Method for forming light olefins using catalyst recycling - Patent Application 20070122997

Abstract

According to embodiments disclosed herein, a method of forming light olefins in a reactor system may include reacting a feed stream in the presence of a catalyst to form a deactivated catalyst; transporting the deactivated catalyst to a combustor and treating the deactivated catalyst to produce a reactivated catalyst; combining a portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form a mixed catalyst stream; contacting the mixed catalyst stream with a first oxygen-containing gas stream upstream of the combustor; transporting the mixed catalyst stream to the combustor and contacting the mixed catalyst stream with a second oxygen-containing gas stream while in the combustor, wherein a molar flow rate of the first oxygen-containing gas stream is 1% to 15% of a combined molar flow rate of the first oxygen-containing gas stream and the second oxygen-containing gas stream.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 428,498, 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 methods and systems for producing light olefins. [Background technology]

[0003] Light olefins such as propylene can be used as a base material to produce many different materials, such as polypropylene, isopropanol, and acrylic acid, which can be used, for example, in packaging, construction, and textiles. As a result of this utility, there is a global demand for light olefins. Suitable processes for producing light olefins generally depend on a given chemical feed and include those that utilize fluidized catalysts. For example, light olefins can be formed by catalytic dehydrogenation of alkanes in a fluidized bed reactor. However, improvements are needed in the systems and associated catalysts used to make light olefins. Summary of the Invention

[0004] Conventional processes for producing light olefins sometimes transfer deactivated catalysts to catalytic treatment systems that include combustion and regeneration steps to heat and reactivate the catalysts, but these processes have several drawbacks. For example, the deactivated catalyst may enter the combustor directly, in which case a relatively large amount of coke may deposit on the deactivated catalyst, resulting in the catalyst still containing a relatively large amount of coke after the deactivated catalyst is treated. In another example, the deactivated catalyst may enter the combustor at a relatively low temperature and may not be uniformly heated to the regeneration temperature, resulting in some catalyst not being properly regenerated. In another example, the coked catalyst may enter the combustor and not be uniformly distributed, which preferentially consumes available oxygen, resulting in poor fuel-air mixing and inefficient combustion. Furthermore, some conventional processes may treat at least a portion of the deactivated catalyst with the gas stream in one or more separate units before entering the combustor, resulting in higher costs associated with having one or more separate units.

[0005] Described herein is a process for producing light olefins that may overcome these problems in some embodiments. According to the embodiments described herein, a portion of the reactivated catalyst may be recycled and combined with the deactivated catalyst upstream of the combustor to form a mixed catalyst stream, which then enters the combustor. This combination of the recycled portion of the reactivated catalyst with the deactivated catalyst can reduce the amount of coke that accumulates on the deactivated catalyst before entering the combustor, thereby exposing more catalytically active sites on the deactivated catalyst and improving the combustion of the auxiliary fuel in the regenerator. In addition, this combination of the recycled portion of the reactivated catalyst with the deactivated catalyst can heat the deactivated catalyst before entering the combustor, thereby achieving a target regeneration temperature more quickly and achieving more uniform regeneration of the catalyst. In addition, if the coke is burned before entering the combustor where the supplemental fuel is mixed with air, catalyst distribution may be less important because maldistribution may not affect the fuel-air mixture in the combustor to the same extent as it would otherwise. In one or more embodiments, combining the deactivated catalyst with the recycled portion of the reactivated catalyst does not require mixing in one or more separate units, thus reducing costs associated with this combining process. Furthermore, the deactivated catalyst and the recycled portion of the reactivated catalyst can be contacted with a single oxygen-containing gas stream prior to entering the combustor, and separate oxygen-containing gas streams can be introduced into the combustor, in which case the oxygen-containing gas stream used to move the deactivated catalyst and the recycled portion of the reactivated catalyst to the combustor contributes to the total oxygen-containing gas for the combustor, thereby reducing costs associated with providing separate oxygen-containing gas streams directly to the combustor.

[0006] According to one or more embodiments of the present disclosure, a method for forming light olefins in a reactor system includes reacting a feed stream in the presence of a catalyst in a reactor to form a product stream and deactivated catalyst comprising coke; separating at least a portion of the product stream from the deactivated catalyst; transferring the deactivated catalyst to a combustor in a catalyst processing section of the reactor system and processing the deactivated catalyst to produce reactivated catalyst and flue gas, wherein coke is removed from the deactivated catalyst in the combustor; separating the reactivated catalyst from the flue gas and separating the reactivated catalyst into a first portion and a second portion; and transferring the first portion of the reactivated catalyst to the reactor. and combining a second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form a mixed catalyst stream, wherein the mixed catalyst stream is contacted with a first oxygen-containing gas stream upstream of the combustor, and wherein coke on the deactivated catalyst is oxidized upon contact with the first oxygen-containing gas stream upstream of the combustor; and transporting the mixed catalyst stream to the combustor and contacting the mixed catalyst stream with a second oxygen-containing gas stream while in the combustor, wherein the sum of the molar flow rate of the first oxygen-containing gas stream and the molar flow rate of the second oxygen-containing gas defines a total oxygen-containing gas molar flow rate, and the molar flow rate of the first oxygen-containing gas stream is between 1% and 15% of the total oxygen-containing gas molar flow rate.

[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] The following detailed description can be better understood when read in conjunction with the following drawings. [Figure 1] 1 illustrates a schematic diagram of a reactor system according to one or more embodiments of the present disclosure. [Figure 2] 1A and 1B illustrate schematic diagrams of a cutaway view of a combustor of a catalytic treatment section of a reactor system in accordance with one or more embodiments of the present disclosure.

[0009] 1, the numerous valves, temperature sensors, electronic controllers, etc. that may be used and that are well known to those skilled in the art are not included. Additionally, accompanying components that are 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.

