Method for dehydrogenating hydrocarbons utilizing multiple catalyst inlets

Abstract

A method for producing one or more olefinic compounds may include dehydrogenating a feed stream in the presence of a catalyst in a reactor to form a product stream and a deactivated catalyst. The feed stream may include one or more hydrocarbons comprising an alkyl moiety. The product stream may include one or more olefinic compounds. The method may also include separating the deactivated catalyst into a first portion of the deactivated catalyst and a second portion of the deactivated catalyst. The method may include sending the second portion of the deactivated catalyst to a regenerator. The method may include treating the second portion of the deactivated catalyst in the regenerator to form a regenerated catalyst. The method may also include sending the first portion of the deactivated catalyst and the regenerated catalyst to the reactor. The first portion of the deactivated catalyst may enter the reactor downstream of the regenerated catalyst relative to the flow direction of the feed stream. The first portion of the deactivated catalyst may have a lower temperature than the regenerated catalyst.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Application No. 63 / 428,521, filed November 29, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE INVENTION FIELD OF THE INVENTION Embodiments described herein relate generally to chemical processing, and more particularly to processes and systems utilized for the dehydrogenation of chemical species. [Background technology]

[0003] Olefin compounds can be used as base materials for producing many types of goods and materials. For example, propylene can be used to produce polypropylene, propylene oxide, and acrylonitrile. Such products can be used in product packaging, chemical manufacturing, fibers, etc. Therefore, there is an industrial demand for olefin compounds such as ethylene, propylene, butene, and styrene, as well as processes for producing such materials. Summary of the Invention

[0004] One method of producing olefinic compounds is by dehydrogenating hydrocarbons. In some embodiments, the dehydrogenation reaction may be facilitated by utilizing a solid particulate catalyst in a circulating fluidized bed (CFB) system. In embodiments, the catalyst may become deactivated as it is utilized in the dehydrogenation reaction. Such deactivated catalyst may be sent to a regenerator to restore at least a portion of its catalytic activity, for example, by decoking or heating the catalyst. Alternatively, a portion of the deactivated catalyst may be recycled and reused in the dehydrogenation reaction without being regenerated.

[0005] As described herein, it has been discovered that utilizing a particular catalyst distribution pattern for the recycled reaction catalyst, regenerated catalyst, and feed stream entering the reactor can be beneficial. The embodiments described herein include a catalyst distribution pattern in which the recycled reaction catalyst may enter the reactor downstream of the regenerated catalyst relative to the flow direction of the feed stream. Such a catalyst distribution pattern can improve catalytic activity within the reactor and improve yield from the dehydrogenation reaction, for example, when compared to a catalyst distribution pattern without a recycled reaction catalyst entering the reactor downstream of the regenerated catalyst relative to the flow direction of the feed stream. Generally, the recycled reaction catalyst is cooler and has lower catalytic activity than the regenerated catalyst. One skilled in the art would expect that premixing the two streams of catalyst would help reduce spatial variations in catalytic activity and temperature within the reactor, which would be beneficial to the process. However, contrary to what would be expected by a skilled artisan, the described method unexpectedly provides superior yields when compared to embodiments in which the recycled reaction catalyst is premixed with the regenerated catalyst by contacting the less catalytically active recycled reaction catalyst with the feed only after the more catalytically active regenerated catalyst has contacted the feed.

[0006] According to one or more embodiments described herein, a method for producing one or more olefinic compounds may include dehydrogenating a feed stream in the presence of a catalyst in a reactor to form a product stream and a deactivated catalyst. The feed stream may include one or more hydrocarbons comprising an alkyl moiety. The product stream may include one or more olefinic compounds. The method may also include separating the deactivated catalyst into a first portion of the deactivated catalyst and a second portion of the deactivated catalyst. The method may include sending the second portion of the deactivated catalyst to a regenerator. The method may include treating the second portion of the deactivated catalyst in the regenerator to form a regenerated catalyst. The method may also include sending the first portion of the deactivated catalyst and the regenerated catalyst to the reactor. The first portion of the deactivated catalyst may enter the reactor downstream of the regenerated catalyst relative to the flow direction of the feed stream. The first portion of the deactivated catalyst may have a lower temperature than the regenerated catalyst.

[0007] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and features of the claimed subject matter. Additional features and advantages of the embodiments are set forth in the detailed description, and in part will become readily apparent to those skilled in the art from that description, including the accompanying drawings and claims, or can be learned by practicing the described embodiments. The drawings are included to provide a further understanding of the embodiments and, together with the detailed description, serve to explain the principles and operation of the claimed subject matter. However, the embodiments shown in the drawings are illustrative and exemplary in nature and are not intended to limit the claimed subject matter. [Brief explanation of the drawings]

[0008] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. [Figure 1] 1 illustrates a schematic diagram of a reactor system according to one or more embodiments of the present disclosure. [Figure 2] 1 illustrates a schematic diagram of a reactor according to one or more embodiments of the present disclosure. [Figure 3A] 1 shows a schematic diagram of a continuous stirred tank reactor system. [Figure 3B] Schematic diagram of a continuous stirred tank reactor system configuration; and [Figure 3C] 1 shows a schematic of a continuous stirred tank reactor system configuration.

[0009] In illustrating the simplified schematic diagrams of Figures 1, 2, 3A, 3B, and 3C, numerous valves, temperature sensors, electronic controllers, etc., which would be used and known to one skilled in the art, are not included. Additionally, accompanying components often included within such reactor systems, such as air supplies, heat exchangers, surge tanks, etc., are also not included. However, it should be understood that these components are within the scope of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] Specific embodiments of the present application will now be described. However, this disclosure may be embodied in different forms and should not be construed as limited to the embodiments set forth in this disclosure. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present subject matter to those skilled in the art.

[0011] Embodiments of the present disclosure will be described in detail in the context of the reactor system of Figure 1 operating as a fluidized dehydrogenation reactor system for producing olefinic compounds such as propylene. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems utilizing different system components oriented in a different manner, or different reaction schemes utilizing various catalyst compositions. For example, the concepts described may be equally applicable to other systems with alternative reactor and regeneration units, such as those operating under non-fluidized conditions or those equipped with a downer rather than a riser. Furthermore, it should be understood that not all parts of the reactor system of Figure 1 should be construed as essential to the claimed subject matter.

[0012] Referring now to FIG. 1 , an exemplary reactor system 103 that may be suitable for use in the methods and / or apparatuses described herein is schematically illustrated. The reactor system 103 generally comprises multiple system components, such as a reactor section 206 and a regeneration unit 306. As described herein, a “system component” refers to a portion of the reactor system 103, such as, for example, a reactor, a separator, a transfer line, or a combination thereof. As used herein in the context of FIG. 1 , the reactor section 206 generally refers to the portion of the reactor system 103 where the primary process reaction (e.g., dehydrogenation) occurs to form a product stream. A feed stream enters the reactor section 206 via a feed inlet 434, is converted to a product stream (including products and unreacted feed), and exits the reactor section 206. The reactor section 206 comprises a reactor 202, which may comprise an upstream reactor section 254 and a downstream reactor section 230. 1, reactor portion 206 may further comprise a catalyst separation section 214 that serves to separate the catalyst from the chemical products formed in reactor 202. The catalyst that exits reactor 202 and is sent to catalyst separation section 214 may be deactivated, e.g., cooler or less active, than the catalyst that is sent from regeneration unit 306 to reactor 202 via line 424.

