molar basis. In one embodiment, the amount of alkanes in the fourth fluid may be 2,500 ppm or less.

[0008] In one embodiment, the method may further include pressurizing a fourth fluid using a primary compressor connected to the ends of multiple reactors. In another embodiment, the method may exclude pressurizing the fourth fluid using a multi-stage compressor.

[0009] In one implementation, the method may also include more than 280 The first fluid is fed into at least one of the multiple reactors at a temperature of C.

[0010] In one embodiment, the multiple reactors may be arranged in a series-parallel configuration. In one embodiment, at least one of the multiple reactors has a weight hourly space velocity (WHSV) of alcohol greater than 0.6 / h and at most 1.5 / h. In one embodiment, at least one of the multiple reactors has a WHSV of alcohol greater than 1 / h and at most 1.3 / h.

[0011] In one embodiment, the plurality of reactors may include: a first group of reactors comprising reactors each having a first height; and a second group of reactors comprising reactors each having a second height, wherein the first height may differ from the second height. In one embodiment, the plurality of reactors may sequentially include: a first reactor comprising a first catalyst bed; a second reactor comprising a second catalyst bed; a third reactor comprising a third catalyst bed; and a fourth reactor comprising a fourth catalyst bed. In one embodiment, the plurality of reactors may further include a fifth reactor after the fourth reactor, the fifth reactor comprising a fifth catalyst bed. In one embodiment, the variance (difference) between the heights of each reactor in the plurality of reactors may not exceed 15%. In one embodiment, the variance (difference) between the heights of each reactor in the plurality of reactors may not exceed 10%. In one embodiment, each reactor in the plurality of reactors may independently have a height of 2.5 m to 4.0 m. In one embodiment, the first reactor may have a height of 2.8 m to 3.1 m. In one embodiment, the third reactor may have a height of 3.2 m to 3.5 m. In one embodiment, the first reactor and the second reactor may have the same height. In one embodiment, the remaining reactors may have a different height than the first and second reactors. In one embodiment, each of the third and fourth reactors may have a height 10% to 50% greater than the height of the first reactor. In one embodiment, the fifth reactor may have a height 10% to 50% greater than the height of the first reactor. In one embodiment, the third to fifth reactors may have the same height. In one embodiment, the fourth and fifth reactors may have the same volume. In one embodiment, the volume of each of the first to fourth reactors may increase from the first to the fourth reactor.

[0012] In one embodiment, the variance (difference) between the heights of each catalyst bed in the catalyst bed may not exceed 15%. In one embodiment, each catalyst bed in the catalyst bed may independently have a height of 2.0 m to 2.8 m. In one embodiment, the first catalyst bed may have a height of 2.0 m to 2.2 m. In one embodiment, the third catalyst bed may have a height of 2.3 m to 2.6 m. In one embodiment, the first and second catalyst beds may have the same height. In one embodiment, the third and fourth catalyst beds may have different heights than the first and second catalyst beds. In one embodiment, each of the third and fourth catalyst beds may have a height 10% to 50% greater than the height of the first catalyst bed. In one embodiment, the fifth catalyst bed may have a height 10% to 50% greater than the height of the first catalyst bed. In one embodiment, the fourth and fifth catalyst beds may have the same height. In one embodiment, the fourth and fifth catalyst beds may have the same volume. In one embodiment, the volume of the catalyst beds may increase from the first catalyst bed to the fourth catalyst bed.

[0013] In one embodiment, at least one of a plurality of reactors may be fluidly coupled to a furnace to form a furnace-reactor coupling unit. In one embodiment, the method may further include passing a first fluid through the furnace before the first fluid enters a reactor in the same furnace-reactor coupling unit. In one embodiment, the furnace-reactor coupling unit may include a single furnace and a single reactor. In one embodiment, a plurality of furnace-reactor coupling units may exist, and each furnace-reactor coupling unit in the furnace-reactor coupling unit may be fluidly coupled to each other. In one embodiment, at least one of the plurality of furnace-reactor coupling units may be a standby furnace-reactor coupling unit. In one embodiment, the standby furnace-reactor coupling unit may include a reactor that may have the same height and / or volume as another reactor in another furnace-reactor coupling unit in the plurality of furnace-reactor coupling units. In one embodiment, the standby furnace-reactor coupling unit may include a reactor that may have the same height and / or volume as another reactor in another furnace-reactor coupling unit immediately preceding the standby furnace-reactor coupling unit. In one embodiment, the plurality of furnace-reactor coupling units may include five furnace-reactor coupling units. In one embodiment, only one of the five furnace-reactor coupling units in the furnace-reactor coupling unit may be a standby furnace-reactor coupling unit. In one embodiment, the standby furnace-reactor coupling unit may be configured to be standby for any other furnace-reactor coupling unit in the plurality of furnace-reactor coupling units. In one embodiment, the standby furnace-reactor coupling unit may be the last furnace-reactor coupling unit in the plurality of furnace-reactor coupling units. In one embodiment, the reactor in the standby furnace-reactor coupling unit may have the largest height and / or volume among the reactors in the plurality of furnace-reactor coupling units. In one embodiment, all furnace-reactor coupling units in the plurality of furnace-reactor coupling units may operate together at 60% to 80% capacity.

[0014] In one implementation, the catalyst operating cycle may be between five and seven months. In another implementation, the catalyst operating cycle may be six months.

[0015] In one embodiment, the method may further include, after a catalyst operating cycle, decoupling at least one of the plurality of furnace-reactor coupling units from the remaining furnace-reactor coupling units, and regenerating the catalyst bed or replacing the catalyst bed in at least one decoupled furnace-reactor coupling unit. In one embodiment, decoupling may occur immediately after a catalyst operating cycle. In one embodiment, the remaining furnace-reactor coupling units may operate together at 100% capacity.

[0016] In one aspect, this disclosure provides a system comprising a plurality of reactors, each reactor including a catalyst bed configured to convert an alcohol to an olefin. The plurality of reactors are fluidly coupled to each other, and at least one of the catalyst beds is configured to have a catalytically active zone that is at least 90% of the catalyst bed during a catalyst operating cycle. In one embodiment, the catalytically active zone may be 100% of the catalyst bed during a catalyst operating cycle. In one embodiment, at least one of the catalyst beds may further include an idle catalyst zone that is less than 10% of the catalyst bed during a catalyst operating cycle. In one embodiment, at least one of the catalyst beds may not include an idle catalyst zone during a catalyst operating cycle. In one embodiment, the alcohol may include at least one of a C2 alcohol, a C3 alcohol, and a C4 alcohol. In one embodiment, the olefin may include ethylene.

[0017] In one embodiment, the multiple reactors may be arranged in a series-parallel configuration. In one embodiment, at least one of the multiple reactors has a weight hourly space velocity (WHSV) of alcohol greater than 0.6 / h and at most 1.5 / h. In one embodiment, at least one of the multiple reactors has a WHSV of alcohol greater than 1 / h and at most 1.3 / h.

[0018] In one embodiment, the plurality of reactors may include: a first group of reactors comprising reactors each having a first height; and a second group of reactors comprising reactors each having a second height, wherein the first height may differ from the second height. In one embodiment, the plurality of reactors may sequentially include: a first reactor comprising a first catalyst bed; a second reactor comprising a second catalyst bed; a third reactor comprising a third catalyst bed; and a fourth reactor comprising a fourth catalyst bed. In one embodiment, the plurality of reactors may further include a fifth reactor after the fourth reactor, the fifth reactor comprising a fifth catalyst bed. In one embodiment, the variance (difference) between the heights of each reactor in the plurality of reactors may not exceed 15%. In one embodiment, the variance (difference) between the heights of each reactor in the plurality of reactors may not exceed 10%. In one embodiment, each of the third and fourth reactors may have a height 10% to 50% greater than the height of the first reactor. In one embodiment, the fifth reactor may have a height 10% to 50% greater than the height of the first reactor. In one embodiment, the third through fifth reactors may have the same height. In one embodiment, the fourth and fifth reactors may have the same volume. In one embodiment, the volume of each of the first to fourth reactors can be increased from the first to the fourth reactor.

[0019] In one embodiment, the variance (difference) in the height of each catalyst bed may not exceed 15%. In one embodiment, each of the third and fourth catalyst beds may have a height 10% to 50% greater than the height of the first catalyst bed. In one embodiment, the fifth catalyst bed may have a height 10% to 50% greater than the height of the first catalyst bed. In one embodiment, the fourth and fifth catalyst beds may have the same height. In one embodiment, the fourth and fifth catalyst beds may have the same volume. In one embodiment, the volume of the catalyst beds may increase from the first catalyst bed to the fourth catalyst bed.