[0010] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. DETAILED DESCRIPTION OF THE INVENTION

[0011] The embodiments disclosed herein are described in detail herein in the context of the reactor system of FIG. 1 operating as a fluidized dehydrogenation reactor system for producing light olefins. 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 to different reaction schemes utilizing various catalyst compositions. For example, the concepts described may equally apply to other systems with alternative reactor and regeneration units, such as those operating under non-fluidized conditions or those including a downer rather than a riser. Furthermore, light olefins may be produced from a wide variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, light olefins may be catalytically produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefins reactions. In some embodiments, oxygen carrier materials may also be utilized to selectively combust hydrogen, as described herein. These reaction types may utilize different feed streams and / or different catalysts to produce light olefins. Furthermore, it should be understood that not all portions of FIG. 1 should be construed as essential to the claimed subject matter.

[0012] Referring now to FIG. 1 , an exemplary reactor system 102 that may be suitable for use with the methods and / or apparatus described herein is shown schematically. The reactor system 102 generally includes multiple system components, such as a reactor section 200 and a catalytic treater section 300. As described herein, a "system component" refers to a portion of the reactor system 102, such as a reactor, a separator, a transfer line, or a combination thereof. As used herein in the context of FIG. 1 , the reactor section 200 generally refers to the portion of the reactor system 102 where the primary process reaction (e.g., dehydrogenation) occurs to form a product stream. A feed stream enters the reactor section 200, is converted to a product stream (containing product and unreacted feed), and exits the reactor section 200. The reactor section 200 includes a reactor 202, which may include an upstream reactor section 250 and a downstream reactor section 230. 1 , reactor section 200 may further include a catalyst separation section 210 that serves to separate the catalyst from the chemical products formed in reactor 202. Also, as used herein, catalytic treater 300 generally refers to the portion of reactor system 102 where the catalyst is treated in some manner, such as by combustion, to improve catalytic activity by, for example, decoking and / or heating the catalyst. Catalytic treater 300 may include combustor 350 and riser 330, and may further include catalyst separation section 310. In one or more embodiments, catalyst separation section 210 may be in fluid communication with combustor 350 (e.g., via water column 426), and catalyst separation section 310 may be in fluid communication with upstream reactor section 250 (e.g., via water column 424 and transfer riser 430). In one or more embodiments, the catalyst from the catalyst separation section 210 (sometimes referred to as deactivated catalyst) travels towards the combustor 350 via a standpipe 426 .In one or more embodiments, a portion of the catalyst from the catalyst treatment section 300 (sometimes referred to as a first portion of the reactivated catalyst) may be transferred to the upstream reactor section 250 via standpipe 424 and transfer riser 430, and a portion of the catalyst from the catalyst treatment section 300 (sometimes referred to as a second portion of the reactivated catalyst) may be recycled and transferred towards the combustor 350 via standpipe 385.

[0013] As described herein, the deactivated catalyst from standpipe 426 may be combined with a second portion of the reactivated catalyst from standpipe 385 to form a mixed catalyst stream that then enters combustor 350. Such a second portion of the reactivated catalyst may be considered a recycle stream within catalytic processing section 300. The advantages of such a configuration are described in more detail below.

[0014] Generally, as described herein, in the embodiment shown in FIG. 1 , a catalyst is circulated between the reactor section 200 and the catalyst treatment section 300. It should be understood that references to "catalyst" herein can refer to solid materials that are 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, such as oxygen carriers. The terms "catalytic activity" and "catalyst activity" refer to the degree to which a catalyst is capable of catalyzing a reaction taking place within a reactor system. The catalyst exiting the reactor section 200 may be a deactivated catalyst. As used herein, "deactivated" may refer to a catalyst that is less catalytically active or cooler than the catalyst entering the reactor section 200. However, a deactivated catalyst may retain some catalytic activity. The reduction in catalytic activity may be due to contamination by materials such as coke. Reactivation (sometimes referred to herein as "regeneration") can remove contaminants such as coke, increase the temperature of the catalyst, and / or rebuild catalytic sites to restore or improve the dehydrogenation and / or combustion activity of the catalyst. In embodiments, a deactivated catalyst may be reactivated by catalyst reactivation in catalytic treater 300. A deactivated catalyst may be reactivated by, but is not limited to, removing coke by combustion, restoring catalyst acidity, oxidizing the catalyst, heating the catalyst, other reactivation processes, or combinations thereof. In some embodiments, the catalyst may also be heated during reactivation by combustion of a supplemental fuel, such as hydrogen, methane, ethane, propane, natural gas, or combinations thereof.

[0015] 1, a feed stream may enter reactor 202 through feed inlet 434, and a product stream may exit reactor system 102 via pipe 420. According to one or more embodiments, reactor system 102 may operate by supplying a chemical feed (e.g., in a feed stream) and a fluidized catalyst to upstream reactor section 250. The chemical feed contacts the catalyst in upstream reactor section 250, and each flows upward into and through downstream reactor section 230 to produce a chemical product.

[0016] Referring now in detail to FIG. 1 , the reactor section 200 may comprise an upstream reactor section 250, a transfer section 258, and a downstream reactor section 230, such as a riser. The transfer section 258 may connect the upstream reactor section 250 with the downstream reactor section 230. As shown in FIG. 1 , the upstream reactor section 250 may be disposed 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 250 may comprise a vessel, drum, barrel, vat, or other vessel suitable for a given chemical reaction. As shown in FIG. 1 , the upstream reactor section 250 may be connected to the downstream reactor section 230 via the transfer section 258. The upstream reactor section 250 may generally comprise a larger cross-sectional area than the downstream reactor section 230. The transfer section 258 may taper from the cross-sectional size of the upstream reactor section 250 to the cross-sectional size of the downstream reactor section 230 such that the transfer section 258 projects inward from the upstream reactor section 250 toward the downstream reactor section 230. For example, the transfer section 258 may be a frustum.

