Multistage process for converting oxygenates to alkylated liquid hydrocarbons

Claim 2

An integrated continuous process for converting oxygenated organic feedstock to liquid hydrocarbons comprising the steps of (a) contacting feedstock with zeolite catalyst in a primary catalyst stage at elevated temperature and moderate pressure to convert at least a portion of the feedstock oxygenate to hydrocarbons containing a major fraction of C 2 -C 4 olefins and a minor fraction containing C 5 + hydrocarbons; (b) cooling and separating effluent from step (a) to provide an aqueous liquid byproduct stream, a heavy hydrocarbon liquid stream and a light hydrocarbon vapor stream rich in C 2 -C 4 olefins; (c) compressing at least a portion of the olefinic light hydrocarbon stream to condense a liquid olefinic hydrocarbon stream rich in C 3 -C 4 olefins and recovering an ethene-rich gaseous stream; (d) further reacting the condensed liquid olefinic hydrocarbon stream from step (c) with isobutane in a secondary alkylation stage with acid catalyst to convert at least a portion of C 3 -C 4 olefins to a heavier C 7 + liquid hydrocarbon product stream comprising alkylate gasoline; and (e) recycling ethene in a gaseous stream to the primary catalytic stage.

Claim 3

The process of claim 1 further comprising the of fractionating gaseous effluent from separation step (b) to recover a recycle gas stream containing at least 90% of ethene from the primary catalytic stage and an olefinic stream rich in C 3 + olefins.

Claim 4

The process of claim 1 wherein the primary stage catalyst comprises ZSM-5 type zeolite and ethene is recycled to the primary stage at a rate of about 1 to 20 parts ethene per 100 parts by weight of methanol equivalent in the feedstock.

Claim 5

The process of claim 1 wherein primary stage feedstock comprising methanol and/or dimethyl ether and recycled ethene are converted over HZSM-5 catalyst to provide a light olefinic hydrocarbon vapor stream comprising a major amount of C 3 -C 4 olefins and a minor amount of ethene.

Claim 6

The process of claim 4 wherein olefin production is optimized by employing fluid bed primary stage conditions in the temperature range of about 425° C. to 550° C., a pressure range of about 100 to 800 kPa and weight hourly space velocity range of about 0.5 to 3.0 based on ZSM-5 equivalent catalyst and methanol equivalent in the primary stage feedstock.

Claim 7

The process of claim 5 wherein at least 90% of feedstock is converted per reactor pass and wherein water diluent is cofed with methanol and/or dimethyl ether in a molar ratio of about 0.01:1 to 2:1.

Claim 8

The process of claim 4 wherein primary stage hydrocarbon effluent contains about 1 to 10 wt.% ethene and about 10 to 60 wt. % C 3 -C 4 olefins.

Claim 9

The process of claim 4 wherein ethene is recovered from the primary stage effluent vapor stream by fractionation.

Claim 10

The process of claim 1 wherein the secondary stage effluent is cooled and separated to provide a light hydrocarbon stream containing unconverted ethene and wherein said unconverted ethene is expanded to about primary stage pressure for recycle.

Claim 11

The process of claim 9 wherein compressed light hydrocarbon vapor is recompressed to recover an ethene-rich recycle Stream.

Claim 12

The process of claim 1 wherein the secondary alkylation stage comprises a liquid phase reaction catalyzed by HF.

Claim 13

A process for converting oxygenate feedstock comprising methanol, dimethyl ether or mixtures thereof to liquid hydrocarbons comprising the steps of contacting the feedstock with zeolite catalyst in a primary catalyst stage at elevated temperature and moderate pressure to convert feedstock to hydrocarbons comprising C 2 -C 4 olefins and C 5 + hydrocarbons; cooling and separating effluent from the primary stage to recover a liquid hydrocarbon stream and a light hydrocarbon vapor stream rich in C 2 -C 4 olefins; compressing the olefinic light hydrocarbon stream to condense a liquid olefinic hydrocarbon stream rich in C 3 + olefins and recovering an ethene-rich gaseous stream; further reacting the condensed liquid olefinic hydrocarbon stream with a tertiary alkane in a secondary catalytic stage with acid alkylation catalyst at substantially increased pressure under liquid conditions to convert at least a portion of olefins to a heavier liquid hydrocarbon product stream comprising alkylate gasoline and/or distillate range liquids; and recycling ethene in a gaseous stream to the primary catalytic stage.