[0020] In one embodiment, at least one of a plurality of reactors may be fluidly coupled to a furnace to form a furnace-reactor coupling unit. In one embodiment, a plurality of furnace-reactor coupling units may exist, and each furnace-reactor coupling unit in the furnace-reactor coupling unit may be fluidly coupled to each other. In one embodiment, at least one of the plurality of furnace-reactor coupling units may be a standby furnace-reactor coupling unit. In one embodiment, a standby furnace-reactor coupling unit may include a reactor that may have the same height and / or volume as another reactor in another furnace-reactor coupling unit in the plurality of furnace-reactor coupling units. In one embodiment, a standby furnace-reactor coupling unit may include a reactor that may have the same height and / or volume as another reactor in another furnace-reactor coupling unit immediately preceding the standby furnace-reactor coupling unit. In one embodiment, the plurality of furnace-reactor coupling units may include five furnace-reactor coupling units. In one embodiment, only one of the five furnace-reactor coupling units in the furnace-reactor coupling unit may be a standby furnace-reactor coupling unit. In one embodiment, the standby furnace-reactor coupling unit may be configured to be standby for any other furnace-reactor coupling unit among the plurality of furnace-reactor coupling units. In one embodiment, the standby furnace-reactor coupling unit may be the last furnace-reactor coupling unit among the plurality of furnace-reactor coupling units. In one embodiment, the reactor in the standby furnace-reactor coupling unit may have the largest height and / or volume among the reactors in the plurality of furnace-reactor coupling units. Attached Figure Description

[0021] The foregoing summary of the invention and the following detailed description of the present disclosure will be better understood when read in conjunction with the accompanying drawings. However, it should be understood that the present disclosure is not limited to the exact arrangements, examples, and means shown.

[0022] Figure 1 It is a diagram showing the reaction front moving downwards as the reaction progresses.

[0023] Figure 2 This is a diagram showing the minimum reaction front section and buffer section in the catalyst bed of the reactor in the comparative process.

[0024] Figure 3 This is a diagram showing catalyst use along the bed (left) and catalyst selectivity in the layers (right). Figure 3 The bottom layer is shown as a possible way to not use a catalyst (especially an idle catalyst), and the selectivity in each layer.

[0025] Figure 4 This is a diagram illustrating a furnace-reactor coupling unit in a process according to an embodiment of the present disclosure.

[0026] Figure 5 This illustrates a scheme for the arrangement of reactors used in the ethanol dehydration process in a comparative process.

[0027] Figure 6 It is a graph showing how the temperature distribution changes over time.

[0028] Figure 7 It is a graph showing a comparison between the pressure curves in the comparative process and the process according to an embodiment of the present disclosure.

[0029] Figure 8 This is a graph showing the changes in ethane concentration (ppm) and yield (%) during the catalyst operating cycle. Detailed Implementation

[0030] This disclosure provides a method for converting alcohols to olefins using a smaller reactor by reducing the amount of idle catalyst bed and thus lowering the catalyst bed height. Not wishing to be bound by theory, it is believed that lowering the catalyst bed height improves selectivity due to lower byproduct formation and also reduces the pressure drop along the catalyst bed, which is considered advantageous for smaller compressor sizes. To calculate the catalyst bed height, the relevant concept is the reaction front segment. The reaction front is defined as the location along the catalyst bed where most of the chemical reaction occurs at a given time. As the reaction progresses, the reaction front slowly moves downwards, such as... Figure 1 As shown in the diagram. Theoretically, the reaction front should reach the bottom of the reactor at the end of the catalyst run cycle. After this, the catalyst will be regenerated, and a new catalyst run cycle will begin.

[0031] Figure 2 The minimum reaction front section of the catalytic bed is shown. The buffer section is the available distance the reaction front travels during a catalyst run. For reactor designs in comparative processes with an idle layer, the reaction front may never reach the bottom of the reactor. The reaction front may only travel half the length of the catalytic bed. This could be due to excessive byproduct formation, potentially requiring catalyst regeneration before the reaction front reaches the bottom. One possible cause of byproduct formation is the temperature in the buffer section (e.g., below the dehydration temperature). Early catalyst regeneration can indicate an over-designed bed height. An over-designed reactor can provide a buffer section longer than it should, and therefore byproduct formation is higher than it could potentially occur. A long bed height can lead to low temperatures in the idle catalyst layer within the buffer section, which can result in unwanted byproduct formation. This can reduce overall yield and selectivity. The desired bed height can be longer than the minimum reaction front section but shorter than the bed height in the reactor of the comparative process.

[0032] In one embodiment, the smaller reactor can be operated with the same amount of layer as used in the reaction front of a comparative system, and byproduct problems can be reduced. This feature can increase selectivity and reduce pressure drop in each reactor, making the use of a smaller booster compressor practically feasible. In one embodiment, the disclosed method for dehydrating alcohols and industrially important products can be cost-effective and / or energy-effective. In one embodiment, the alcohol dehydration method can be made cost-effective by using a smaller reactor and reducing catalyst consumption. In one embodiment, a single-stage compressor is used instead of a multi-stage compressor (…). For example The separation method can be made more energy-efficient by using a three-stage compressor to reduce power consumption. This disclosure also provides a system for converting alcohols to olefins.

[0033] As used herein, the term "catalyst run-through" is intended to refer to the period of time during which a particular reactor is running. During this run-through, alcohols are dehydrated to form olefins. "Catalyst run-through" refers to the period between catalyst regenerations and excludes the period of spent catalyst regeneration.

[0034] As used herein, the term “catalyst bed” is intended to refer to a layer of catalyst inside a single reactor and consists of the catalyst itself excluding inert materials.

[0035] As used herein, the term "catalytically active zone" is intended to refer to the region in the catalyst bed where the catalytic dehydration of alcohols occurs at any time during the catalyst's operating cycle.

[0036] As used herein, the term "idle catalyst zone" is intended to refer to the area in the catalyst bed where catalytic dehydration of alcohols has never occurred during the catalyst operating cycle.

[0037] The boundary between the catalytically active zone and the idle catalyst zone during the catalyst operating cycle can be determined by, for example, the temperature measured by a temperature sensor that is in direct thermal contact with the catalyst bed.

[0038] As used herein, the term "catalyst" is intended to mean, as understood by those skilled in the art, a catalyst suitable for the dehydration of alcohols, including but not limited to alumina (…). For example γ-Al2O3), silica-alumina, zeolite ( For example (HZSM-5), metal oxides, or supported phosphoric acid and phosphates. The catalyst can be in solid form (…). For example (pills, powders or granules).

[0039] As used herein, the term “catalyst cycle” is intended to refer to the lifespan of the catalyst within the reactor and from a new catalyst state until the catalyst is replaced.

[0040] As used herein, the term “C2 alcohol” is intended to refer to ethanol having the general formula CH3CH2OH (CAS No.: 64-17-5).

[0041] As used herein, the term “C3 alcohol” is intended to cover n-propanol having the general formula CH3CH2CH2OH (CAS No.: 71-23-8) and / or isopropanol having the general formula (CH3)2CHOH (CAS No.: 67-63-0).

[0042] As used herein, the term "C4 alcohol" is intended to encompass n-butanol having the general formula CH3CH2CH2CH2OH (CAS No.: 71-36-3) and C4 alcohol having the general formula CH3CH2CH(OH)CH3 (CAS No.: 78-92-2). Zhong Butanol, isobutanol having the general formula CH3CH(CH3)CH2OH (CAS No.: 78-83-1), and isobutanol having the general formula (CH3)3COH (CAS No.: 75-65-0). Uncle Butanol.

[0043] As used herein, the term “C2 olefin” is intended to refer to ethylene having the general formula CH2=CH2 (CAS number: 74-85-1).

[0044] As used herein, the term “C3 olefin” is intended to cover propylene having the general formula CH2=CHCH3 (CAS No.: 115-07-1).

[0045] As used herein, the term “C4 olefin” is intended to cover 1-butene having the general formula CH3CH2CH=CH2 (CAS No.: 106-98-9), cis-2-butene having the general formula CH3CH=CHCH3 (CAS No.: 590-18-1), trans-2-butene having the general formula CH3CH=CHCH3 (CAS No.: 624-64-6), and isobutene having the general formula (CH3)2C=CH2 (CAS No.: 115-11-7).

[0046] As used herein, the term “weight time space velocity” or “WHSV” is intended to refer to the velocity per mass of catalyst bed (WHSV). For example The specific mass flow rate of the alcohol in the catalyst (kg). The specific mass flow rate of the alcohol can be measured by methods known to those skilled in the art.

[0047] As used in this article, the term “regenerated catalyst bed” is intended to refer to the process used to restore the catalytic activity of spent catalysts.

[0048] As used in this article, the term "catalyst bed replacement" is intended to refer to the process of replacing spent catalyst with fresh catalyst.

[0049] As used herein, the term “capacity” in the furnace-reactor coupling unit is intended to mean Vo / V, where Vo represents the mass flow rate of alcohol entering the reactor and V represents the volume of the reactor itself.

[0050] Unless otherwise defined herein, all technical and scientific terms used herein shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Jonathan Law et al. The Oxford Dictionary of Chemistry, Oxford University Press, Oxford (2020) and Carl Schaschke, Oxford Dictionary of Chemical Engineering, Oxford University Press, Oxford (2014) provide general dictionaries for those skilled in the art of the art of the use of many terms used in this disclosure.

[0051] While this disclosure can be implemented in various forms, the description of several embodiments below is done under the understanding that this disclosure will be regarded as illustrative of this disclosure and is not intended to limit this disclosure to the specific embodiments shown. Headings are provided for convenience only and should not be construed as limiting this disclosure in any way. Embodiments illustrated under any heading may be combined with embodiments illustrated under any other heading.