[0017] The upstream reactor section 250 can be connected to a transfer riser 430 that can provide reactivated catalyst in a feed stream to the reactor section 200 during operation. The reactivated catalyst and / or reaction chemicals can be mixed in a distributor 260 housed within the upstream reactor section 250. Catalyst entering the upstream reactor section 250 via the transfer riser 430 can be sent to the transfer riser 430 through a distribution tower 424 and thus arrives from the catalyst treatment section 300. In some embodiments, the catalyst may enter the transfer riser 430 directly from the catalyst separation section 210 via a standpipe 422, in which case the catalyst enters the upstream reactor section 250; in such embodiments, a portion of the catalyst does not pass through the catalyst treatment section 300. Catalyst can also be fed directly to the upstream reactor section 250 via the standpipe 422 (not shown in FIG. 1 ). This catalyst may be somewhat deactivated but may still be suitable for reaction in the upstream reactor section 250 in some embodiments, especially when used in conjunction with a reactivated catalyst.

[0018] 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 250 and the downstream reactor section 230, the upstream reactor section 250 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 more in a plug flow regime, such as a riser reactor. For example, the reactor 202 of FIG. 1 may have the upstream reactor section 250 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 described herein, a "fast-fluid" reactor may refer to a reactor utilizing a fluidization regime in which the superficial velocity of the gas phase is greater than the choking velocity and may be semi-dense during operation. As described herein, a "turbulent" reactor may refer to a fluidization regime in which the superficial velocity is less than the choking velocity and is denser than the fast-fluidization regime. As described 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 described herein, a "dilute-phase riser" may refer to a riser reactor operating at a transport velocity, in which the gas and catalyst have approximately the same velocity in the dilute phase.

[0019] According to an embodiment, the chemical products and catalyst may be discharged from downstream reactor section 230 and sent to a separator 220 in catalyst separation section 210, where the catalyst is separated from the chemical products and the chemical products are transported out of catalyst separation section 210. According to one or more embodiments, following separation from the vapors in separator 220, the catalyst may generally travel through a stripper 224 to a catalyst outlet port 222, where it is transported out of reactor section 200 via standpipe 426 toward catalyst treatment section 300.

[0020] According to one or more embodiments, separator 220 may be a cyclonic separation system that can include two or more stages of cyclonic separation. In embodiments in which separator 220 includes more than one cyclonic separation stage, the first separator into which the fluidized stream enters is referred to as the primary cyclonic separator. The fluidized effluent from the primary cyclonic separator may enter a secondary cyclonic separator for further separation. Primary cyclonic separators 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 a primary cyclonic separator 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 separator can be used in the embodiments disclosed herein.

[0021] 1 , the separated deactivated catalyst is transported from the catalyst separation section 210 toward the combustor 350 via standpipe 426 and J-bend 393. The deactivated catalyst is then combined with a second portion of the reactivated catalyst that was transported via standpipe 385 and J-bend 392. The second portion of the reactivated catalyst may be transported from the catalyst separation section 310 and recycled toward the combustor 350 of the catalyst processing section 300 via standpipe 385 and J-bend 392. The deactivated catalyst is combined with the second portion of the reactivated catalyst to form a mixed catalyst stream. The combination of the deactivated catalyst and the second portion of the reactivated catalyst may occur in pipe 395, which may be in fluid communication with the combustor 350, such that the components of the mixed catalyst stream contact the first oxygen-containing gas stream and are thoroughly mixed for at least 1 second, at least 2 seconds, at least 3 seconds, at least 4 seconds, at least 5 seconds, or even longer, e.g., about 8 seconds, before the mixed catalyst stream is transported to the combustor 350. The mixed catalyst stream may then enter the combustor 350. The mixing of these streams is generally upstream of their insertion into the combustor 350.

[0022] In one or more embodiments, a first oxygen-containing gas may be contacted with the mixed catalyst stream via one or more pipes 510 before the mixed catalyst stream travels to combustor 350. The first oxygen-containing gas stream may enter via pipe 510 at J bend 393, may enter via pipe 510 at J bend 392, and / or may enter via pipe 510 at pipe 395. The first oxygen-containing gas may enter one or more of pipes 510. When the first oxygen-containing gas enters via pipe 510 at J bend 393, the first oxygen-containing gas contacts at least a portion of the deactivated catalyst passing through standpipe 426 and then contacts a second portion of the reactivated catalyst that is combined with the deactivated catalyst in pipe 395. Prior to contacting line 510, the catalyst in line 426 may be in the presence of an inert gas, such as nitrogen or water vapor. When the first oxygen-containing gas enters via pipe 510 at J bend 392, the first oxygen-containing gas contacts at least a portion of the second portion of the reactivated catalyst passing through standpipe 385 before the deactivated catalyst is combined with the second portion of the reactivated catalyst. When the first oxygen-containing gas enters via pipe 510 at pipe 395, the first oxygen-containing gas contacts the mixed catalyst stream in pipe 395 containing both the deactivated catalyst and the second portion of the reactivated catalyst. The use of oxygen from pipe 510 can further contribute to less oxygen needing to be added directly to combustor 350, which can have advantages in terms of achieving a desired fluidization regime in combustor 350.

[0023] Without being bound by any particular theory, it is believed that combining the deactivated catalyst with the second portion of the reactivated catalyst to form a mixed catalyst stream and contacting the mixed catalyst stream with the first oxygen-containing gas stream reduces the amount of coke that accumulates on the deactivated catalyst before the mixed catalyst stream enters the combustor 350. Furthermore, it is believed that combining the deactivated catalyst with the second portion of the reactivated catalyst to form a mixed catalyst stream and contacting the mixed catalyst stream with the first oxygen-containing gas stream pre-oxidizes coke on the deactivated catalyst before the deactivated catalyst enters the combustor 350 and also helps achieve sufficient mixing of the deactivated catalyst with the second portion of the reactivated catalyst in the pipe 395. This, in turn, is believed to improve catalyst performance in the combustion of the auxiliary fuel in the combustor 350. In an additional embodiment, the combination of catalyst streams can introduce fluidization efficiency by placing all of the catalyst in the center of the combustor 350.