[0013] In one or more embodiments, the catalyst may be separated into multiple portions of catalyst and discharged via lines 422 and 426. As described herein, a "first portion" of the deactivated catalyst is returned to reactor 202 in a recycle stream (that does not go to combustor 355) via line 422. A "second portion" of the deactivated catalyst is sent to regeneration unit 306 via line 426. As described herein, the first portion of catalyst and the "regenerated catalyst" (i.e., a regenerated version of the second portion of catalyst sent to reactor 202 via line 424) are generally introduced separately into reactor 202, at different portions of reactor 202, e.g., at different heights. Such a configuration can have a positive effect on catalyst efficiency.

[0014] As used herein, regeneration unit 306 generally refers to the portion of reactor system 103 where the catalyst is treated in some manner, such as by combustion, to improve catalytic activity or heat the catalyst. Regeneration unit 306 may include combustor 355 and riser 330, particulate solids separation section 316, and may further include oxygen treatment zone 370. In one or more embodiments, particulate solids separation section 214 may be in fluid communication with combustor 355 (e.g., via standpipe 426), and particulate solids separation section 316 may be in fluid communication with upstream reactor section 250 (e.g., via standpipe 424 and transport riser 430).

[0015] Generally, as described herein, in the embodiment shown in FIG. 1 , the catalyst is circulated between the reactor section 200 and the regeneration unit 300. It should be understood that references herein to a “catalyst” can refer to a solid material that is catalytically active for a desired reaction, or can equally refer to other particulate solids mentioned with respect to the system of FIG. 1 that do not necessarily have catalytic activity but affect the reaction. The terms “catalytic activity” and “catalyst activity” refer to the extent to which a catalyst is capable of catalyzing a reaction taking place in the reactor system 106. In embodiments, a second portion of the deactivated catalyst can be reactivated by catalyst reactivation in the regeneration unit 306. Reactivation (sometimes referred to herein as “regeneration”) can remove contaminants such as coke, increase the temperature of the particulate solids, or both. The deactivated catalyst can be reactivated by, but is not limited to, removing coke by combustion, restoring catalyst acidity, oxidizing the particulate solids, other reactivation processes, or a combination thereof. The regenerated catalyst from the regeneration unit 306 may then be returned to the reactor section 202 via line 424 .

[0016] Referring now in detail to FIG. 1 , the reactor portion 206 may comprise an upstream reactor section 254, a transition section 258, and a downstream reactor section 230, such as a riser. The transition section 258 may connect the upstream reactor section 254 with the downstream reactor section 230. As shown in FIG. 1 , the upstream reactor section 254 may be positioned below the downstream reactor section 230. Such a configuration may be referred to as an upflow configuration for the reactor 202. The upstream reactor section 254 may comprise a vessel, drum, barrel, vat, or other containment vessel suitable for a given chemical reaction. As shown in FIG. 1 , the upstream reactor section 254 may connect to the downstream reactor section 230 via the transition section 258. The upstream reactor section 254 may generally comprise a larger cross-sectional area than the downstream reactor section 230. The transition section 258 may taper from the cross-sectional size of the upstream reactor section 254 to the cross-sectional size of the downstream reactor section 230 such that the transition section 258 projects inward from the upstream reactor section 254 toward the downstream reactor section 230. For example, the transition section 258 may be a frustum.

[0017] 1, a feed stream may enter reactor 202 via feed inlet 434, and a product stream may exit reactor system 103 via pipe 420. According to one or more embodiments, reactor system 103 may operate by supplying a chemical feed (e.g., in a feed stream) and a fluidized catalyst to upstream reactor section 254. The chemical feed contacts the catalyst in upstream reactor section 254, and each flows upward into and through downstream reactor section 230 to produce a chemical product.

[0018] The upstream reactor section 254 may be connected to a transport riser 430, which may provide reactivated catalyst in the feedstream to the reactor section 206 during operation. In one or more embodiments, a first portion of the deactivated catalyst may enter the reactor downstream of the regenerated catalyst relative to the flow direction of the feedstream. As described herein, in one or more embodiments, the regenerated catalyst and the first portion of the deactivated catalyst may enter the reactor 202 via the particulate solids distribution device 100. The particulate solids distribution device 100 may deliver the regenerated catalyst and the first portion of the deactivated catalyst separately to the reactor 202. The catalyst entering the upstream reactor section 254 via the transport riser 430 may arrive from the regeneration unit 306, sent to the transport riser 430 through line 424. The first portion of the deactivated catalyst may enter the transport riser 430 directly from the catalyst separation section 214 via line 422, where it enters the upstream reactor section 254. This catalyst may be somewhat deactivated but may still, in some embodiments, be suitable for reaction in the upstream reactor section 254, especially when used in conjunction with regenerated catalyst. The regenerated catalyst arriving from the regeneration unit 306 and a first portion of the deactivated catalyst arriving from the catalyst separation section 214 via line 422 may be kept separate in the transport riser 430 before being sent to the reactor 202 via the particulate solids distributor 100.

[0019] 1 , in one or more embodiments, based on the shape, size, and other process conditions (such as temperature and pressure) of the upstream reactor section 254 and the downstream reactor section 230, the upstream reactor section 254 can operate as a fluidized bed, such as a fast fluidized bed, turbulent bed, or bubbling bed upflow reactor, while the downstream reactor section 230 can operate in a plug flow regime, specifically as a riser reactor. For example, the reactor 202 of FIG. 1 can have the upstream reactor section 254 operating as a fast fluidized bed, turbulent bed, or bubbling bed reactor and the downstream reactor section 230 operating as a dilute-phase riser reactor, such that the average catalyst and gas flows move upward simultaneously. "Average flow," as that term is used herein, refers to net flow, i.e., total upward flow minus countercurrent or reflux, as is generally typical of fluidized particle behavior. As used herein, a "fast-fluid" reactor may refer to a reactor that utilizes a fluidization regime in which the superficial velocity of the gas phase is greater than the choking velocity and that may be semi-dense during operation. As used herein, a "turbulent" reactor may refer to a fluidization regime in which the superficial velocity is less than the choking velocity and that is denser than the fast-fluidization regime. As used herein, a "bubble-bed" reactor may refer to a fluidization regime in which well-defined bubbles within a dense bed exist in two distinct phases. "Choking velocity" refers to the minimum velocity required to maintain solids in a dilute-phase mode in a vertical transport line. As used herein, a "dilute-phase riser" may refer to a riser reactor that operates at a transport velocity, where the gas and catalyst have approximately the same velocity in the dilute phase.

[0020] According to an embodiment, the chemical product and catalyst may be discharged from downstream reactor section 230 and sent to separation device 226 in catalyst separation section 214, where the catalyst is separated from the chemical product and the chemical product is transported from catalyst separation section 214. According to one or more embodiments, following separation from the vapor in separation device 226, the deactivated catalyst may generally travel through strip zone 224, with a first portion of the deactivated catalyst being sent from strip zone 224 to reactor 202 via line 422, a second portion of the deactivated catalyst being sent to catalyst outlet port 222, and a second portion of the deactivated catalyst being transferred from reactor section 206 to regeneration unit 306 via line 426.