[0052] Unless otherwise expressly stated, the use of numerical values ​​in the various quantitative values ​​specified in this application is described as approximations, as the minimum and maximum values ​​within the stated range are preceded by the word "about". The terms "about" or "approximately" used when referring to numbers or ranges of values ​​mean that the mentioned number or range of values ​​is an approximation within experimental variability (or within statistical experimental error), and therefore in some cases, the number or range of values ​​will vary between 1% and 15% of the stated number or range of values. Therefore, unless otherwise indicated, the numerical parameters set forth in the specification and appended claims are approximations that may vary according to the desired properties sought to be obtained in this disclosure. At least, and without attempt to limit the application of the doctrine of equivalence to the scope of the claims, each numerical parameter should be interpreted at least according to the number of significant figures reported and by applying ordinary rounding techniques. The numerical ranges provided herein include the numbers that define the range. Furthermore, the disclosure of ranges is intended as a continuous range, including every value between the stated minimum and maximum values ​​and any range that can be formed from such values. This document also discloses any and all ratios (and ranges of any such ratios) that can be formed by dividing a disclosed numerical value by any other disclosed numerical value. Therefore, those skilled in the art will understand that many such ratios, ranges, and ranges of ratios can be clearly derived from the values ​​presented herein, and in all cases, such ratios, ranges, and ranges of ratios represent various embodiments of this disclosure.

[0053] Although the numerical ranges and parameters described in this disclosure are approximate, the values ​​illustrated in specific examples are reported as precisely as possible. However, any numerical value inherently contains some error that is necessarily caused by the standard deviation present in its corresponding test measurement.

[0054] Unless otherwise stated herein or obviously contradicted by the context, the terms “a” and “an” and “the” as used in the context of describing this disclosure (especially in the context of the appended claims), and similar designations, shall be understood to cover both singular and plural designations. The description of ranges of values ​​herein is intended only as a shorthand for individually referring to each individual value falling within that range. Unless otherwise stated herein, each individual value is incorporated into the specification as if it were individually described herein. Unless otherwise stated herein or obviously contradicted by the context, all methods described herein may be performed in any suitable order. Unless otherwise stated, any and all instances or exemplary language provided herein (…) For example The use of "such as" is intended only to better illustrate this disclosure and does not constitute a limitation on the scope of this disclosure. Nothing in the specification should be construed as indicating that any unclaimed element is essential to the practice of this disclosure.

[0055] Methods for converting alcohols to alkenes In one aspect, this disclosure provides a method for converting an alcohol to an olefin. The method includes passing a first fluid containing an alcohol through a plurality of reactors. Each reactor may include a catalyst bed. During a catalyst operating cycle of at least one of the plurality of reactors, the corresponding catalyst bed includes a catalytically active region comprising at least 90% of the catalyst bed. In some embodiments, the corresponding catalyst bed may include a catalytically active region comprising at least 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the catalyst bed. In one embodiment, the catalytically active region may be 100% of the catalyst bed during the catalyst operating cycle. The proportion of the catalytically active region relative to the catalyst bed may be based on the height of the catalytically active region during the catalyst operating cycle and the height of the entire catalyst bed in the reactor. The height of the catalytically active region may be determined as further described below. In some embodiments, the proportion of the catalytically active region relative to the catalyst bed may be based on the volume of the catalytically active region during the catalyst operating cycle and the volume of the entire catalyst bed in the reactor. Formula πr can be used. 2 h is used to calculate the volume of the catalytically active region, where r is the radius of the catalyst bed and h is the height of the catalytically active region.

[0056] In one embodiment, the catalytically active region can be maintained at 280°C during the catalyst operating cycle. C to 500 It operates at a temperature of C. In some embodiments, the boundary of the catalytically active region can be at least 280°C. C, 300 C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C or 480 C, and / or less than 300 C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C, 480 C or 500 C, or the temperature at which the catalytic dehydration of alcohols to olefins occurs. The height of the catalytically active region can be the vertical distance between the boundary of the catalytically active region and the topmost surface of the catalyst bed. In some embodiments, the catalytically active region can be at least 280°C. C, 300 C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C or 480 C, and / or up to 300 C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C, 480 C or 500 It operates at a temperature of C. In one embodiment, the catalytic active region can be 360°C. C to 470 It operates at a temperature of C.

[0057] In one embodiment, the olefin comprises ethylene, and the catalytically active region is at 360°. C to 470 It operates at a temperature of C.

[0058] Temperature can be measured, for example, by temperature sensors that are in direct thermal contact with the catalyst bed. The temperature sensors can be positioned along the height of the reactor. The distance between sensors can be at least 0.2 m, 0.3 m, 0.4 m, 0.5 m, or 0.6 m, and / or no more than 0.4 m, 0.5 m, 0.6 m, 0.7 m, 0.8 m, 0.9 m, or 1 m. Depending on the height of the reactor, the distance between sensors can be at least 0.8 m, 0.81 m, 0.82 m, 0.83 m, 0.85 m, 0.86 m, 0.87 m, 0.88 m, 0.89 m, 0.9 m, 0.91 m, 0.92 m, 0.93 m, and / or no more than 0.82 m, 0.83 m, 0.85 m, 0.86 m, 0.87 m, 0.88 m, 0.89 m, 0.9 m, 0.91 m, 0.92 m, 0.93 m, 0.94 m, 0.95 m, 0.96 m, 0.97 m, or 0.98 m.

[0059] In one embodiment, at least one catalyst bed may further include an idle catalyst zone, which may be less than 10% of the catalyst bed during the catalyst operating cycle. In some embodiments, the idle catalyst zone may be less than 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1% of the catalyst bed during the catalyst operating cycle. In one embodiment, at least one catalyst bed may not include an idle catalyst zone during the catalyst operating cycle. The temperature of the idle catalyst zone may be below 280°C. C, 300 C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C, 480 C, or the lower limit of temperature at which the catalytic dehydration of alcohols to olefins occurs. The ratio of the idle catalyst zone to the catalyst bed can be based on the height of the idle catalyst zone during the catalyst operating cycle and the height of the entire catalyst bed in the reactor. The height of the idle catalyst zone can be the vertical distance between the boundary of the catalytically active zone and the bottom surface of the catalyst bed.

[0060] In some embodiments, the first fluid may be fed into at least two, three, four, five, six, seven, eight, or nine reactors. In some embodiments, the first fluid may be fed into each reactor. In some embodiments, the first fluid may consist of an alcohol. In some embodiments, the first fluid may include an alcohol as a major component.

[0061] In one implementation, the method may also include more than 280 A first fluid is fed into at least one of a plurality of reactors at a temperature of C. The temperature can be measured, for example, by a temperature sensor located at the inlet of each reactor or the inlet of each furnace in the furnace-reactor coupling unit. In some embodiments, the temperature may be greater than 300°C. C, 320 C, 340 C, 360 C, 380 C, 400 C, 420 C, 440 C, 460 C or 480 C. In one implementation, the temperature may be greater than 400°C. C. In one implementation, the temperature may be greater than 450°C. C. In one implementation, the temperature may be greater than 400°C. C. In one implementation, the temperature may be greater than 450°C. C. In some embodiments, the first fluid comprises ethanol, which can be fed into the reactor at 470°C.

[0062] In one embodiment, the method may further include contacting the first fluid with a second fluid comprising steam before contacting the first fluid with a plurality of reactors, wherein the ratio of steam to alcohol is 1:1 to 3:1; obtaining a third fluid from at least one of the plurality of reactors, wherein the third fluid contains alcohol at a concentration lower than that of alcohol in the first fluid; contacting the third fluid with the first fluid before contacting the third fluid with another of the plurality of reactors; and obtaining a fourth fluid from the ends of the plurality of reactors, the fourth fluid comprising olefins and alkanes having the same number of carbon atoms.

[0063] In one embodiment, the first fluid may come into contact with the second fluid before the first fluid comes into contact with the first reactor. In one embodiment, the first fluid may come into contact with the second fluid before the first fluid comes into contact with the second fluid. In one embodiment, the first fluid may come into contact with the second fluid before the first fluid comes into contact with each of the first and second reactors.

[0064] In some embodiments, the second fluid may consist of steam. In some embodiments, the second fluid may include steam as a major component. In one embodiment, the steam may be medium-pressure steam, as understood by those skilled in the art. Medium-pressure steam may have a pressure of 14 kgf / cm³. 2 The pressure. In some embodiments, the ratio of vapor to alcohol can be at least 1:1, 1.1:1, 1.2:1, 1.3:1, 1.4:1, 1.5:1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1 or 2.9:1, and / or at most 1.2:1, 1.3:1, 1.4:1, 1.5:1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1 or 3:1. In some implementations, the ratio can be 2.5:1. In some implementations, the steam to alcohol ratio can refer to the ratio of the steam to alcohol feed flow rates. The feed flow rate can be the mass flow rate.

[0065] In some embodiments, the third fluid may include alcohols and olefins. In some embodiments, the third fluid may be fed to the immediate subsequent reactor. In some embodiments, the third fluid may be fed only to the immediate subsequent reactor. For example, the third fluid from the penultimate reactor may be fed only to the last reactor. In some embodiments, the third fluid may be fed to the immediate subsequent reactor during operation. For example, the third fluid from the first reactor may be fed to the second or third reactor. For example, the third fluid from the second reactor may be fed to the third or fourth reactor. For example, the third fluid from the third reactor may be fed to the fourth or fifth reactor. For example, the third fluid from the fourth reactor may be fed to the fifth reactor or a quench tower.

[0066] In some embodiments, the third fluid may come into contact with the first fluid before contacting the immediately following reactor. In some embodiments, the third fluid may come into contact with the first fluid before contacting two, three, four, five, six, seven, or eight immediately following reactors.

[0067] In some embodiments, the fourth fluid may be obtained from the last of the multiple reactors. In some embodiments, the fourth fluid may be obtained from both the last and penultimate reactors. In some embodiments, the fourth fluid may be obtained from only the last and penultimate reactors.