[0024] Furthermore, without being bound by any particular theory, it is believed that combining the deactivated catalyst with a second portion of the reactivated catalyst to form a mixed catalyst stream and contacting the mixed catalyst stream with the first oxygen-containing gas stream heats the deactivated catalyst before it enters the combustor 350. In many conventional processes, various distributors, mixing devices, such as pipes, baffles, etc., attempt to rapidly spread and mix the deactivated catalyst to heat it to a target regeneration temperature. However, in these conventional processes, the mixing devices may not sufficiently mix the catalyst uniformly throughout the catalyst treatment section, or at least to the extent that the premixing scheme disclosed herein can be achieved, resulting in regions within the catalyst treatment section where the catalyst is insufficiently heated, resulting in some degree of non-uniform deactivated catalyst regeneration. In the processes described herein, according to one or more embodiments, the deactivated catalyst may be heated before it enters the combustor 350, thereby allowing the deactivated catalyst to reach a target regeneration temperature more quickly and achieving more uniform regeneration of the deactivated catalyst. For example, it is believed that higher conversion rates of auxiliary fuels such as methane may be achieved due to the deactivated catalyst being heated before entering the combustor 350 compared to a process in which the deactivated catalyst is simply transferred directly from the reactor section 200 to the combustor 350.

[0025] In one or more embodiments, combining the second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form the mixed catalyst stream occurs in pipe 395 in a dense phase lift fluidization regime. The term "dense phase lift fluidization regime" may refer to a fluidization regime that results in contact of the mixed catalyst stream with the first oxygen-containing gas stream, where the first oxygen-containing gas stream has a velocity that sufficiently contacts the first oxygen-containing gas stream with the mixed catalyst stream, but the velocity is not high enough to transport the mixed catalyst stream to combustor 350 before sufficient mixing of the mixed catalyst stream is achieved. It is contemplated that pipe 395 may be a pipe or vessel having various cross-sectional shapes and sizes and a length that allows sufficient mixing of the mixed catalyst stream and the first oxygen-containing gas stream before the mixed catalyst stream enters combustor 350.

[0026] In one or more embodiments, the pipe 395 can operate at a superficial gas velocity of 0.3 m / s to 5 m / s, e.g., 0.4 m / s to 2.5 m / s, 0.6 m / s to 2.3 m / s, 0.7 m / s to 2.2 m / s, 0.9 m / s to 2.2 m / s, 1.0 m / s to 2.1 m / s, or 1.5 m / s to 2.1 m / s. In one or more embodiments, the pipe 395 can operate at a superficial gas velocity of 245 kg / m 2 -s~1710kg / m 2 -s, e.g., 300 kg / m 2 -s~1500kg / m 2 -s, 400 kg / m 2 -s~1450kg / m 2 -s, 400 kg / m 2 -s~1400kg / m 2 -s, 500 kg / m 2 -s~1,350kg / m 2 -s, 500 kg / m 2 -s~1,300kg / m 2 -s, 550 kg / m 2 -s~1,220kg / m 2 -s, or 600 kg / m 2 -s~1,000kg / m 2 -s solids flux.

[0027] In one or more embodiments, combining the second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor 350 to form a mixed catalyst stream results in a temperature difference of 10° C. or less between the second portion of the reactivated catalyst and the deactivated catalyst before entering the combustor 350. For example, the temperature difference may be 10° C. or less, 9° C. or less, 8° C. or less, 7° C. or less, 6° C. or less, 5° C. or less, 4° C. or less, 3° C. or less, 2° C. or less, or even 1° C. or less.

[0028] In one or more embodiments, the mixed catalyst flow enters the catalytic treatment section 300 through the bottom center section of the combustor 350. The center section of the combustor 350 refers to a point that is approximately half the diameter of any two points along the circumference of the combustor body. It should be noted that the mixed catalyst flow does not have to enter the combustor 350 at the exact center point of the bottom of the combustor 350; the mixed catalyst flow may enter the combustor 350 at any point along the bottom of the combustor 350, allowing the flow to properly rise toward the riser 330.

[0029] In one or more embodiments, the mixed catalyst stream may enter the combustor 350 at a flow velocity between 0.5 m / s and 4.0 m / s. For example, the mixed catalyst stream may enter combustor 350 at a flow velocity of 0.5 m / s to 3.5 m / s, 0.5 m / s to 3.0 m / s, 0.5 m / s to 2.5 m / s, 0.5 m / s to 2.0 m / s, 0.5 m / s to 1.5 m / s, 0.5 m / s to 1.0 m / s, 1.0 m / s to 4.0 m / s, 1.5 m / s to 4.0 m / s, 2.0 m / s to 4.0 m / s, 2.5 m / s to 4.0 m / s, 3.0 m / s to 4.0 m / s, 3.5 m / s to 4.0 m / s, 1.0 m / s to 3.5 m / s, 1.5 m / s to 3.0 m / s, or 2.0 m / s to 3.0 m / s.

[0030] The term "oxygen-containing gas" can refer to any gas containing at least 0.5% by weight of oxygen. For example, the oxygen-containing gas can contain at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% by weight of oxygen. In some embodiments, the oxygen-containing gas can include 0.5% to 99.9% oxygen by weight, e.g., 1% to 99.9% oxygen by weight, 10% to 99.9% oxygen by weight, 20% to 99.9% oxygen by weight, 50% to 99.9% oxygen by weight, 0.5% to 80% oxygen by weight, 0.5% to 60% oxygen by weight, 0.5% to 40% oxygen by weight, or 0.5% to 30% oxygen by weight. In one or more embodiments, the oxygen-containing gas can be air.