[0021] Returning now to FIG. 1 , according to one or more embodiments, separation device 226 may be a cyclonic separation system that may include two or more stages of cyclonic separation. In embodiments in which separation device 226 comprises one or more cyclonic separation stages, the first separation device into which the fluidized stream enters is referred to as the primary cyclonic separation device. The fluidized effluent from the primary cyclonic separation device may enter a secondary cyclonic separation device for further separation. Primary cyclonic separation devices may include, for example, primary cyclones and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster), and RS2 (commercially available from Stone and Webster). Primary cyclones are described, for example, in U.S. Pat. Nos. 4,579,716, 5,190,650, and 5,275,641, each of which is incorporated herein by reference in its entirety. Some separation systems utilizing a primary cyclone as the primary cyclonic separating device use one or more sets of additional cyclones, e.g., secondary and tertiary cyclones, to further separate the catalyst from the product gas. It should be understood that any primary cyclonic separating device may be used in embodiments of the present invention.

[0022] As previously described herein, the deactivated catalyst in catalyst separation section 214 may be separated into a first portion of deactivated catalyst that is returned to reactor 202 via line 422 and a second portion of deactivated catalyst that is sent to combustor 350 via line 426. The mass flow ratio of the first portion of deactivated catalyst to the second portion of deactivated catalyst may be between 0.1 and 5. For example, the mass flow ratio of the first portion of deactivated catalyst to the second portion of deactivated catalyst may be 0.1 to 4.5, e.g., 0.1 to 4, 0.1 to 3.5, 0.1 to 3, 0.1 to 2.5, 0.1 to 2, 0.1 to 1.5, 0.1 to 1, 0.1 to 0.5, 0.5 to 5, 0.5 to 4.5, 0.5 to 4, 0.5 to 3.5, 0.5 to 3, 0.5 to 2.5, 0.5 to 2, 0.5 to 1.5, 0.5 to 1, 1 to 5, 1 to 4.5, 1 to 4, 1 to 3.5, 1 to 3, 1 to 2.5, 1 to The mass flow rate of the second portion of deactivated catalyst delivered to combustor 350 may be approximately the same as the mass flow rate of the regenerated catalyst delivered to reactor 202 via line 424, as described later herein.

[0023] In one or more embodiments, the first portion of the deactivated catalyst (passing through line 422) is heated to a temperature between 580°C and 800°C, e.g., between 580°C and 775°C, between 580°C and 750°C, between 580°C and 725°C, between 580°C and 700°C, between 580°C and 675°C, between 580°C and 650°C, between 580°C and 625°C, between 580°C and 600°C, between 600°C and 800°C, between 600°C and 775°C, between 600°C and 750°C, between 600°C and 725°C, between 600°C and 700°C, between 600°C and 675°C, between 600°C and 650°C, between 600°C and 625°C, between 625°C and 800°C, between 625°C and 775°C, between 625°C and 750°C, between 625°C and 725 ... The temperature may be 600°C, 625°C to 675°C, 625°C to 650°C, 650°C to 800°C, 650°C to 775°C, 650°C to 750°C, 650°C to 725°C, 650°C to 700°C, 650°C to 675°C, 675°C to 800°C, 675°C to 775°C, 675°C to 750°C, 675°C to 725°C, 675°C to 700°C, 700°C to 800°C, 700°C to 775°C, 700°C to 750°C, 700°C to 725°C, 725°C to 800°C, 725°C to 775°C, 725°C to 750°C, 750°C to 800°C, 750°C to 775°C, 775°C to 800°C, or any combination of these ranges. This is generally lower than the temperature of the regenerated catalyst sent to reactor 202 via line 424 .

[0024] Continuing with reference to FIG. 1 , the second portion of the deactivated catalyst may be sent from the catalyst separation section 214 to the combustor 355 via line 426. In the combustor 355, the second portion of the deactivated catalyst may be treated, for example, by burning any coke on the catalyst with oxygen or an auxiliary fuel. For example, without limitation, the catalyst may be decoked and / or fuel may be combusted to heat the catalyst. The catalyst then exits the combustor 355 and passes through the riser 330 to the end-of-riser separator 378, where the gas and solid components from the riser 330 are at least partially separated. The vapor and remaining solids are transported to the secondary separation device 326 in the catalyst separation section 316, where the remaining catalyst is separated from gases from the catalyst treatment (e.g., gases emitted by the combustion of spent catalyst or fuel, referred to herein as flue gas). The flue gas may exit the regeneration unit 306 via an outlet pipe 432. The separated catalyst then travels via line 424 and transport riser 430 through oxygen treatment zone 370 in catalyst separation section 316 to upstream reactor section 254 where it is further utilized in catalytic reactions. This catalyst, treated as described, is referred to as the "regenerated catalyst" and is returned to reactor 202 in a separate stream from the first portion of the deactivated catalyst.

[0025] In one or more embodiments, the regenerated catalyst may have a temperature of between 680°C and 900°C when sent from the regeneration unit 306 to the reactor 202 via line 424. For example, the temperature of the regenerated catalyst is 680°C to 875°C, for example, 680°C to 850°C, 680°C to 825°C, 680°C to 800°C, 680°C to 775°C, 680°C to 750°C, 680°C to 725°C, 680°C to 700°C, 700°C to 900°C, 700°C to 875°C, 700°C to 850°C, 700°C to 825°C, 700°C to 800°C, 700°C to 775°C, 700°C to 750°C, 700°C to 725°C, 725°C to 900°C, 725°C to 875°C, 725°C to 850°C, 725°C to 825°C, 725°C to 800°C, 725°C to 775°C, 725°C to 725°C °C to 750°C, 750°C to 900°C, 750°C to 875°C, 750°C to 850°C, 750°C to 825°C, 750°C to 800°C, 750°C to 775°C, 775°C to 900°C, 775°C to 875°C, 775°C to 850°C, 775°C to 825°C, 775°C to 800°C, 800°C to 900°C, 800°C to 875°C, 800°C to 850°C, 800°C to 825°C, 825°C to 900°C, 825°C to 875°C, 825°C to 850°C, 850°C to 900°C, 850°C to 875°C, 875°C to 900°C, or any combination of these ranges.

[0026] Referring now to the regeneration unit 306, as shown in FIG. 1 , the combustor 355 of the regeneration unit 306 may include one or more lower combustor inlet ports 356 and may be in fluid communication with the riser 330. An oxygen-containing gas, such as air, may be delivered to the combustor 350 through a pipe 428. The combustor 355 is in fluid communication with the catalyst separation section 214 via a line 426, which may provide a second portion of the deactivated catalyst from the reactor portion 206 to the regeneration unit 306 for regeneration. The combustor 355 and the riser 330, collectively referred to as the catalytic combustion reactor 302, may operate with a fluidization regime similar to or identical to that disclosed for the upstream reactor section 254 and downstream reactor section 230 of the reactor portion 206. That is, the combustor 350 may operate as a fluidized bed, such as in a fast fluidized bed, turbulent bed, or bubbling bed upflow reactor, while the riser 330 may operate in a plug flow regime, such as in a riser reactor. The geometries described with respect to the upstream reactor section 254 and the downstream reactor section 230 are equally applicable to the combustor 355 and the riser 330. Additionally, the combustor 355 may also include a fuel inlet 354 through which a fuel, such as a hydrocarbon stream or hydrogen, may be supplied to the combustor 355.