[0068] In one embodiment, the amount of olefins in the fourth fluid is at least 1,000 ppm greater than the amount of alkanes by a molar amount. In some embodiments, the amount of olefins in the fourth fluid is at least 1,000 ppm, 2,000 ppm, 3,000 ppm, 4,000 ppm, 5,000 ppm, 10,000 ppm, 15,000 ppm, or 20,000 ppm greater than the amount of alkanes by a molar amount.

[0069] In one embodiment, the amount of alkane in the fourth fluid may be 2,500 ppm or less. In some embodiments, the amount of alkane in the fourth fluid may be 2,400 ppm or less, 2,200 ppm or less, 2,000 ppm or less, 1,800 ppm or less, 1,500 ppm or less, 1,200 ppm or less, 1,000 ppm or less, 800 ppm or less, or 500 ppm or less. In some embodiments, the fourth fluid may be free of alkane. The amounts of alkane and olefin can be measured by gas chromatography or any other method known to those skilled in the art.

[0070] In some implementations, the conversion of alcohol to olefin may be at least 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99%, based on the molar number of alcohols.

[0071] In one embodiment, the method may further include pressurizing a fourth fluid using a primary compressor connected to the ends of multiple reactors. For example, the primary compressor may be connected to the last reactor. In some embodiments, the primary compressor may be a single-stage compressor. In one embodiment, the method may exclude pressurizing the fourth fluid using a multi-stage compressor.

[0072] catalyst bed In some embodiments, based on the total weight of the components in the catalyst bed, the catalyst bed may contain at least 80 wt%, 81 wt%, 82 wt%, 83 wt%, 84 wt%, 85 wt%, 86 wt%, 87 wt%, 88 wt%, 89 wt%, 90 wt%, 90 wt%, 91 wt%, 92 wt%, 93 wt%, 94 wt%, 95 wt%, 96 wt%, 97 wt%, 98 wt%, or 99 wt% of catalyst. In some embodiments, the catalyst bed may contain 100 wt% catalyst.

[0073] In some implementations, there may be three, four, five, six, seven, eight, nine, or ten catalyst beds. In some implementations, a single reactor may contain only one catalyst bed.

[0074] In one embodiment, the variance (difference) of the height between each catalyst bed in the catalyst bed may not exceed 15%. In some embodiments, the variance (difference) of the height between each catalyst bed in the catalyst bed may not exceed 14%, 13%, 12%, or 11%. In one embodiment, each catalyst bed in the catalyst bed may independently have a height of 2.0 m to 2.8 m. The height of each catalyst bed in the catalyst bed can be obtained by measuring the vertical distance from the bottom surface to the top surface of the catalyst bed. In some embodiments, each catalyst bed in the catalyst bed may independently have a height of 2.1 m, 2.2 m, 2.3 m, 2.4 m, 2.5 m, or 2.6 m to 2.2 m, 2.3 m, 2.4 m, 2.5 m, 2.6 m, or 2.7 m. In one embodiment, the first catalyst bed may have a height of 2.0 m to 2.2 m. In some embodiments, the first catalyst bed may have a height of 2.1 m. In one embodiment, the third catalyst bed may have a height of 2.3 m to 2.6 m. In one embodiment, the third catalyst bed may have a height of 2.4 m or 2.5 m. In one embodiment, the first and second catalyst beds may have the same height. In one embodiment, the third and fourth catalyst beds may have different heights than the first and second catalyst beds. In one embodiment, each of the third and fourth catalyst beds may have a height that is 10% to 50% greater than the height of the first catalyst bed. In some embodiments, each of the third and fourth catalyst beds has a height that is 5%, 6%, 7%, 8%, 9%, 10%, 12%, 15%, 18%, 20%, 24%, 27%, 30%, 35%, 40%, or 45% greater than the height of the first catalyst bed. In one embodiment, the fifth catalyst bed may have a height that is 10% to 50% greater than the height of the first catalyst bed. In some embodiments, the fifth catalyst bed has a height that is 5%, 6%, 7%, 8%, 9%, 10%, 12%, 15%, 18%, 20%, 24%, 27%, 30%, 35%, 40%, or 45% greater than the height of the first catalyst bed. In one implementation, the fourth and fifth catalyst beds may have the same height.

[0075] The desired catalyst bed height can be calculated by selecting the desired catalyst operating cycle duration and the average feed of the first fluid into the reactor. The desired catalyst operating cycle duration can be the duration during which the olefin yield can be maintained at the same level as the olefin yield at the start of the catalyst operating cycle or at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the olefin yield.

[0076] In one embodiment, the fourth and fifth catalyst beds may have the same volume. In some embodiments, the fourth and fifth catalyst beds may each have a volume of 20 to 23 m³. 3 Or 22 to 23 m 3 The volume of the catalyst bed. In one embodiment, the volume of the catalyst bed may increase from the first catalyst bed to the fourth catalyst bed. In some embodiments, the volume of each of the first to fourth catalyst beds may be 7 to 9 m³. 3 10 to 15 m 3 16 to 19 m 3 and 20 to 23 m 3 In some implementations, the volume of each of the first to fourth catalyst beds can be 8 to 9 m³, respectively. 3 10 to 11 m 3 17 to 18 m 3 and 22 to 23 m 3 .

[0077] reactor In some implementations, the reactor may be a fixed-bed reactor.

[0078] In one embodiment, at least one of the plurality of reactors may have a weight hourly space velocity (WHSV) of alcohol greater than 0.6 / h and up to 1.5 / h / kg catalyst. In some embodiments, at least one of the plurality of reactors may have a WHSV of alcohol greater than 0.7 / h, 0.8 / h, 0.9 / h, 1 / h, 1.1 / h, 1.2 / h, or 1.3 / h, and / or up to 0.8 / h, 0.9 / h, 1.0 / h, 1.1 / h, 1.2 / h, 1.3 / h, or 1.4 / h / kg catalyst. In one embodiment, at least one of the plurality of reactors may have a WHSV of alcohol greater than 1 / h and up to 1.3 / h / kg catalyst.

[0079] In some embodiments, there may be three, four, five, six, seven, eight, nine, or ten reactors. In one embodiment, the plurality of reactors may include: a first group of reactors comprising reactors each having a first height; and a second group of reactors comprising reactors each having a second height, wherein the first height may differ from the second height. In some embodiments, the first group of reactors may precede the second group of reactors, and the first height may be shorter than the second height.

[0080] In one embodiment, the plurality of reactors may sequentially include: a first reactor including a first catalyst bed; a second reactor including a second catalyst bed; a third reactor including a third catalyst bed; and a fourth reactor including a fourth catalyst bed. In one embodiment, the plurality of reactors may further include a fifth reactor after the fourth reactor, the fifth reactor including a fifth catalyst bed.

[0081] In one embodiment, the variance (difference) in the height of each reactor in the plurality of reactors may not exceed 15%. In some embodiments, the variance (difference) in the height of each reactor in the plurality of reactors may not exceed 14%, 13%, 12%, or 11%. In one embodiment, the variance (difference) in the height of each reactor in the plurality of reactors may not exceed 10%. In one embodiment, each reactor in the plurality of reactors may independently have a height of 2.5 m to 4.0 m. The height of each reactor can be obtained by measuring the vertical distance from the bottom surface to the top surface of the reactor. In some implementations, each of the multiple reactors may independently have a height of 2.6 m, 2.7 m, 2.8 m, 2.9 m, 3 m, 3.1 m, 3.2 m, 3.3 m, 3.4 m, 3.5 m, 3.6 m, 3.7 m, or 3.8 m, and at most 2.7 m, 2.8 m, 2.9 m, 3 m, 3.1 m, 3.2 m, 3.3 m, 3.4 m, 3.5 m, 3.6 m, 3.7 m, or 3.8 m.

[0082] In one embodiment, the first reactor may have a height of 2.8 m to 3.1 m. In some embodiments, the first reactor may have a height of 2.9 m or 3 m. In one embodiment, the third reactor may have a height of 3.2 m to 3.5 m. In some embodiments, the third reactor may have a height of 3.3 m or 3.4 m. In one embodiment, the first and second reactors may have the same height. In one embodiment, the first and second reactors may each have a height of 3 m. In one embodiment, the remaining reactors may have a different height than the first and second reactors. In one embodiment, each of the third and fourth reactors may have a height that is 10% to 50% greater than the height of the first reactor. In some embodiments, each of the third and fourth reactors may have a height that is 5%, 6%, 7%, 8%, 9%, 10%, 12%, 15%, 18%, 20%, 24%, 27%, 30%, 35%, 40%, or 45% greater than the height of the first reactor. In one embodiment, the fifth reactor may have a height that is 10% to 50% greater than the height of the first reactor. In some embodiments, the fifth reactor may have a height that is 5%, 6%, 7%, 8%, 9%, 10%, 12%, 15%, 18%, 20%, 24%, 27%, 30%, 35%, 40%, or 45% greater than that of the first reactor. In one embodiment, the third to fifth reactors may have the same height. In some embodiments, the third to fifth reactors may each have a height of 3.3 m.