[0031] In one or more embodiments, the temperature of the deactivated catalyst can be 550°C to 800°C. For example, the temperature of the deactivated catalyst can be 600°C to 800°C, 650°C to 800°C, 700°C to 800°C, 750°C to 800°C, 550°C to 750°C, 550°C to 700°C, 550°C to 650°C, 550°C to 600°C, or 600°C to 650°C. In one or more embodiments, the temperature of the second portion of the reactivated catalyst can be 700°C to 900°C. For example, the temperature of the second portion of the reactivated catalyst can be 750°C to 900°C, 800°C to 900°C, 850°C to 900°C, 700°C to 850°C, 700°C to 800°C, 700°C to 750°C, or 750°C to 950°C. In one or more embodiments, the temperature of the deactivated catalyst is increased when combined with the second portion of the reactivated catalyst. In some embodiments, the temperature of the deactivated catalyst can be between 600°C and 850°C after combination with the second portion of the reactivated catalyst. For example, the temperature of the deactivated catalyst can be between 650°C and 850°C, 700°C and 850°C, 750°C and 850°C, 800°C and 850°C, 600°C and 800°C, 600°C and 750°C, 600°C and 700°C, 600°C and 750°C, 650°C and 750°C, or 700°C and 800°C after combination with the second portion of the reactivated catalyst.

[0032] Continuing with FIG. 1 , the mixed catalyst stream may enter combustor 350, where it then contacts a second oxygen-containing gas stream. One or more of the first oxygen-containing gas stream and / or the second oxygen-containing gas stream may be air. The second oxygen-containing gas stream may enter combustor 350 via pipe 428. The second oxygen-containing gas stream may promote combustion of one or more fuel gases or auxiliary gases present in combustor 350 and burn at least a portion of any coke still present on the catalyst in combustor 350. The catalyst then exits combustor 350 and passes through riser 330 to end-of-riser separator 378, where gas and solid components from riser 330 are at least partially separated. Steam and remaining solids are transferred to secondary separator 320 in catalyst separation section 310, where the remaining catalyst is separated from gases from the catalytic process (e.g., gases emitted by combustion of spent catalyst or auxiliary fuel, referred to herein as flue gas). The flue gas can exit the catalytic treatment section 300 via an outlet pipe 432. The separated first portion of the catalyst (also referred to as the deactivated catalyst first portion) is then transferred via a standpipe 424 and a transfer riser 430 through an oxygen treatment zone 370 in the catalyst separation section 310 to the upstream reactor section 250, where it is further utilized in catalytic reactions. The separated second portion of the catalyst (also referred to as the reactivated catalyst second portion) is transferred via a standpipe 385 toward the combustor 350 and combined with the deactivated catalyst from the reactor section 200 to form a mixed catalyst stream, which then enters the combustor 350. The second portion of the catalyst may be exposed to the oxygen-containing gas for at least 5 seconds, or even for a period longer than 30 seconds (e.g., several minutes), which may be shorter than the time the first portion of the catalyst was exposed to oxygen. The catalyst can be circulated between the reactor section 200 and the catalytic treatment section 300 during operation. Generally, the treated chemical streams, including the feed stream and the product stream, may be gaseous, and the catalyst may be a fluidized particulate solid.

[0033] Referring to FIG. 2, a schematic cutaway view of an embodiment of a combustor 350 is shown. FIG. 2 illustrates the combustor 350 used as a fluidized fuel gas combustor system for a catalytic dehydrogenation process. However, as detailed herein, the chemical feedstock distributor 100 can be used in a variety of vessels. Referring again to FIG. 2, the combustor 350 can include a generally cylindrical lower portion 201 and an upper portion including a frustum 202. The angle between the frustum 202 and an internal horizontal imaginary line drawn at the intersection of the frustum 202 and the lower portion 201 can range from 10 to 80 degrees. All individual values ​​and subranges between 10 and 80 degrees are included and disclosed herein. For example, the angle between the tubular component and the frustum 202 component can range from a lower limit of 10, 40, or 60 degrees to an upper limit of 30, 50, 70, or 80 degrees. For example, the angle may be between 10 and 80 degrees, or alternatively between 30 and 60 degrees, or alternatively between 10 and 50 degrees, or alternatively between 40 and 80 degrees. Further, in alternative embodiments, the angle may vary continuously or discontinuously along the height of the frustum 202. In some embodiments, the combustor 350 may or may not be lined with a refractory material.

[0034] The deactivated catalyst may move toward the combustor 350 via standpipe 426, and the second portion of the reactivated catalyst may move toward the combustor 350 via standpipe 385, and the deactivated catalyst and the second portion of the reactivated catalyst may combine to form a mixed catalyst stream in pipe 395. The mixed catalyst stream may move upward toward the air distributor 205. Above the air distributor 205 may be a grid 207. Above the grid 207 may be multiple chemical feedstock distributors 100. One or more additional grids 208 may be positioned within the combustor 350 above the chemical feedstock distributors 100. In an embodiment, the chemical feedstock distributors 100 may enter the combustor 350 and move substantially across the combustor 350, as described in U.S. Patent Application Publication No. 2017 / 0087528.