[0027] As described in one or more embodiments, following separation of the flue gas from the catalyst in the end-of-riser separator 378 and secondary separation device 326, treatment of the treated catalyst with an oxygen-containing gas occurs in oxygen treatment zone 370. In some embodiments, oxygen treatment zone 370 comprises a fluid-solid contacting device. The fluid-solid contacting device may include baffles or grid structures to facilitate contact of the treated catalyst with the oxygen-containing gas. Examples of fluid-solid contacting devices are described in more detail in U.S. Patent Nos. 9,827,543 and 9,815,040. The fluidization regime within oxygen treatment zone 370 may be bubbling bed fluidization.

[0028] As described herein, the regenerated catalyst and the first portion of the deactivated catalyst enter reactor 202 in separate streams. In one or more embodiments, the first portion of the deactivated catalyst and the regenerated catalyst may comprise at least 95% by weight of the catalyst fed to reactor 202. For example, the first portion of the deactivated catalyst and the regenerated catalyst may comprise at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, or even at least 99.9% by weight of the catalyst fed to reactor 202.

[0029] As described in one particular embodiment with respect to Figure 2 herein below, in one or more embodiments, the first portion of the deactivated catalyst and the regenerated catalyst may enter reactor 202 through separate distributors. In one or more embodiments, the first portion of the deactivated catalyst and the regenerated catalyst may not enter reactor 202 through the bottom end of reactor 202.

[0030] 2, an exemplary reactor 202 that may be utilized with the reactor system 103 of FIG. 1 is shown schematically, including a particulate solids distributor 100 suitable for passing the regenerated catalyst and the first portion of the deactivated catalyst at different elevations. FIG. 2 illustrates one contemplated particulate solids distributor. However, other solids distributors may be suitable, and the embodiments described herein should not be construed as limited by the design, shape, size, architecture, etc., of the distributor or distributors that deliver the particulate solids to the combustor 350.

[0031] Referring now to Figure 2, the reactor 202 of the reactor system 103 of Figure 1 is shown schematically. The first portion of the deactivated catalyst 104 and the regenerated catalyst 105 may enter the reactor 202 through a particulate solids distributor 100. The particulate solids distributor 100 may deliver the first portion of the deactivated catalyst 104 to the reactor 202 downstream of the regenerated catalyst 105 relative to the flow direction of the feed stream through a feed inlet 434 and through a feed distribution plate 450 into the reactor 202. The first portion of the deactivated catalyst 104 may pass up the inner section of the particulate solids distributor 100 to an inner conduit outlet 220. The deactivated first portion of the particulate solids 104 may then contact a first catalyst director 240, which may direct the first portion of the deactivated catalyst 104 into the reactor 202. The regenerated catalyst 104 may pass through an outer portion of the particulate solids distributor and contact the second catalyst director 340, which directs the regenerated catalyst 105 into the reactor 202. As shown in FIG. 2 , in one or more embodiments, the regenerated catalyst 105 may enter the reactor 202 between the feed stream and the first portion 104 of the deactivated catalyst. The feed stream enters the reactor 202 through the feed inlet 434 and travels in an upward direction from the upstream reactor section 254 to the downstream reactor section 230. As the feed stream travels through the reactor 202, the feed stream first contacts the regenerated catalyst 105, which is directed into the reactor 202 by the second catalyst director 340. At least a portion of the feed stream may react with the regenerated catalyst 105 to produce one or more products. The combined stream, which may include one or more products, regenerated catalyst 105, and the feed stream, continues upward through the reactor and contacts a first portion of deactivated catalyst 104 that is directed into reactor 202 by first catalyst director 240. The first portion of deactivated catalyst 104 may contact the combined stream and react with unreacted feed from the feed stream to produce one or more products. The mixture of regenerated catalyst 105, first portion of deactivated catalyst 104, one or more products, and any remaining unreacted feed travels to upstream reactor section 230, where it may be sent to catalyst separation section 214 of reactor system 103 of FIG. 1 .

[0032] Without being bound by any particular theory, and with reference to the following examples, it has been unexpectedly discovered that the catalyst input patterns described herein can, in some embodiments, produce superior results compared to embodiments that do not include the described catalyst input patterns. In particular, it was expected that introducing a cooler recycled catalyst upstream of a hotter regenerated catalyst would result in better selectivity and subsequently higher yield. It was also expected that premixing the two catalyst streams would help reduce spatial variations in catalyst activity and temperature within the reactor, favoring better yield. However, as demonstrated in this example, the opposite is unexpectedly true.

[0033] In one or more additional embodiments, hydrocarbons, such as methane and ethane, may be entrained in the first portion of the deactivated catalyst. In one or more embodiments, the hydrocarbons may be entrained in the first portion of the deactivated catalyst as it is returned to reactor 202 via line 422. In the regeneration unit, the entrained hydrocarbons in the second portion of the deactivated catalyst may be combusted, and the regenerated catalyst returned to reactor 202 from regeneration unit 306 via line 424 may have no or substantially no entrained hydrocarbons; for example, the entrained hydrocarbons in the regenerated catalyst may be less than 0.5 mol %. However, there may be oxygen-containing gases entrained by the regenerated catalyst particles. Without being bound by theory, it is believed that when the hydrocarbons entrained in the first portion of the deactivated catalyst contact the oxygen-entrained regenerated catalyst at high temperatures (such as in the comparative embodiment), coke and steam may form on the regenerated catalyst. This may partially deactivate at least a portion of the regenerated catalyst. For example, contacting the high-temperature regenerated catalyst with hydrocarbons may partially deactivate the regenerated catalyst before the catalyst has a chance to contact the feed stream in the reactor, which may reduce the efficiency of the reactor system 103. It is believed that introducing the first portion of the deactivated catalyst and the regenerated catalyst at different locations into the reactor may prevent or reduce premature deactivation of the regenerated catalyst because entrained hydrocarbons in the first portion of the deactivated catalyst may not contact the regenerated catalyst before the regenerated catalyst enters the reactor 202. Furthermore, because the first portion of the deactivated catalyst may be delivered to the reactor 202 downstream of the regenerated catalyst relative to the flow direction of the feed stream, the regenerated catalyst may contact the feed stream before contacting the first portion of the deactivated catalyst and any entrained hydrocarbons in the first portion of the deactivated catalyst.

[0034] As discussed with respect to Figure 2, in one or more embodiments, reactor 202 can include a feed distribution plate 450, as shown in Figures 1 and 2. In one or more embodiments, when reactor 202 includes feed distribution plate 450, regenerated catalyst can enter reactor 202 between feed distribution plate 450 and the first portion of the deactivated catalyst.