[0083] In one embodiment, the fourth and fifth reactors may have the same volume. In some embodiments, the fourth and fifth reactors each have a volume of 30 to 33 m³. 3 Or 31 to 32 m 3 The volume. In one embodiment, the volume of each of the first to fourth reactors may increase from the first to the fourth reactor. In some embodiments, the volume of each of the first to fourth reactors may be 10 to 13 m³ respectively. 3 14 to 20m 3 21 to 29 m 3 and 30 to 33 m 3 In some embodiments, the volume of each of the first to fourth reactors can be 11 to 12 m³, respectively. 3 15 to 16 m 3 24 to 25 m 3 and 31 to 32 m 3 .

[0084] In one embodiment, at least one of the plurality of reactors may be a standby reactor. In one embodiment, the standby reactor may have the same height and / or volume as another reactor among the plurality of reactors. In one embodiment, the standby reactor may have the same height and / or volume as another reactor immediately preceding the standby reactor. In one embodiment, the plurality of reactors may include five reactors. In one embodiment, only one of the five reactors may be a standby reactor. In some embodiments, the standby reactor is the fifth reactor. In one embodiment, the standby reactor may be configured as a standby reactor for any of the other reactors among the plurality of reactors. In one embodiment, the standby reactor may be the last reactor among the plurality of reactors. In one embodiment, the standby reactor may have the largest height and / or volume among the reactors among the plurality of reactors. In some embodiments, the standby reactor may be the same as or similar to the other reactors in terms of catalyst operating cycle duration (as further described below) and the amount of time used for regenerating or replacing the catalyst bed (as further described below).

[0085] In some implementations, multiple reactors can be arranged in a series-parallel configuration. Compared to a series arrangement, a series-parallel combination can provide the benefit of maintaining high temperatures inside the reactor because the first fluid ( For example Ethanol can be added to each reactor. Furthermore, adding fresh alcohol can improve selectivity by avoiding more byproducts. For example, when the first fluid heated is ethanol, ethylene can be converted to other molecules when the reactors are arranged in series. Additionally, the series-parallel combination reduces steam consumption compared to a parallel arrangement, as this consumption can be based solely on the conditions of the first reactor.

[0086] In some embodiments, any or all of the multiple reactors may be arranged in parallel, and any or all of the multiple reactors may be arranged in series. In some embodiments, the first two, three, four, five, or six reactors, the last two, three, four, five, or six reactors, or any two, three, four, five, or six reactors may be arranged in parallel. In some embodiments, the first two, three, four, five, or six reactors, the last two, three, four, five, or six reactors, or any two, three, four, five, or six reactors may be arranged in series. In some embodiments, all reactors may be connected in parallel and in series with each other. In some embodiments, all reactors may be arranged in parallel.

[0087] In some embodiments, a first group of reactors and a second group of reactors may exist. In some embodiments, the reactors in the first group may be connected in parallel and in series with each other, and at least one reactor in the second group may be connected in series with each other. In some embodiments, the reactors in the first group may be connected in parallel and in series with each other, and at least one reactor in the first group may be connected in series with each other. In some embodiments, the reactors in the first and second groups may be connected in parallel and in series with each other.

[0088] In some embodiments, five reactors may be present. In some embodiments, the first and second reactors may be connected in parallel and in series, and reactors two through five may be connected in series. In some embodiments, the first through third reactors may be connected in parallel and in series, and reactors three through five may be connected in series. In some embodiments, the first through fourth reactors may be connected in parallel and in series, and reactor five may be connected in series with reactor four. In some embodiments, reactor four and fifth reactors may be connected in parallel and in series, and reactors one through four may be connected in series. In some embodiments, reactors three through five may be connected in parallel and in series, and reactors one through three may be connected in series. In some embodiments, reactors two through five may be connected in parallel and in series, and reactor two may be connected in series with reactor one.

[0089] Furnace-reactor coupling unit In one embodiment, at least one of a plurality of reactors may be fluidly coupled to a furnace to form a furnace-reactor coupling unit. In one embodiment, the method may further include passing a first fluid through the furnace before the first fluid enters the reactor in the same furnace-reactor coupling unit. In one embodiment, the furnace may be directly coupled to the reactor. In one embodiment, the furnace-reactor coupling unit may include a single furnace and a single reactor. In one embodiment, a plurality of furnace-reactor coupling units may exist, and each furnace-reactor coupling unit in the furnace-reactor coupling unit may be fluidly coupled to each other. In some embodiments, the reactor in a furnace-reactor coupling unit may be directly coupled to the furnace in a subsequent furnace-reactor coupling unit.

[0090] In some embodiments, there may be three, four, five, six, seven, eight, nine, or ten furnace-reactor coupling units. In one embodiment, the plurality of furnace-reactor coupling units may include: a first group of furnace-reactor coupling units comprising reactors each having a first height; and a second group of furnace-reactor coupling units comprising reactors each having a second height, wherein the first height may differ from the second height. In some embodiments, the first group of furnace-reactor coupling units may precede the second group of reactors, and the first height may be shorter than the second height.

[0091] In one embodiment, a plurality of furnace-reactor coupling units may sequentially include: a first furnace-reactor coupling unit comprising a first furnace and a first reactor including a first catalyst bed; a second furnace-reactor coupling unit comprising a second furnace and a second reactor including a second catalyst bed; a third furnace-reactor comprising a third furnace and serving as a third reactor including a third catalyst bed; and a fourth furnace-reactor coupling unit comprising a fourth furnace and a fourth reactor including a fourth catalyst bed. In one embodiment, the plurality of reactors may further include a fifth furnace-reactor coupling unit after the fourth furnace-reactor coupling unit, the fifth furnace-reactor coupling unit comprising a fifth furnace and a fifth reactor including a fifth catalyst bed.

[0092] In one embodiment, at least one of the plurality of furnace-reactor coupling units may be a standby furnace-reactor coupling unit. In one embodiment, the standby furnace-reactor coupling unit may include a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit. In one embodiment, the standby furnace-reactor coupling unit may include a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit immediately preceding the standby furnace-reactor coupling unit. In one embodiment, the plurality of furnace-reactor coupling units may include five furnace-reactor coupling units. In one embodiment, only one of the five furnace-reactor coupling units may be a standby furnace-reactor coupling unit. In some embodiments, the standby furnace-reactor coupling unit includes only the fifth reactor among the plurality of reactors. In one embodiment, the standby furnace-reactor coupling unit may be configured to be standby for any other furnace-reactor coupling unit among the plurality of furnace-reactor coupling units. In one embodiment, the standby furnace-reactor coupling unit may be the last furnace-reactor coupling unit among the plurality of furnace-reactor coupling units. In one embodiment, the reactor in the standby furnace-reactor coupling unit may have the largest height and / or volume among the reactors in multiple furnace-reactor coupling units. In some embodiments, the standby furnace-reactor coupling unit may be the same as or similar to other furnace-reactor coupling units in terms of catalyst operating cycle duration and the amount of time used for regenerating or replacing the catalyst bed.

[0093] In one embodiment, multiple furnace-reactor coupling units can be arranged in a series-parallel configuration, wherein any or all furnace-reactor coupling units within the furnace-reactor coupling unit can be connected in series, and any or all furnace-reactor coupling units within the furnace-reactor coupling unit can be connected in parallel with each other. In some embodiments, the furnace-reactor coupling units arranged in parallel can be the first two, three, four, five, or six furnace-reactor coupling units, the last two, three, four, five, or six furnace-reactor coupling units, or any two, three, four, five, or six furnace-reactor coupling units among multiple furnace-reactor coupling units. In some embodiments, the first two, three, four, five, or six furnace-reactor coupling units, the last two, three, four, five, or six furnace-reactor coupling units, or any two, three, four, five, or six furnace-reactor coupling units in a plurality of reactors may be arranged in series. In some embodiments, all furnace-reactor coupling units within a furnace-reactor coupling unit may be connected in parallel and in series with each other.

[0094] In some embodiments, there may be a first group of furnace-reactor coupling units and a second group of furnace-reactor coupling units. In some embodiments, the furnace-reactor coupling units in the first group may be connected in parallel and in series with each other, and at least one furnace-reactor coupling unit in the second group may be connected in series with each other. In some embodiments, the furnace-reactor coupling units in the second group may be connected in parallel and in series with each other, and at least one furnace-reactor coupling unit in the first group may be connected in series with each other. In some embodiments, the furnace-reactor coupling units in the first and second groups may be connected in parallel and in series with each other.

[0095] In some embodiments, five furnace-reactor coupling units may exist. In some embodiments, the first and second furnace-reactor coupling units may be connected in parallel and in series, and the second through fifth furnace-reactor coupling units may be connected in series. In some embodiments, the first through third furnace-reactor coupling units may be connected in parallel and in series, and the third through fifth furnace-reactor coupling units may be connected in series. In some embodiments, the first through fourth furnace-reactor coupling units may be connected in parallel and in series, and the fifth furnace-reactor coupling unit may be connected in series with the fourth furnace-reactor coupling unit. In some embodiments, the fourth and fifth furnace-reactor coupling units may be connected in parallel and in series, and the first through fourth furnace-reactor coupling units may be connected in series. In some embodiments, the third to fifth furnace-reactor coupling units can be connected in parallel and in series with each other, and the first to third furnace-reactor coupling units can be connected in series. In some embodiments, the second to fifth furnace-reactor coupling units can be connected in parallel and in series.

[0096] In some implementations, all furnace-reactor coupling units within a furnace-reactor coupling unit can be connected in parallel and series with each other. In some implementations, multiple furnace-reactor coupling units are arranged in a series-parallel configuration, such as... Figure 4 As shown in the image. Figure 4 The terms “R1”, “R2”, “R3”, “R4” and “standby” are intended to refer to the first reactor, the second reactor, the third reactor, the fourth reactor and the fifth reactor, respectively, and the terms “F1”, “F2”, “F3”, “F4” and “F5” are intended to refer to the first furnace, the second furnace, the third furnace, the fourth furnace and the fifth furnace, respectively.