[0035] Referring now generally to catalytic treater section 300, as shown in FIG. 1 , combustor 350 of catalytic treater section 300 may be in fluid communication with riser 330. A second oxygen-containing gas stream may enter combustor 350 through pipe 428. Combustor 350 and riser 330, collectively referred to as catalytic combustion reactor 302, may operate in a similar or identical fluidization regime to that disclosed for upstream reactor section 250 and downstream reactor section 230 of reactor section 200. That is, combustor 350 may operate as a fluidized bed, such as in a fast fluidized bed, turbulent bed, or bubbling bed upflow reactor, while riser 330 may operate more in a plug flow mode, such as a riser reactor. The geometries described for upstream reactor section 250 and downstream reactor section 230 are equally applicable to combustor 350 and riser 330. Additionally, the combustor 350 may also include a fuel inlet 354 through which a fuel, such as a hydrocarbon stream, may be supplied to the combustor 350 .

[0036] In one or more embodiments, the first oxygen-containing gas stream and the second oxygen-containing gas stream may be combined in the combustor 350 to have a combined oxygen-containing gas flow rate, with the flow rate of the first oxygen-containing gas stream being 1% to 15% of the combined oxygen-containing gas flow rate. It should be understood that because the first oxygen-containing gas stream can transport the mixed catalyst stream to the combustor 350, the first oxygen-containing gas stream also exists in the combustor 350 after contacting and reacting with the mixed catalyst stream, and therefore contributes to the amount of oxygen-containing gas required in the combustor 350. In this manner, the presence of the first oxygen-containing gas stream supplements the total amount of oxygen-containing gas present in the combustor 350, thereby reducing the amount of second oxygen-containing gas required during the combustion step in the combustor 350. Importantly, this reduces the costs associated with providing a larger second oxygen-containing gas stream to the combustor 350 that would be required if the mixed catalyst stream were not in contact with the first oxygen-containing gas stream and transported to the combustor 350 by the first oxygen-containing gas stream.

[0037] 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 unit 320, 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 contactor. The fluid-solid contactor may include a baffle or grid structure to facilitate contact of the treated catalyst with the oxygen-containing gas. Examples of fluid-solid contactors are described in more detail in U.S. Pat. Nos. 9,827,543 and 9,815,040. The fluidization regime within the oxygen treatment zone may be bubbling bed fluidization. Oxygen treatment zone 370 may include an oxygen-containing gas inlet 372 through which oxygen-containing gas may be delivered to oxygen treatment zone 370 for oxygen treatment of the catalyst.

[0038] In one or more embodiments, light olefins may be present in a "product stream," sometimes referred to as an "olefin-containing effluent," and may include light olefins. Such a stream may exit the reactor system of FIG. 1 and be subsequently processed. As used in this disclosure, the term "light olefin" refers to one or more of ethylene, propylene, and butene. The term butene includes any isomer of butene, such as α-butylene, cis-β-butylene, trans-β-butylene, and isobutylene. In some embodiments, the olefin-containing effluent comprises at least 25 wt.% light olefins, based on the total weight of the olefin-containing effluent. For example, the olefin-containing effluent may comprise at least 30 wt.% light olefins, at least 35 wt.% light olefins, at least 40 wt.% light olefins, at least 45 wt.% light olefins, at least 55 wt.% light olefins, or at least 60 wt.% light olefins, based on the total weight of the olefin-containing effluent. The olefin-containing effluent may further contain unreacted components of the feed stream, as well as other reaction products that are not considered light olefins, which can be separated from the unreacted components in a subsequent separation step.

[0039] In a non-limiting example, the reactor system 102 described herein may be utilized to produce light olefins from a hydrocarbon feed stream. Light olefins may be produced from a wide variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, light olefins may be produced by at least dehydrogenation reactions, dehydrogenation reactions with selective hydrogen combustion, cracking reactions, dehydration reactions, and methanol-to-olefins reactions. These reaction types may utilize different feed streams and different particulate solids to produce light olefins. It should be understood that when "catalysts" are referred to herein, they may equally refer to the particulate solids referred to with respect to the system of FIG. 1.

[0040] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethylbenzene, ethane, propane, n-butane, and i-butane. In one or more embodiments, the hydrocarbon feed stream may comprise 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 comprise 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 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% propane. In additional embodiments, the hydrocarbon feed stream may comprise 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% n-butane. In additional embodiments, the hydrocarbon feed stream may comprise 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% i-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of the total of ethane, propane, n-butane, and i-butane.

[0041] 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, the 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.

[0042] 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 WO 2020 / 046978, the teachings of which are incorporated herein by reference in their entirety.

[0043] According to one or more embodiments, the reaction may be a cracking reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of naphtha, n-butane, or i-butane. According to one or more embodiments, the hydrocarbon feed stream may comprise 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% naphtha. In additional embodiments, the hydrocarbon feed stream may comprise 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% n-butane. In additional embodiments, the hydrocarbon feed stream may comprise 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% i-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of the total of naphtha, n-butane, and i-butane.

[0044] In one or more embodiments, the cracking reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solid may include one or more zeolites. In some embodiments, the one or more zeolites utilized in the cracking reaction may include ZSM-5 zeolite. However, it should be understood that other suitable catalysts may be utilized to carry out the cracking reaction. For example, suitable commercially available catalysts may include Intercat Super Z Excel or Intercat Super Z Exceed. In additional embodiments, the cracking catalyst may include platinum in addition to the catalytically active material. For example, the cracking catalyst may include 0.001% to 0.05% by weight of platinum. The platinum may be sprayed as platinum nitrate and calcined at a high temperature, such as about 700°C. Without being bound by theory, it is believed that the addition of platinum to the catalyst may enable easier combustion of auxiliary fuels, such as methane.

[0045] According to one or more embodiments, the reaction may be a dehydration reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethanol, propanol, or butanol. According to one or more embodiments, the hydrocarbon feed stream may comprise 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% ethanol. In additional embodiments, the hydrocarbon feed stream may comprise 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% propanol. In additional embodiments, the hydrocarbon feed stream may comprise 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% butanol. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% of the total of ethanol, propanol, and butanol.