[0035] In one or more embodiments, the temperature of the feed distribution plate can be between 25° C. and 700° C. For example, the temperature of the feed distribution plate can be between 25° C. and 600° C., between 25° C. and 500° C., between 25° C. and 400° C., between 25° C. and 300° C., between 25° C. and 200° C., between 25° C. and 100° C., between 100° C. and 700° C., between 100° C. and 600° C., between 100° C. and 500° C., between 100° C. and 400° C., between 100° C. and 300° C., between 100° C. and 200° C., between 200° C. and 700° C., between 200° C. and 600° C., between 200° C. and 2 ... The heating temperature can be 00°C to 500°C, 200°C to 400°C, 200°C to 300°C, 300°C to 700°C, 300°C to 600°C, 300°C to 500°C, 300°C to 400°C, 400°C to 700°C, 400°C to 600°C, 400°C to 500°C, 500°C to 700°C, 500°C to 600°C, 600°C to 700°C, or any combination of these ranges.

[0036] In one or more embodiments, the deactivated catalyst may be separated into a third portion of the deactivated catalyst (not shown in FIG. 1 ) in catalyst separation section 214. In such embodiments, the regenerated catalyst may be mixed with the third portion of the deactivated catalyst to form a mixed catalyst prior to being introduced into reactor 202. In such embodiments, the first portion of the deactivated catalyst may be fed to reactor 202 downstream of the mixed catalyst relative to the flow direction of the feedstream. Without being bound by theory, it is believed that mixing the regenerated catalyst with the third portion of the deactivated catalyst to form a mixed catalyst may have a less adverse effect on the activity of the regenerated catalyst due to a lower amount of hydrocarbons being entrained in the third portion of the deactivated catalyst.

[0037] In one or more embodiments, the temperature of the mixed catalyst can be 600° C. to 850° C. For example, the temperature of the mixed catalyst can be 600° C. to 825° C., 600° C. to 800° C., 600° C. to 775° C., 600° C. to 750° C., 600° C. to 725° C., 600° C. to 700° C., 600° C. to 675° C., 600° C. to 650° C., 600° C. to 625° C., 625° C. to 850° C., 625° C. to 825° C., 625° C. to 800° C., 625° C. to 775° C., 6 25℃~750℃, 625℃~725℃, 625℃~700℃, 625℃~675℃, 625℃~650℃, 650℃~850℃, 650℃~825℃, 650℃~800℃, 650℃~775℃, 650℃~750℃, 650℃~725℃, 650℃~700℃, 650℃~675℃, 675℃~850℃, 675℃~ 825℃, 675℃~800℃, 675℃~775℃, 675℃~750℃, 675℃~725℃, 675℃~700℃, 700℃~850℃, 700℃~825℃, 700℃~800℃, 700℃~775℃, 700℃~750℃, 700℃~725℃, 725℃~850℃, 725℃~825℃, 725℃~800℃ , 725°C to 775°C, 725°C to 750°C, 750°C to 850°C, 750°C to 825°C, 750°C to 800°C, 750°C to 775°C, 775°C to 850°C, 775°C to 825°C, 775°C to 800°C, 800°C to 850°C, 800°C to 825°C, 825°C to 850°C, or any combination of these ranges.

[0038] With continued reference to FIG. 1 , in a non-limiting example, the reactor system 103 described herein may be utilized to produce olefinic compounds from a hydrocarbon feedstream. As used herein, the term “olefinic compound” refers to a hydrocarbon having one or more carbon-carbon double bonds, separate from the formal double bonds present in aromatic compounds. For example, ethylene and styrene are olefinic compounds, while ethylbenzene is not an olefinic compound because the only double bond present in ethylbenzene is a formal double bond present as part of the aromatic structure. Olefinic compounds may be produced from a wide variety of hydrocarbon feedstreams by utilizing different reaction mechanisms. For example, olefinic compounds may be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These reaction types may utilize different feedstreams and different particulate solids to produce olefinic compounds. It should be understood that when particulate solids are referred to herein, they may also refer to the catalysts referred to with respect to the systems of FIGS. 1 and 2.

[0039] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the one or more hydrocarbons may be a hydrocarbon feed stream. In one or more embodiments, the one or more hydrocarbons may include an alkyl moiety. As used in this disclosure, a hydrocarbon includes an "alkyl moiety" if the molecule has at least one carbon-carbon single bond that can be dehydrogenated to form a carbon-carbon double bond. The hydrocarbon feed stream may include one or more of ethylbenzene, ethane, propane, n-butane, and i-butane. In one or more embodiments, the hydrocarbon feed stream may include at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethylbenzene. In one or more embodiments, the hydrocarbon feed stream may include at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% by weight of propane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% by weight of n-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% by weight of i-butane. In additional embodiments, the hydrocarbon feed stream may comprise a total of at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethylbenzene, ethane, propane, n-butane, and i-butane.

[0040] In one or more embodiments, the dehydrogenation reaction may utilize a gallium and / or platinum particulate solid as a catalyst. In such embodiments, the particulate solid may include a gallium and / or platinum catalyst. As described herein, a gallium and / or platinum catalyst includes gallium, platinum, or both. The gallium and / or platinum catalyst may be supported on an alumina or alumina-silica support and may optionally include potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Pat. No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts may be utilized to carry out the dehydrogenation reaction.

[0041] In one or more embodiments, the reaction mechanism may be dehydrogenation followed by combustion (in the same chamber). In such embodiments, the dehydrogenation reaction may produce hydrogen as a by-product, and the oxygen carrier material may contact the hydrogen to promote combustion of the hydrogen to form water. Examples of such reaction mechanisms contemplated as possible reaction mechanisms for the systems and methods described herein are disclosed in International Publication No. WO 2020 / 046978 and U.S. Patent Application Publication No. 2021 / 0292259, the teachings of which are incorporated herein by reference in their entireties.

[0042] In one or more embodiments, the particulate solid may comprise an oxygen carrier material and a dehydrogenation catalyst material. In some embodiments, the particulate solid may consist essentially of an oxygen carrier material. As used herein, "consisting essentially of" refers to a material that contains less than 1 wt. % of an unlisted material (i.e., consisting essentially of A means that A is at least 99 wt. % of the composition). In some embodiments, the particulate solid may be free of a dehydrogenation catalyst material. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst material may be separate particles of the particulate solid. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst may be contained within the same particle of the particulate solid.

[0043] In embodiments in which the particulate solid comprises a dehydrogenation catalyst, the dehydrogenation of one or more hydrocarbons may be at least partially due to catalytic dehydrogenation. Catalytic dehydrogenation is the dehydrogenation of hydrocarbons facilitated by the use of a dehydrogenation catalyst. In embodiments in which the particulate solid does not comprise a dehydrogenation catalyst, the dehydrogenation reaction may be non-catalytic thermal dehydrogenation. Non-catalytic thermal dehydrogenation refers to the dehydrogenation of hydrocarbons that does not use a dehydrogenation catalyst and instead may occur through elevated temperatures, pressures, or a combination thereof.