[0097] Catalyst operating cycle In one implementation, the catalyst operating period may be between five and seven months. In some implementations, the catalyst operating period may be three months, four months, five months, six months, seven months, or eight months to four months, five months, six months, seven months, eight months, nine months, or ten months. In some implementations, the catalyst operating period may be between six months and seven months. In one implementation, the catalyst operating period may be six months.

[0098] In some implementations, the catalyst operating cycles of each reactor can overlap. This means that all reactors are operating. In some implementations, the catalyst operating cycles of each reactor can overlap for at least three, four, or five months and / or at most four, five, six, or seven months. In some implementations, the catalyst operating cycles of each reactor can overlap for four to five months. In one implementation, all reactors in a plurality of reactors can operate together at 60% to 80% capacity. In some implementations, all reactors in a plurality of reactors can operate together at at least 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, or 79%, and / or at most 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, or 80% capacity. In one implementation, all furnace-reactor coupling units in a plurality of furnace-reactor coupling units can operate together at 60% to 80% capacity. In some implementations, all furnace-reactor coupling units in a plurality of furnace-reactor coupling units can operate together at at least 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, or 79%, and / or at most 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, or 80% capacity.

[0099] regeneration In one embodiment, the method may further include, after a catalyst operating cycle, decoupling at least one of the plurality of reactors from the remaining reactors, and regenerating the catalyst bed or replacing the catalyst bed in at least one decoupled reactor. The decoupled reactor may not be used for dehydrating alcohols to form olefins. In one embodiment, decoupling may occur immediately after a catalyst operating cycle. In one embodiment, the remaining reactors may operate together at 100% capacity. In some embodiments, the remaining reactors may operate together at more than 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% capacity.

[0100] Catalyst bed regeneration may involve passing at least steam and air through the catalyst bed in a decoupled furnace-reactor coupling unit. Catalyst bed regeneration may take five, six, seven, eight, or nine days, and at most seven, eight, nine, ten, twelve, fifteen, or twenty days. In some embodiments, catalyst bed regeneration may take ten days. Catalyst bed replacement may take five, six, seven, eight, or nine days, and at most seven, eight, nine, ten, twelve, fifteen, or twenty days. In some embodiments, catalyst bed replacement may take ten days.

[0101] In some embodiments, the method may further include coupling a decoupled reactor having a regenerated or replaced catalyst bed to the remaining reactor, and then decoupling at least one other reactor to regenerate or replace its catalyst bed.

[0102] In one embodiment, the method may further include, after a catalyst operating cycle, decoupling at least one of the plurality of furnace-reactor coupling units from the remaining furnace-reactor coupling units, and regenerating the catalyst bed or replacing the catalyst bed in at least one decoupled furnace-reactor coupling unit. The decoupled furnace-reactor coupling unit may not be used for dehydrating alcohols to form olefins. In one embodiment, decoupling may occur immediately after a catalyst operating cycle.

[0103] In one implementation, the remaining furnace-reactor coupling units can operate together at 100% capacity. In some implementations, the remaining furnace-reactor coupling units can operate together at more than 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% capacity. In a comparative process operating with four reactors and four furnaces, the reactor being regenerated is bypassed, resulting in a significant reduction in production capacity. The standby furnace-reactor coupling units disclosed herein can maintain production at full capacity continuously. For example The standby furnace-reactor coupling unit operates at 100% capacity, even during regeneration or replacement of other catalyst beds. It can also increase process yield by allowing frequent regeneration to reduce byproduct formation.

[0104] In some embodiments, the method may further include coupling a decoupled furnace-reactor coupling unit having a regenerated or replaced catalyst bed to the remaining furnace-reactor coupling units, and then decoupling at least one other furnace-reactor coupling unit to regenerate or replace its catalyst bed. The coupling and decoupling processes may be repeated as needed, such that all catalyst beds in the catalyst bed can be regenerated or replaced to, for example, maintain the desired product yield.

[0105] alcohol In some implementations, the alcohol may be a precursor to an olefin, which may be industrially important. For example, olefins may be raw materials for chemicals and / or polymers.

[0106] In some embodiments, the alcohol may be derived from sugarcane, corn, beetroot, and / or biomass. In one embodiment, the alcohol may include at least one of C2, C3, and C4 alcohols. In some embodiments, the alcohol may be a C2 alcohol. In some embodiments, the alcohol may be a C3 alcohol. In some embodiments, the alcohol may be a C4 alcohol. In some embodiments, the alcohol may be a C5, C6, C7, and / or C8 alcohol.

[0107] In some embodiments, the alcohol can be a C2 alcohol and the olefin can be a C2 olefin. In some embodiments, the alcohol can be a C3 alcohol and the olefin can be a C3 olefin. In some embodiments, the alcohol can be a C4 alcohol and the olefin can be a C4 olefin.

[0108] Olefins In one embodiment, the olefin may include an olefin having the same number of carbon atoms as the alcohol. In some embodiments, the alcohol may be a C2 alcohol, and the olefin may be a C2 olefin. In some embodiments, the olefin may be a C2 olefin, such as ethylene. In some embodiments, the olefin may be a C3 olefin. In some embodiments, the olefin may be a C4 olefin.

[0109] Systems that convert alcohols to olefins In one aspect, this disclosure provides a system comprising a plurality of reactors, each reactor including a catalyst bed and configured to convert an alcohol to an olefin. The plurality of reactors are fluidly coupled to each other, and at least one of the catalyst beds is configured to have a catalytically active region that is at least 90% of the catalyst bed during a catalyst operating cycle. In some embodiments, a corresponding catalyst bed may include a catalytically active region that is at least 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the catalyst bed. In one embodiment, the catalytically active region may be 100% of the catalyst bed during a catalyst operating cycle. In one embodiment, at least one of the catalyst beds may further include an idle catalyst region that is less than 10% of the catalyst bed during a catalyst operating cycle. In some embodiments, the idle catalyst region may be less than 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1% of the catalyst bed during a catalyst operating cycle. In one embodiment, at least one of the catalyst beds may not include an idle catalyst region during a catalyst operating cycle.

[0110] Example Example 1. Determining the desired catalyst bed height and other reactor characteristics Ethylene production occurs through the dehydration of ethanol. This process can be achieved using four reactors and four furnaces, such as... Figure 5 The diagram illustrates a comparative system without a backup reactor and where the catalytically active zone is less than 90% of the catalyst bed. The ethanol dehydration reactor in the comparative process is a fixed-bed reactor with inert material at the top, a catalyst bed in the middle, and inert material at the bottom. Several temperature sensors are located along the height of the reactor, monitoring the temperature distribution inside to determine the location of the reaction front. The space between the sensors is called a layer, which can be either an inert layer or a catalyst layer.

[0111] To calculate the height of the catalyst bed, the relevant concept is the reaction front segment. The reaction front is defined as the location along the catalyst bed where most of the chemical reactions occur at a given time. As the reaction progresses, the reaction front slowly moves downwards, as... Figure 6 As shown in the image.

[0112] In theory, the reaction front should reach the bottom of the reactor at the end of the catalyst cycle. After that, the catalyst will be regenerated, and a new catalyst cycle will begin.

[0113] One possible reason for the formation of byproducts is the temperature in the buffer zone, such as... Figure 6 As shown. Low temperature ( For example Approximately 350 C) It can favor the formation of byproducts (especially ethane). Early catalyst regeneration indicates over-designed bed height. Over-designed reactors provide buffer sections longer than they should, and therefore byproduct formation is higher than it could potentially occur. Long bed heights can lead to low temperatures in the idle catalyst layer within the buffer section, resulting in unwanted byproduct formation. This can reduce overall yield and selectivity.

[0114] This application relates to determining a desired bed height, which can be longer than the minimum reaction front section but shorter than the bed height of the reactor in a comparative process. Another aspect of this application relates to reducing byproduct formation compared to the reactor in the comparative process.

[0115] In this application, the dimensions of the reactors are determined individually. Temperature is a relevant parameter for defining the catalyst bed height for each reactor, as it is considered related to byproduct formation in the buffer zone. Therefore, understanding the temperature distribution within the reactor is likely important for defining the bed height.

[0116] Table 1 lists the reactor height variations and the weight hourly space velocity (WHSV) of ethanol used in the reactors for a given capacity in the comparative processes. Based on the study of the ethanol dehydration unit, common behavior was observed in all reactors ( For example (A large number of idle layers).

[0117] To calculate the desired height of the catalyst bed, an average ethanol feed rate to the reactor was chosen. Since the ethanol feed rate was kept the same as in the comparative process, the smaller reactor disclosed herein resulted in a higher ethanol weight hourly space velocity, which indicates lower catalyst consumption and therefore lower catalyst cost.

[0118] Table 1. Characteristics of the reactor in the comparative process Example 2. Reduced catalyst bed height leads to reduced pressure drop. In both the comparative process and the process according to the embodiments of this disclosure, ethanol is pressurized and pressure-lost through equipment (including the reactor) and pipelines until it reaches the suction inlet of the booster compressor. The lower pressure drop along the catalyst bed will allow the feed stream to reach the suction inlet of the booster compressor at a higher pressure. At higher pressures, the compressor size can be reduced, and therefore capital expenditure and power can be reduced. The compressor in the comparative process has three stages. Simulations have shown that, with the smaller reactor according to the embodiments of this disclosure, a single-stage compressor would be suitable for the purposes of this disclosure.