[0046] In one or more embodiments, the dehydration reaction may utilize one or more acid catalysts. In such embodiments, the particulate solid may include one or more acid catalysts. In some embodiments, the one or more acid catalysts utilized in the dehydration reaction may include a zeolite (such as ZSM-5 zeolite), alumina, an amorphous aluminosilicate, an acid clay, or a combination thereof. For example, commercially available alumina catalysts that may be suitable, according to one or more embodiments, include SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol). Commercially available zeolite catalysts that may be suitable include CBV 8014, CBV 28014 (each available from Zeolyst). Commercially available amorphous aluminosilicate catalysts that may be suitable include silica-alumina catalyst support, grade 135 (available from Sigma-Aldrich). However, it should be understood that other suitable catalysts may be utilized to carry out the dehydration reaction.

[0047] According to one or more embodiments, the reaction can be a methanol to olefins reaction. According to such embodiments, the hydrocarbon feed stream can include methanol. According to one or more embodiments, the hydrocarbon feed stream can 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% methanol.

[0048] In one or more embodiments, the methanol-to-olefins reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solid may comprise one or more zeolites. In some embodiments, the one or more zeolites utilized in the methanol-to-olefins reaction may comprise one or more of ZSM-5 zeolite or SAPO-34 zeolite. However, it should be understood that other suitable catalysts may be utilized to carry out the methanol-to-olefins reaction. [Example]

[0049] Examples are provided herein and should not be construed as limiting the claimed embodiments provided below.

[0050] Example 1 A reactor system including a reactor section and a catalytic treatment section, in which the deactivated catalyst was combined with a recycled stream of reactivated catalyst from the catalytic treatment section, was operated for 60 cycles. In this manner, the process of catalytic dehydrogenation in the reactor section and methane combustion in the catalytic treatment section was repeated 60 times. This test is referred to as the inventive test. In contrast, a reactor system including a reactor section and a catalytic treatment section, in which the deactivated catalyst was sent directly to the combustor of the catalytic treatment section and not combined with the recycled stream of reactivated catalyst from the catalytic treatment section, was operated for 60 cycles. In this manner, the process of catalytic dehydrogenation in the reactor section and methane combustion in the catalytic treatment section was repeated 60 times. This test is referred to as the comparative test.

[0051] Table 1 below shows the methane conversion achieved for the inventive and comparative tests. As can be seen, the inventive test, which combined the deactivated catalyst with a portion of the reactivated catalyst from the catalytic treater, achieved a higher conversion of methane in the combustor on each cycle than the comparative test, which only sent the deactivated catalyst directly to the combustor.

[0052] [Table 1]

[0053] Example 2 This example demonstrates the effectiveness of combining deactivated catalyst with recycled, reactivated catalyst before transferring this mixed catalyst stream to the combustor. The process conditions and pipe dimensions for the section of piping where the two catalyst streams are mixed are summarized in Table 2 below.

[0054] [Table 2]

[0055] A computational fluid dynamics (CFD) model developed in Ansys Fluent V19.2 using a drag model that has been extensively validated against experimental data was used to simulate the mixing of deactivated catalyst with recycled reactivated catalyst. The predicted coefficient of variance (CoV), as shown in Table 3, was calculated using Equation 1 below, where X 失活,i represents the mass fraction of deactivated catalyst relative to the mixed catalyst at position i in the pipe where the mixed catalyst flow enters the combustor.

[0056]

number

[0057] [Table 3]

[0058] Table 3 shows the mixing of deactivated catalyst and recycled reactivated catalyst along the pipe length. Each percent of CoV corresponds to a temperature difference of 1.2°C between the catalyst streams.

[0059]

number

[0060] The present disclosure includes one or more non-limiting embodiments. A first embodiment is a method of forming light olefins in a reactor system, comprising: reacting a feed stream in the presence of a catalyst in the reactor to form a product stream and deactivated catalyst comprising coke; separating at least a portion of the product stream from the deactivated catalyst; transferring the deactivated catalyst to a combustor in a catalyst processing section of the reactor system and processing the deactivated catalyst to produce reactivated catalyst and flue gas, wherein coke is removed from the deactivated catalyst in the combustor; separating the reactivated catalyst from the flue gas and separating the reactivated catalyst into a first portion and a second portion; transferring the first portion of the reactivated catalyst to the reactor; combining a second portion of the activated catalyst with a deactivated catalyst upstream of the combustor to form a mixed catalyst stream, wherein the mixed catalyst stream is contacted with a first oxygen-containing gas stream upstream of the combustor, and wherein coke on the deactivated catalyst is oxidized upon contact with the first oxygen-containing gas stream upstream of the combustor; and transporting the mixed catalyst stream to the combustor and contacting the mixed catalyst stream with a second oxygen-containing gas stream while in the combustor, wherein the sum of the molar flow rate of the first oxygen-containing gas stream and the molar flow rate of the second oxygen-containing gas define a total oxygen-containing gas molar flow rate, and wherein the molar flow rate of the first oxygen-containing gas stream is between 1% and 15% of the total oxygen-containing gas molar flow rate.

[0061] A second embodiment includes any of the above embodiments, wherein the flow velocity of the mixed catalyst stream entering the combustor is between 0.5 m / s and 4 m / s.

[0062] A third embodiment includes any of the above embodiments, wherein the second portion of the reactivated catalyst is passed through an oxygen-containing gas for more than 5 seconds before being combined with the deactivated catalyst.

[0063] A fourth embodiment includes any of the above embodiments, wherein the temperature of the deactivated catalyst is increased when combined with the second portion of the reactivated catalyst.

[0064] A fifth embodiment includes any of the above embodiments, wherein the temperature of the deactivated catalyst is from 550°C to 800°C and the temperature of the second portion of the reactivated catalyst is from 700°C to 900°C.