[0044] In some embodiments, the particulate solid may comprise a "dual-purpose material" that can act as both a dehydrogenation catalyst and an oxygen-carrying material. It should be understood that, at least in the embodiments described herein in which an oxygen-carrying material and a dehydrogenation catalyst are utilized in the same reactor vessel (such as that of FIG. 1), such a dual-purpose material may be utilized in place of or in combination with the particulate solid oxygen-carrying material or the particulate solid dehydrogenation catalyst.

[0045] In one or more embodiments, the particulate solid may be capable of fluidization. In some embodiments, the particulate solid may exhibit properties known in the industry as "Geldart A" or "Geldart B" properties. Particles may be classified as "Group A" or "Group B" according to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), 34-37, and D. Geldart, "Types of Gas Fluidization," Powder Technol. 7 (1973) 285-292, which are incorporated herein by reference in their entireties.

[0046] Group A represents powders that can be aerated and are understood by those skilled in the art to have the following characteristics: fluidization in a bubble-free regime; high bed expansion; slow and linear degassing rate; the predominance of divided / recombined bubbles and bubble characteristics with a maximum bubble size and a large wake; a high level of solid mixing and gas backmixing assuming equal U-Umf (where U is the velocity of the carrier gas and Umf is the minimum fluidization velocity, typically not necessarily measured in meters per second, m / s, i.e., there is an excess gas velocity); axisymmetric slug characteristics; and no ejection except for very shallow beds. Assuming equal cfp, the listed characteristics tend to improve as the average particle size decreases; or as the proportion less than 45 micrometers (μm) increases; or as the pressure, temperature, viscosity, and density of the gas increase. Generally, the particles exhibit a small average particle size and / or a low particle density (less than 1.4 grams per cubic centimeter, g / cm 3 3) and can be easily fluidized to have smooth fluidization at low gas velocities and can exhibit controlled bubbling by small bubbles at higher gas velocities.

[0047] Group B represents "sand-like" powders that are understood by those skilled in the art to have the following characteristics: starting to foam at Umf; showing moderate bed expansion; rapid degassing; no limit on bubble size; assuming equal U-Umf, having a moderate level of solid mixing and gas backmixing; both axisymmetric and asymmetric slugs; and ejecting only in shallow beds. These characteristics tend to improve as the average particle size decreases, but the particle size distribution and, with some uncertainty, the gas pressure, temperature, viscosity, or density do not seem to contribute much to the improvement of the above characteristics. Generally, most of the particles have a particle size (cfp) of 40 μm < cfp < 500 μm when the density (pp) is 1.4 < pp < 4 g / cm 3 3, preferably 60 μm < cfp < 500 μm when the density (pp) is 4 g / cm 3 3, and 250 μm < cfp < 100 μm when the density (pp) is 1 g / cm 3 3.

[0048] In one or more embodiments, olefinic compounds may be present in a "product stream," sometimes referred to as an "olefin-containing effluent." Such a stream may exit the reactor system of FIG. 1 and be subsequently processed. In one or more embodiments, the olefinic compounds may include one or more of ethylene, propylene, butylene, or styrene. The term butylene includes any isomer of butylene, such as α-butylene, cis-β-butylene, trans-β-butylene, and isobutylene. In some embodiments, the olefin-containing effluent may comprise at least 20 wt.%, at least 30 wt.%, at least 40 wt.%, at least 50 wt.%, or even at least 60 wt.% ethylene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt.%, at least 30 wt.%, at least 40 wt.%, at least 50 wt.%, or even at least 60 wt.% propylene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% butylene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% styrene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% of the total of one or more of ethylene, propylene, butylene, and styrene. The olefin-containing effluent may further comprise unreacted components of the feed stream and other reaction products that are not considered light olefins. The olefin compounds may be separated from the unreacted components in a subsequent separation step. [Example]

[0049] Example 1 - Catalyst deactivation from CH4 and steam In Example 1, the effects of CH4 exposure and steam exposure on catalyst activity were observed. Tests were conducted in a fixed-bed rig using 0.5 g of supported gallium catalyst loaded with platinum promoter. Laboratory-simulated reaction-combustion-reactivation cycles were conducted in the fixed-bed rig. In each cycle, the dehydrogenation reaction was first performed at 625°C for 10 hours. -1 The catalyst was then treated with a weight hourly space velocity (WHSV) of 90% propane / 10% nitrogen for 60 seconds. The catalyst was then treated with a simulated combustion flow at 750°C for 3 minutes. Finally, the catalyst was reactivated under air at 750°C for 15 minutes. Dehydrogenation performance was collected for 15 seconds on-stream. To test the effect of CH exposure on catalytic activity, the catalyst was treated with 100% CH at a flow rate of 10 standard cubic centimeters per minute (sccm) for 2 minutes at 750°C after reactivation under air. The cycle was then run again, and the dehydrogenation performance of the CH-treated catalyst was collected for 15 seconds on-stream. A laboratory-simulated reaction-combustion-reactivation cycle was then run without CH treatment to restore the catalyst activity to baseline. The catalyst was then treated with 100% CH at a lower temperature, 625°C, for 2 minutes. The cycle was then run again and the dehydrogenation performance of the low temperature CH4 treated catalyst was collected with 15 seconds on-stream time.

[0050] A laboratory-simulated reaction-combustion-reactivation cycle was then performed without CH4 treatment to restore the catalyst activity to baseline. The catalyst was then treated with steam at a flow rate of 24 sccm at 625°C for 2 minutes, followed by stripping under helium for 5 minutes, after which the catalyst was subjected to a laboratory-simulated reaction-combustion reactivation cycle. The dehydrogenation performance of the steam-treated catalyst was collected with an on-stream time of 15 seconds. The dehydrogenation performance of the catalyst under various treatment conditions is recorded in Table 1.

[0051] [Table 1]

[0052] As shown in Table 1, exposing the catalyst to steam or CH4 at high temperatures (750 °C) before use in the dehydrogenation reaction adversely affected the catalyst's propane conversion and propane selectivity performance, as well as the catalyst's intrinsic rate. As seen in Sample B1, exposure to CH4 caused an approximately 40% loss in propane conversion performance, a 2.4% loss in propane selectivity, and a 68% loss in activity when compared to a catalyst that was not exposed to CH4 before use in the dehydrogenation reaction (i.e., Sample A). Similarly, Sample C shows that exposing the catalyst to steam before use in the dehydrogenation reaction resulted in an approximately 60% decrease in propane conversion performance, an 8% decrease in propane selectivity, and an 86% decrease in activity when compared to a catalyst that was not exposed to steam before use in the dehydrogenation reaction (i.e., Sample A). This demonstrates that premixing a high-temperature regenerated catalyst carrying oxygen with a low-temperature recycle-deactivated catalyst carrying a stripping hydrocarbon gas, such as methane, can cause unexpected deactivation of the regenerated catalyst. In contrast, exposing the catalyst to CH4 at low temperature (625°C) prior to using the catalyst in the dehydrogenation reaction has only a small effect on the propane conversion and propane selectivity performance of the catalyst and the intrinsic rate of the catalyst.