[0119] System curves for the comparative process were constructed to understand the pressure loss in each unit until the product reaches the inlet of the booster compressor. A direct correlation between pressure drop and bed height was observed. Based on this information, the system curves for the process according to an embodiment of this disclosure were recalculated. For the recalculation, a fifth furnace-reactor coupled unit was considered, where each reactor has a design flow rate of 70%. This is a 9-month operating condition. Additionally, there are additional units arranged in series (the fifth furnace and the fifth reactor) up to the compressor inlet.

[0120] Figure 7 The system curves are presented based on a comparative process (“current pressure curve”) and a process according to an embodiment of this disclosure (“new pressure curve”). Figure 7 In this context, for example, the terms "F-01" and "R-01" refer to the first furnace and reactor, respectively; "HE-05" refers to the heat exchanger; "T-01" refers to the tower; "V-07" refers to the vessel; and "C-01" refers to the compressor. To achieve 5 kgf / cm³ at the suction inlet of the booster compressor in the process disclosed herein... 2 (g) also increases the initial pressure of the system.

[0121] Example 3. Study on the formation of byproducts One of the byproducts of ethanol dehydration is difficult to separate from ethylene and can directly affect the ethylene yield. This study uses a comparative system and treats the reaction as a system. The study focuses on the time between interventions (catalyst regeneration or replacement) in each reactor. Figure 8 Typical behavior of ethane and ethylene yield are shown over an 11-month catalyst operating cycle. Based on this behavior, a 6-month catalyst operating cycle (the period between regeneration or catalyst replacement) could allow for higher yields and lower ethane concentrations. This is the time period considered in the following studies.

[0122] To better understand how the 6-month operating cycle of the reactors according to this disclosure is implemented, a reactor occupancy chart has been constructed. According to Table 2, a 6-month catalyst operating cycle and 10 days of regeneration or catalyst replacement for each reactor result in a total of 9 months of operation. In Table 2, “x” indicates that the reactor is operating, and the numbers represent the number of days the reactor is being regenerated.

[0123] Table 2. Reactor occupancy chart according to this disclosure within one year In summary, using a smaller reactor results in a reduction in compressor size. This replacement and addition of a fifth reactor and its furnace significantly reduces capital expenditure and catalyst consumption by more than half. The system according to this disclosure also consumes less ethanol, electricity, and steam, and affects fuel gas consumption. These changes also impact the CO2 footprint, which is also reduced.

[0124] The grouping of alternative elements or embodiments of the disclosure herein should not be construed as limiting. Each member of a group may be mentioned and claimed individually or in any combination with other members of that group or other elements visible herein. It is foreseeable that one or more members of a group may be included in or removed from the group for convenience and / or patentability reasons. When any such inclusion or removal occurs, the specification is deemed to contain the modified group, thereby satisfying the written description of all groups as used in the appended claims.

[0125] This document describes certain embodiments of the present disclosure, including the best mode known to the inventors for carrying out the disclosure. Of course, variations of those embodiments will become apparent to those skilled in the art upon reading the foregoing description. The inventors intend that those skilled in the art will employ such variations as appropriate, and the inventors intend to practice the disclosure in ways other than those specifically described herein. Therefore, this disclosure includes all modifications and equivalents of the subject matter set forth in the claims appended herein, as permitted by applicable law. Furthermore, this disclosure covers any combination of the foregoing elements and all their possible variations, unless otherwise stated herein or clearly contradicted by the context.

[0126] The specific embodiments disclosed herein may be further limited by the language "consisting of" and / or "substantially consisting of" in the claims. The embodiments of this disclosure thus claimed are inherently or explicitly described and implemented herein.

[0127] It should be understood that the embodiments disclosed herein are merely illustrative of the principles of this disclosure. Other modifications may be adopted within the scope of this disclosure. Therefore, as examples but not limitations, alternative configurations of this disclosure may be adopted in accordance with the teachings herein. Accordingly, this disclosure is not limited to the content shown and described precisely as illustrated herein.

[0128] While this disclosure has been described and illustrated herein by reference to various specific materials, procedures, and examples, it should be understood that this disclosure is not limited to the specific combination of materials and procedures chosen for this purpose. Many variations of such details may be implied, as will be understood by those skilled in the art. This specification and embodiments are intended to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the following claims. All references, patents, and patent applications mentioned in this application are incorporated herein by reference in their entirety.

Claims

1. A method for converting an alcohol into an olefin, the method comprising: A first fluid containing the alcohol is passed through multiple reactors, each reactor comprising a catalyst bed. During the catalyst operation cycle of at least one of the plurality of reactors, the corresponding catalyst bed includes a catalytically active zone, which is at least 90% of the catalyst bed.

2. The method of claim 1, wherein the catalytically active region is 100% of the catalyst bed during the catalyst operating cycle.

3. The method of claim 1, wherein at least one catalyst bed in the catalyst bed further comprises an idle catalyst zone, the idle catalyst zone being less than 10% of the catalyst bed during the catalyst operating cycle.

4. The method of claim 1, wherein at least one catalyst bed in the catalyst bed does not include an idle catalyst zone during the catalyst operating cycle.

5. The method of claim 1, wherein the catalytically active region is at 280°C. C to 500 It operates at a temperature of C.

6. The method of claim 1, wherein the catalytically active region is at 360°. C to 470 It operates at a temperature of C.

7. The method of any of the preceding claims, wherein the alcohol comprises at least one of C2 alcohols, C3 alcohols, and C4 alcohols.

8. The method of claim 7, wherein the olefin comprises an olefin having the same number of carbon atoms as the alcohol.

9. The method of claim 1, wherein the olefin comprises ethylene, and the catalytically active region is at 360°. C to 470 It operates at a temperature of C.

10. The method as described in any of the preceding claims, further comprising: Before the first fluid contacts the plurality of reactors, the first fluid is contacted with a second fluid comprising steam, wherein the ratio of steam to alcohol is 1:1 to 3:

1. A third fluid is obtained from at least one of the plurality of reactors, wherein the third fluid contains the alcohol at a concentration lower than that of the alcohol in the first fluid. Before contacting the third fluid with another reactor among the plurality of reactors, the third fluid is contacted with the first fluid, and A fourth fluid is obtained from the end of the plurality of reactors, the fourth fluid comprising the olefin and an alkane having the same number of carbon atoms, wherein the amount of the olefin in the fourth fluid is at least 1,000 ppm greater than the amount of the alkane by molar.

11. The method of claim 10, wherein the amount of the alkane in the fourth fluid is 2,500 ppm or less.

12. The method of claim 10, further comprising pressurizing the fourth fluid using a primary compressor connected to the end of the plurality of reactors.

13. The method of claim 12, wherein the method excludes pressurizing the fourth fluid using a multi-stage compressor.

14. The method of claim 10, further comprising: in more than 280 The first fluid is fed into at least one of the plurality of reactors at a temperature of C.

15. The method of claim 14, wherein the temperature is greater than 400°C. C.

16. The method of claim 14, wherein the temperature is greater than 450°C. C.

17. The method of any of the preceding claims, wherein the plurality of reactors are arranged in a series-parallel configuration.

18. The method of any of the preceding claims, wherein at least one of the plurality of reactors has a weight hourly space velocity of the alcohol greater than 0.6 / h and at most 1.5 / h.

19. The method as claimed in any of the preceding claims, wherein at least one of the plurality of reactors has a weight hourly space velocity of the alcohol greater than 1 / h and at most 1.3 / h.

20. The method as claimed in any of the preceding claims, wherein the plurality of reactors comprises: The first group of reactors comprises reactors, each having a first height, and The second group of reactors comprises reactors, each having a second height. The first height is different from the second height.

21. The method as claimed in any of the preceding claims, wherein the plurality of reactors comprises, in sequence: The first reactor includes a first catalyst bed. The second reactor includes a second catalyst bed. A third reactor, comprising a third catalyst bed, and The fourth reactor includes a fourth catalyst bed.

22. The method of claim 21, wherein the plurality of reactors further comprises a fifth reactor after the fourth reactor, the fifth reactor comprising a fifth catalyst bed.

23. The method as claimed in any of the preceding claims, wherein the variance between the heights of each of the plurality of reactors does not exceed 15%.

24. The method as claimed in any of the preceding claims, wherein the variance between the heights of each of the plurality of reactors does not exceed 10%.

25. The method as claimed in any of the preceding claims, wherein each of the plurality of reactors independently has a height of 2.5 m to 4.0 m.

26. The method of any one of claims 21 to 25, wherein the first reactor has a height of 2.8 m to 3.1 m.

27. The method of any one of claims 21 to 26, wherein the third reactor has a height of 3.2 m to 3.5 m.

28. The method of any one of claims 21 to 27, wherein the first reactor and the second reactor have the same height.

29. The method of any one of claims 21 to 28, wherein the remaining reactor has a different height than the first reactor and the second reactor.

30. The method of any one of claims 21 to 29, wherein each of the third reactor and the fourth reactor has a height that is 10% to 50% greater than the height of the first reactor.

31. The method of any one of claims 22 to 30, wherein the fifth reactor has a height that is 10% to 50% greater than the height of the first reactor.