[0065] A sixth aspect includes any of the above aspects, further including burning a supplemental fuel in the combustor.

[0066] A seventh aspect includes any of the above aspects, wherein the supplemental fuel includes hydrogen, methane, ethane, propane, or natural gas.

[0067] An eighth embodiment includes any of the above embodiments, wherein the mixed catalyst stream promotes combustion of the auxiliary fuel.

[0068] A ninth embodiment includes any of the above embodiments, wherein the feed stream is reacted by a dehydrogenation reaction, a dehydrogenation reaction with selective hydrogen combustion, a cracking reaction, a dehydration reaction, or a methanol to olefins reaction.

[0069] A tenth embodiment includes any of the above embodiments, wherein the product stream includes one or more of ethylene, propylene, styrene, or butene.

[0070] An eleventh embodiment includes any of the above embodiments, wherein the product stream comprises at least 25 wt% light olefins.

[0071] A twelfth embodiment includes any of the above embodiments, wherein combining the second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form the mixed catalyst stream occurs in a vessel or pipe operated in a dense phase lift fluidization regime.

[0072] In a thirteenth aspect, the vessel or pipe has a superficial gas velocity of 0.3 m / s to 5 m / s and a gas flow rate of 245 kg / m 2 -s~1,710kg / m 2 -s solids flux.

[0073] A fourteenth embodiment includes any of the above embodiments, wherein the vessel or pipe has a chocking velocity and the vessel or pipe is operated at a superficial gas velocity that is less than the chocking velocity.

[0074] A fifteenth embodiment includes any of the above embodiments, wherein the second portion of the reactivated catalyst is combined with the deactivated catalyst upstream of the combustor to form a mixed catalyst stream, thereby resulting in a temperature difference of 10° C. or less between the second portion of the reactivated catalyst and the deactivated catalyst before entering the combustor.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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."

[0081] As understood in the context of the term as used herein, the term "transfer" can include directly transferring a substance between two portions of a disclosed system, and in some other instances, refers to indirectly transferring a substance between two portions of a disclosed system. For example, indirect transfer may include passing the specified substance through intermediate separation devices, valves, sensors, etc.

[0082] 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 present 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.

Claims

1. 1. A method for forming light olefins in a reactor system comprising: reacting the feed stream in the presence of a catalyst in a reactor to form a product stream and a deactivated catalyst comprising coke; separating at least a portion of the product stream from the deactivated catalyst; transferring the deactivated catalyst to a combustor in a catalyst processing portion of the reactor system and processing the deactivated catalyst to produce reactivated catalyst and flue gas, wherein coke is removed from the deactivated catalyst in the combustor; separating the reactivated catalyst from the flue gas and separating the reactivated catalyst into a first portion and a second portion; transferring the first portion of the reactivated catalyst to the reactor; combining the second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form a mixed catalyst stream, wherein the mixed catalyst stream is contacted with a first oxygen-containing gas stream upstream of the combustor, and wherein coke on the deactivated catalyst is oxidized upon contact with the first oxygen-containing gas stream upstream of the combustor; moving the mixed catalyst stream to the combustor and contacting the mixed catalyst stream with a second oxygen-containing gas stream while in the combustor; the sum of the molar flow rate of the first oxygen-containing gas stream and the molar flow rate of the second oxygen-containing gas defines a total oxygen-containing gas molar flow rate, and the molar flow rate of the first oxygen-containing gas stream is between 1% and 15% of the total oxygen-containing gas molar flow rate.

2. The method of claim 1, wherein the flow velocity of the mixed catalyst stream entering the combustor is between 0.5 m / s and 4 m / s.

3. 3. The method of claim 1 or 2, wherein the second portion of the reactivated catalyst is passed through an oxygen-containing gas for more than 5 seconds before being combined with the deactivated catalyst.

4. The method of any of claims 1 to 3, wherein the temperature of the deactivated catalyst is increased when combined with the second portion of the reactivated catalyst.

5. The method of any one of claims 1 to 4, wherein the temperature of the deactivated catalyst is from 550°C to 800°C and the temperature of the second portion of the reactivated catalyst is from 700°C to 900°C.

6. The method of any of claims 1 to 5, further comprising burning a supplemental fuel in the combustor.

7. The method of claim 6 , wherein the supplemental fuel comprises hydrogen, methane, ethane, propane, or natural gas.

8. The method of claim 6 , wherein the mixed catalyst stream promotes combustion of the supplemental fuel.

9. The method of any of claims 1 to 8, wherein the feed stream is reacted by a dehydrogenation reaction, a dehydrogenation reaction with selective hydrogen combustion, a cracking reaction, a dehydration reaction, or a methanol to olefins reaction.

10. The method of any preceding claim, wherein the product stream comprises one or more of ethylene, propylene, styrene, or butenes.

11. The process of any preceding claim, wherein the product stream comprises at least 25 wt% light olefins.

12. 12. The method of any of claims 1 to 11, wherein combining the second portion of the reactivated catalyst with the deactivated catalyst upstream of the combustor to form the mixed catalyst stream occurs in a vessel or pipe operated in a dense phase lift fluidization regime.

13. The vessel or the pipe has a superficial gas velocity of 0.3 m / s to 5 m / s and a gas velocity of 245 kg / m ２ -s~1,710kg / m ２ 13. The process of claim 12, operated at a solids flux of -s.

14. 13. The method of claim 12, wherein the vessel or the pipe has a choking velocity and the vessel or the pipe is operated at a superficial gas velocity that is lower than the chocking velocity.

15. 15. The method of any of claims 1 to 14, wherein the second portion of the reactivated catalyst is combined with the deactivated catalyst upstream of the combustor to form the mixed catalyst stream, thereby providing a temperature difference of 10°C or less between the second portion of the reactivated catalyst and the deactivated catalyst before entering the combustor.

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