[0053] Example 2 - Effect of catalyst distributor configuration To simulate the catalyst mixing and dehydrogenation reaction in a typical fluid catalytic dehydrogenation reactor, a reactor model consisting of three continuous stirred tank reactors (CSTRs) in series was utilized, with the catalyst and reactants thoroughly mixed in each CSTR, as shown in Figure 3. In Figure 3, the three CSTRs are shown as part of a single reactor system 600. The catalyst and / or reactants flow from the first CSTR 610 to the second CSTR 620 to the third CSTR 630. Upstream of the reactor, one of the regenerated catalyst 640 and one of the deactivated catalyst 606 are added. stPremixing with propane, if any, was represented by the mixer (mixing pot) 640. The catalytic dehydrogenation and thermal reactions were solved using the kinetic model by Lobera et al. (2008) and Sundaram and Froment (1977). Mass and energy conservation equations were solved for the mixer and each CSTR to determine the effluent gas composition and temperature. 50% of the catalyst from the third CSTR 630 was recycled as recycled catalyst 606 for reuse in the reactor simulation without regeneration. The catalyst is continuously deactivated as it travels from CSTR to CSTR due to the net amount of propane reacted in each CSTR. The same total catalyst amount in each CSTR was used in simulating each reactor configuration shown below. The reactor model utilized the same regeneration process for each configuration, resulting in the same catalytic activity for the regenerated catalyst 604 with adsorbed oxygen. The regenerated catalyst was at a temperature of 750°C. The model also utilized CH4 as the stripping gas in all configurations, which resulted in the recycled catalyst adsorbing a portion of the CH4. The recycled catalyst temperature was predicted as the outlet temperature of the third CSTR.

[0054] Three reactor configurations were evaluated using the reactor model described above. In Configuration A, as shown in FIG. 3A, regenerated catalyst 604 carrying adsorbed oxygen is mixed with recycled catalyst 606 from third CSTR 630 in a mixing pot 640 upstream of first CSTR 610. The mixed catalyst 642 then enters first CSTR 610, where propane 602 is fed to reactor 600. Based on the experimental data shown in Example 1, it was estimated that the adsorbed CH in recycled catalyst 606 would react with residual oxygen in regenerated catalyst 604 at a mixing pot 640 temperature of 685°C, resulting in 40% activity. Configuration A approximates the reactor conditions that would occur if recycled catalyst 606 and regenerated catalyst 604 were premixed in mixing pot 640 before entering reactor 600.

[0055] In Configuration B, as shown in Figure 3B, recycled catalyst 606 from third CSTR 630 is fed to first CSTR 610, propane 602 is also fed separately to first CSTR 610, and regenerated catalyst 604 is fed to second CSTR 620. Thus, recycled catalyst 606 travels from third CSTR 630 to first CSTR 610 and then to second CSTR 620, where it is mixed with regenerated catalyst 604 fed to second CSTR 620. Due to the endothermic dehydrogenation reaction, the process temperature decreases along the CSTRs in series. Mixing of regenerated catalyst 604 carrying adsorbed oxygen and recycled catalyst 606 with adsorbed CH4 occurs in second CSTR 620, where the temperature was predicted to be 623.5°C. As shown in Example 1, the effect of CH4 on catalytic activity was significantly reduced at lower temperatures and was then negligible for configuration B.

[0056] In Configuration 1, as shown in FIG. 3C, the regenerated catalyst 604 is fed to the first CSTR 610, propane 602 is also fed separately to the first CSTR 610, and recycled catalyst 606 from the third CSTR 630 is fed separately to the second CSTR 620. Thus, the regenerated catalyst 604 enters the second CSTR 620 from the first CSTR 610 before being mixed with the recycled catalyst 606 in the second CSTR 620. The adsorbed oxygen in the regenerated catalyst 604 was assumed to be consumed in the first CSTR 610 before mixing with the recycled catalyst 606 with adsorbed CH. Therefore, the deactivation of CH in the catalytic dehydrogenation activity was ignored. Configuration 1 represents the reactor conditions that occur when the regenerated catalyst 604 is fed to the reactor 600 at a location between the propane feed 602 and the recycled catalyst 604. The results from runs of configurations A, B, and 1 are recorded in Table 2.

[0057] [Table 2]

[0058] As shown in Table 2, Configuration 1 according to the present invention has the highest overall propane conversion of 36.3% and propylene yield of 32.7% among the three configurations. The next closest propane conversion is Configuration B, which has a propane conversion and propylene yield that are 2.4% and 1.3% lower, respectively, than Configuration 1, indicating that Configuration 1 has significantly better propane conversion compared to the other tested configurations.

[0059] In a first aspect of the present disclosure, one or more olefinic compounds can be produced by a method comprising dehydrogenating a feed stream in a reactor in the presence of a catalyst to form a product stream and a deactivated catalyst. The feed stream comprises one or more hydrocarbons comprising an alkyl moiety, and the product stream comprises one or more olefinic compounds. The method also comprises separating the deactivated catalyst into a first portion of the deactivated catalyst and a second portion of the deactivated catalyst. The method also comprises sending the second portion of the deactivated catalyst to a regenerator and treating the second portion of the deactivated catalyst in the regenerator to form a regenerated catalyst. The method also comprises sending the first portion of the deactivated catalyst and the regenerated catalyst to the reactor. The first portion of the deactivated catalyst enters the reactor downstream of the regenerated catalyst relative to the flow direction of the feed stream. The first portion of the deactivated catalyst has a lower temperature than the regenerated catalyst.

[0060] A second aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the first portion of the deactivated catalyst and the regenerated catalyst are delivered to the reactor through a particulate solids distributor that delivers the first portion of the deactivated catalyst and the regenerated catalyst separately to the reactor.

[0061] A third aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the particulate solids distributor extends into the reactor through the bottom end of the reactor.

[0062] A fourth aspect of the present disclosure includes any of the preceding aspects or combinations of aspects, wherein the one or more hydrocarbons include propane and the one or more olefinic compounds include propylene.

[0063] A fifth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the catalyst comprises one or more of gallium or platinum.

[0064] A sixth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the reactor operates as a fast fluidized, turbulent, or bubbling fluidized bed reactor.

[0065] A seventh aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the temperature of the first portion of the deactivated catalyst fed to the reactor is between 580°C and 800°C.

[0066] An eighth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the temperature of the regenerated catalyst delivered to the reactor is between 680°C and 900°C.

[0067] A ninth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the hydrocarbon is entrained in the first portion of the deactivated catalyst and the second portion of the deactivated catalyst.

[0068] A tenth aspect of the present disclosure includes any of the preceding aspects or combinations of aspects, wherein the one or more hydrocarbons include propane and the one or more olefin compounds include propylene. The catalyst includes one or more of gallium and platinum. The temperature of the first portion of the deactivated catalyst fed to the reactor is 580°C to 800°C. The temperature of the regenerated catalyst fed to the reactor is 680°C to 900°C. The first portion of the deactivated catalyst and the regenerated catalyst are fed to the reactor through a particulate solids distributor that feeds the first portion of the deactivated catalyst and the regenerated catalyst separately to the reactor. The particulate solids distributor extends into the reactor through the bottom of the reactor. The reactor operates as a fast fluidized, turbulent, or bubbling fluidized bed reactor.