32. The method of any one of claims 22 to 31, wherein the third to fifth reactors have the same height.

33. The method of any one of claims 22 to 32, wherein the fourth reactor and the fifth reactor have the same volume.

34. The method of any one of claims 21 to 33, wherein the volume of each of the first to fourth reactors increases from the first to the fourth reactor.

35. The method as claimed in any of the preceding claims, wherein the variance between the heights of each catalyst bed in the catalyst bed does not exceed 15%.

36. The method as claimed in any of the preceding claims, wherein each catalyst bed in the catalyst bed independently has a height of 2.0 m to 2.8 m.

37. The method of any one of claims 21 to 36, wherein the first catalyst bed has a height of 2.0 m to 2.2 m.

38. The method of any one of claims 21 to 37, wherein the third catalyst bed has a height of 2.3 m to 2.6 m.

39. The method of any one of claims 21 to 38, wherein the first catalyst bed and the second catalyst bed have the same height.

40. The method of any one of claims 21 to 39, wherein the third catalyst bed and the fourth catalyst bed have different heights than the first catalyst bed and the second catalyst bed.

41. The method of any one of claims 21 to 40, wherein each of the third catalyst bed and the fourth catalyst bed has a height that is 10% to 50% greater than the height of the first catalyst bed.

42. The method of any one of claims 22 to 41, wherein the fifth catalyst bed has a height that is 10% to 50% greater than that of the first catalyst bed.

43. The method of any one of claims 22 to 42, wherein the fourth catalyst bed and the fifth catalyst bed have the same height.

44. The method of any one of claims 22 to 43, wherein the fourth catalyst bed and the fifth catalyst bed have the same volume.

45. The method of any one of claims 21 to 44, wherein the volume of the catalyst bed increases from the first catalyst bed to the fourth catalyst bed.

46. ​​The method of any of the preceding claims, wherein at least one of the plurality of reactors is fluidly coupled to a furnace to form a furnace-reactor coupling unit.

47. The method of claim 46, further comprising passing the first fluid through the furnace before the first fluid enters the reactor in the same furnace-reactor coupling unit.

48. The method of claim 46, wherein the furnace-reactor coupling unit comprises a single furnace and a single reactor.

49. The method of claim 46, wherein there are a plurality of said furnace-reactor coupling units, and each of the furnace-reactor coupling units is fluidly coupled to each other.

50. The method of claim 46, wherein at least one of the plurality of furnace-reactor coupling units is a standby furnace-reactor coupling unit.

51. The method of claim 50, wherein the standby furnace-reactor coupling unit comprises a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit of the plurality of furnace-reactor coupling units.

52. The method of claim 50, wherein the standby furnace-reactor coupling unit comprises a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit immediately preceding the standby furnace-reactor coupling unit.

53. The method of claim 49, wherein the plurality of furnace-reactor coupling units comprises five furnace-reactor coupling units.

54. The method of claim 53, wherein only one of the five furnace-reactor coupling units in the furnace-reactor coupling unit is a standby furnace-reactor coupling unit.

55. The method of claim 50, wherein the standby furnace-reactor coupling unit is configured to be standby for any other furnace-reactor coupling unit among the plurality of furnace-reactor coupling units.

56. The method of claim 50, wherein the standby furnace-reactor coupling unit is the last furnace-reactor coupling unit among the plurality of furnace-reactor coupling units.

57. The method of claim 50, wherein the reactor in the standby furnace-reactor coupling unit has the largest height and / or volume among the reactors in the plurality of furnace-reactor coupling units.

58. The method as described in any of the preceding claims, wherein the catalyst operating cycle is between five and seven months.

59. The method as described in any of the preceding claims, wherein the catalyst operates for six months.

60. The method of claim 58 or 59, further comprising, after the catalyst operating cycle: Decouple at least one of the plurality of furnace-reactor coupling units from the remaining furnace-reactor coupling units, and Regenerate the catalyst bed or replace the catalyst bed in the at least one decoupled furnace-reactor coupling unit.

61. The method of claim 60, wherein the decoupling occurs immediately after the catalyst operating cycle.

62. The method of claim 49, wherein all of the plurality of furnace-reactor coupling units operate together at 60% to 80% capacity.

63. The method of claim 60, wherein the remaining furnace-reactor coupling units operate together at 100% capacity.

64. A system comprising: Multiple reactors, each including a catalyst bed and configured to convert alcohols to olefins, wherein: The plurality of reactors are fluidly coupled to each other, and At least one of the catalyst beds is configured to have a catalytically active region, which constitutes at least 90% of the catalyst bed during the catalyst operating cycle.

65. The system of claim 64, wherein the catalytically active region is 100% of the catalyst bed during the catalyst operating cycle.

66. The system of claim 64, wherein at least one of the catalyst beds further comprises an idle catalyst region, the idle catalyst region being less than 10% of the catalyst bed during the catalyst operating cycle.

67. The system of claim 64, wherein at least one of the catalyst beds does not include an idle catalyst zone during the catalyst operating cycle.

68. The system of any one of claims 64 to 67, wherein the alcohol comprises at least one of C2 alcohols, C3 alcohols, and C4 alcohols.

69. The system of claim 64, wherein the olefin comprises ethylene.

70. The system of any one of claims 64 to 69, wherein the plurality of reactors are arranged in a series-parallel configuration.

71. The system of any one of claims 64 to 70, wherein at least one of the plurality of reactors has a weight hourly space velocity of the alcohol greater than 0.6 / h and at most 1.5 / h.

72. The system of any one of claims 64 to 71, wherein at least one of the plurality of reactors has a weight hourly space velocity of the alcohol greater than 1 / h and at most 1.3 / h.

73. The system of any one of claims 64 to 72, wherein the plurality of reactors comprises: The first group of reactors comprises reactors, each having a first height, and The second group of reactors comprises reactors, each having a second height. The first height is different from the second height.

74. The system of any one of claims 64 to 73, wherein the plurality of reactors comprises, in sequence: The first reactor includes a first catalyst bed. The second reactor includes a second catalyst bed. A third reactor, comprising a third catalyst bed, and The fourth reactor includes a fourth catalyst bed.

75. The system of claim 74, wherein the plurality of reactors further comprises a fifth reactor after the fourth reactor, the fifth reactor comprising a fifth catalyst bed.

76. The system of any one of claims 64 to 75, wherein the variance between the heights of each of the plurality of reactors does not exceed 15%.

77. The system of any one of claims 64 to 76, wherein the variance between the heights of each of the plurality of reactors does not exceed 10%.

78. The system of any one of claims 74 to 77, wherein each of the third reactor and the fourth reactor has a height that is 10% to 50% greater than the height of the first reactor.

79. The system of any one of claims 75 to 78, wherein the fifth reactor has a height that is 10% to 50% greater than the height of the first reactor.

80. The system of any one of claims 75 to 79, wherein the third to fifth reactors have the same height.

81. The system of any one of claims 75 to 80, wherein the fourth reactor and the fifth reactor have the same volume.

82. The system of any one of claims 74 to 81, wherein the volume of each of the first to fourth reactors increases from the first to the fourth reactor.

83. The system of any one of claims 64 to 82, wherein the variance between the heights of each catalyst bed in the catalyst bed does not exceed 15%.

84. The system of any one of claims 74 to 83, wherein each of the third catalyst bed and the fourth catalyst bed has a height that is 10% to 50% greater than the height of the first catalyst bed.

85. The system of any one of claims 75 to 84, wherein the fifth catalyst bed has a height that is 10% to 50% greater than that of the first catalyst bed.

86. The system of any one of claims 75 to 85, wherein the fourth catalyst bed and the fifth catalyst bed have the same height.

87. The system of any one of claims 75 to 86, wherein the fourth catalyst bed and the fifth catalyst bed have the same volume.

88. The system of any one of claims 74 to 87, wherein the volume of the catalyst bed increases from the first catalyst bed to the fourth catalyst bed.

89. The system of any one of claims 64 to 88, wherein at least one of the plurality of reactors is fluidly coupled to the furnace to form a furnace-reactor coupling unit.

90. The system of claim 89, wherein there are a plurality of said furnace-reactor coupling units, and each of the furnace-reactor coupling units is fluidly coupled to each other.

91. The system of claim 90, wherein at least one of the plurality of furnace-reactor coupling units is a standby furnace-reactor coupling unit.

92. The system of claim 91, wherein the standby furnace-reactor coupling unit comprises a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit of the plurality of furnace-reactor coupling units.

93. The system of claim 91 or 92, wherein the standby furnace-reactor coupling unit comprises a reactor having the same height and / or volume as another reactor in another furnace-reactor coupling unit immediately preceding the standby furnace-reactor coupling unit.

94. The system of any one of claims 90 to 93, wherein the plurality of furnace-reactor coupling units comprises five furnace-reactor coupling units.

95. The system of claim 94, wherein only one of the five furnace-reactor coupling units in the furnace-reactor coupling unit is a standby furnace-reactor coupling unit.

96. The system of any one of claims 91 to 95, wherein the standby furnace-reactor coupling unit is configured to be standby for any other furnace-reactor coupling unit among the plurality of furnace-reactor coupling units.

97. The system of any one of claims 91 to 96, wherein the standby furnace-reactor coupling unit is the last furnace-reactor coupling unit among the plurality of furnace-reactor coupling units.

98. The system of any one of claims 91 to 97, wherein the reactor in the standby furnace-reactor coupling unit has the largest height and / or volume among the reactors in the plurality of furnace-reactor coupling units.

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