[0069] An eleventh aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the reactor includes a feed distribution plate, the regenerated catalyst enters the reactor between the feed distribution plate and the first portion of the deactivated catalyst, and the temperature of the feed distribution plate is from 25°C to 700°C.

[0070] A twelfth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the first portion of the deactivated catalyst and the regenerated catalyst comprise at least 95% by weight of the catalyst fed to the reactor.

[0071] A thirteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the mass flow ratio of the first portion of the deactivated catalyst to the regenerated catalyst is 0.1 to 5.

[0072] A fourteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the deactivated catalyst is separated into a third portion in addition to the first portion of deactivated catalyst and the second portion of deactivated catalyst, and the third portion of deactivated catalyst is combined with the regenerated catalyst before being sent to the reactor to form a mixed catalyst.

[0073] A fifteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the mixed catalyst has a temperature of from 600°C to 850°C.

[0074] It will be apparent to those skilled in the art that various modifications and variations can be made to the technology of the present disclosure without departing from the spirit and scope of the technology. Since combinations, subcombinations, and variations of the disclosed embodiments incorporating the spirit and substance of the technology of the present disclosure may occur to those skilled in the art, the technology should be construed as including all within the scope of the appended claims and their equivalents. Furthermore, although some aspects of the present disclosure may be identified herein as preferred or particularly advantageous, it is intended that the present disclosure is not limited to these aspects.

[0075] It should be noted that the various details described in this disclosure should not be construed to imply that these details relate to elements that are essential components of the various embodiments described in this disclosure, even if a particular element is illustrated in each of the drawings accompanying this specification. Unless specifically identified as such, features disclosed and described herein should not be construed as "essential." Contemplated embodiments of the technology include those that include some or all of the features of the appended claims.

[0076] It should be noted that for purposes of describing and defining this disclosure, the term "about" is utilized in this disclosure to express the inherent degree of uncertainty that may result from any quantitative comparison, value, measurement, or other representation. The term "about" is also utilized in this disclosure to express the degree to which a quantitative representation may vary from the basis of description without resulting in a change in the basic functionality of the subject matter in question.

[0077] Where relevant, when a composition is described as "comprising" one or more elements, embodiments of the composition that "consist" or "consist essentially of" those one or more elements are contemplated herein.

[0078] It is understood that the compositional ranges of chemical components in a stream or reactor should, in some embodiments, be understood to contain a mixture of isomers of that component. For example, a compositional range specifying butene may include a mixture of various isomers of butene. It is understood that the examples provide compositional ranges for various streams, and that the total amount of isomers of a particular chemical composition may constitute a range.

[0079] It should be noted that one or more of the following claims utilize the term "where" or "wherein" as a transitional phrase. It should be noted that, for purposes of defining the art, this term is introduced in the claims as an open-ended transitional phrase used to introduce the recitation of a series of features of structure, and should be interpreted in a similar manner to the more commonly used open-ended preamble term "comprising."

[0080] It should be understood that any two quantitative values ​​assigned to a property may constitute a range for that property, and all combinations of ranges formed from all stated quantitative values ​​for a given property are contemplated in the application. When multiple ranges are given for quantitative values, these ranges may be combined to form larger ranges, which are contemplated in the embodiments described herein.

[0081] As understood in the context of the term as used herein, the term "passing" can include passing a substance directly between two portions of the disclosed system, and in some other instances, can mean passing a substance indirectly between two portions of the disclosed system. For example, indirect passing can include passing the specified substance through an intermediate operating unit, valve, sensor, etc.

Claims

1. 1. A method for producing one or more olefinic compounds, said method comprising: dehydrogenating a feed stream in a reactor in the presence of a catalyst to form a product stream and a deactivated catalyst, wherein the feed stream comprises one or more hydrocarbons comprising alkyl moieties and the product stream comprises one or more olefinic compounds; separating the deactivated catalyst into a first portion of deactivated catalyst and a second portion of deactivated catalyst; sending the second portion of the deactivated catalyst to a regenerator; treating the second portion of the deactivated catalyst in the regenerator to form a regenerated catalyst; and and feeding the first portion of the deactivated catalyst and the regenerated catalyst to the reactor, wherein the first portion of the deactivated catalyst enters the reactor downstream of the regenerated catalyst relative to a flow direction of the feed stream, and the first portion of the deactivated catalyst has a lower temperature than the regenerated catalyst.

2. 10. The method of claim 1, wherein the first portion of the deactivated catalyst and the regenerated catalyst are delivered to the reactor through a particulate solids distributor that delivers the first portion of the deactivated catalyst and the regenerated catalyst separately to the reactor.

3. 3. The method of claim 2 wherein the particulate solids distributor extends into the reactor through a bottom end thereof.

4. The method of any one of claims 1 to 3, wherein the one or more hydrocarbons comprise propane and the one or more olefinic compounds comprise propylene.

5. The method of any one of claims 1 to 4, wherein the catalyst comprises one or more of gallium and platinum.

6. 6. The method of any one of claims 1 to 5, wherein the reactor operates as a fast fluidized, turbulent, or bubbling fluidized bed reactor.

7. 7. The process of any one of claims 1 to 6, wherein the temperature of the first portion of deactivated catalyst fed to the reactor is from 580°C to 800°C.

8. The method of any one of claims 1 to 7, wherein the temperature of the regenerated catalyst fed to the reactor is from 680°C to 900°C.

9. 9. The method of any one of claims 1 to 8, wherein hydrocarbons are entrained with the first portion of deactivated catalyst and the second portion of deactivated catalyst.

10. the one or more hydrocarbons comprise propane and the one or more olefinic compounds comprise propylene; the catalyst comprises one or more of gallium and platinum; the temperature of the first portion of deactivated catalyst fed to the reactor is between 580°C and 800°C; the temperature of the regenerated catalyst fed to the reactor is between 680°C and 900°C; and the first portion of the deactivated catalyst and the regenerated catalyst are delivered to the reactor through a particulate solids distributor that delivers the first portion of the deactivated catalyst and the regenerated catalyst separately to the reactor; the particulate solids distributor extends into the reactor through the bottom of the reactor; and 10. The method of claim 1, wherein the reactor operates as a fast fluidized, turbulent, or bubbling fluidized bed reactor.

11. 11. The method of any one of claims 1 to 10, wherein the reactor comprises a feed distribution plate, the regenerated catalyst enters the reactor between the feed distribution plate and the first portion of deactivated catalyst, and the temperature of the feed distribution plate is from 25°C to 700°C.

12. 12. The process of any one of claims 1 to 11, wherein the first portion of deactivated catalyst and the regenerated catalyst comprise at least 95% by weight of the catalyst fed to the reactor.

13. 13. The method of any one of claims 1 to 12, wherein the mass flow ratio of the first portion of deactivated catalyst to the regenerated catalyst is from 0.1 to 5.

14. 14. The method of any one of claims 1 to 13, wherein the deactivated catalyst is separated into the first portion of deactivated catalyst and the second portion of deactivated catalyst plus a third portion, and the third portion of deactivated catalyst is combined with the regenerated catalyst to form a mixed catalyst before being fed to the reactor.

15. 15. The method of claim 14, wherein the mixed catalyst has a temperature of 600°C to 850°C.

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