Claim 14

A process for converting oxygenate feedstock comprising methanol, dimethyl ether or mixtures thereof to liquid hydrocarbons comprising the steps of contacting the feedstock with zeolite catalyst in a primary catalyst stage at elevated temperature and moderate pressure to convert feedstock to hydrocarbons comprising C 2 -C 4 olefins and C 5 + hydrocarbons; cooling and separating effluent from the primary stage to recover a liquid hydrocarbon stream and a light hydrocarbon vapor stream rich in C 2 -C 4 olefins; compressing the olefinic light hydrocarbon stream to condense a liquid olefinic hydrocarbon stream rich in C 3 + olefins and recovering an ethene-rich gaseous stream; further reacting the condensed liquid olefinic hydrocarbon stream with a tertiary alkane in a secondary catalytic stage with acid alkylation catalyst at substantially increased pressure under liquid conditions to convert at least a portion of olefins to a heavier liquid hydrocarbon product stream comprising alkylate gasoline and/or distillate range liquids; and recycling ethene in a gaseous stream to the primary catalytic stage.

Claim 15

The process of claim 12 wherein primary stage feedstock is converted over HZSM-5 catalyst to provide a light olefinic hydrocarbon vapor stream comprising a major amount of C 3 -C 4 olefins and a minor amount of ethene.

Claim 16

The process of claim 12 further comprising the step of fractionating gaseous effluent separated from primary stage effluent to recover a recycle gas stream containing at least 90% of ethene from the primary catalytic stage and an olefinic stream rich in C 3 + olefins.

Claim 17

The process of claim 12 wherein the primary stage catalyst comprises ZSM-5 type zeolite and ethene is recycled to the primary stage at a rate of about 1 to 10 parts ethene per 100 parts by weight of methanol equivalent in the feedstock.

Claim 18

The process of claim 12 wherein the light hydrocarbon vapor stream separated from the primary stage effluent is compressed in a plurality of compression stages to condense liquid olefinic hydrocarbons, and wherein uncondensed compreseed light hydrocarbons are further fractionated to recover a recycle stream containing at least 90 mole percent ethene.

Claim 19

The process of claim 12 wherein isobutane is reacted with propene and/or butylene in the seconday stage in the presence of a liquid phase acid catalyst at a pressure of about 1500 to 3000 kPa.

Claim 20

A process for converting oxygenated organic feedstock to liquid hydrocarbons comprising the steps of contacting a lower aliphatic oxygenate feedstock with zeolite catalyst in a primary catalyst state at low pressure and elevated temperature to convert at least a portion of the oxygenate feedstock to hydrocarbons containing C 2 -C 4 olefins and C 5 + hydrocarbons; separating primary stage effluent to provide an aqueous liquid byproduct stream, a heavy hydrocarbon liquid stream rich in C 5 + hydrocarbons and a light hydrocarbon vapor stream rich in in C 2 -C 4 olefins; compressing at least a portion of the olefinic light hydrocarbon stream in a plurality of compression stages to condense a liquid olefinic hydrocarbon stream rich in propene and butylenes; fractionating uncondensed compressed light hydrocarbons to recover a recycle stream containing at least 90 mole percent ethene; further reacting the condensed liquid olefinic hydrocarbon stream with C 4 + isoparaffin in a secondary alkylation stage with liquid phase acid catalyst to convert at least a portion of C 3 -C 4 olefins to a heavier C 7 + liquid hydrocarbon product stream comprising alkylate gasoline; and further contacting said ethene-rich gaseous stream under conversion conditions with zeolite catalyst in the primary catalyst stage, thereby increasing yield of C 3 + olefins.

Claim 21

A process for converting oxygenated organic feedstock to liquid hydrocarbons comprising the steps of contacting a lower aliphatic oxygenate feedstock with zeolite catalyst in a primary catalyst state at low pressure and elevated temperature to convert at least a portion of the oxygenate feedstock to hydrocarbons containing C 2 -C 4 olefins and C 5 + hydrocarbons; separating primary stage effluent to provide an aqueous liquid byproduct stream, a heavy hydrocarbon liquid stream rich in C 5 + hydrocarbons and a light hydrocarbon vapor stream rich in in C 2 -C 4 olefins; compressing at least a portion of the olefinic light hydrocarbon stream in a plurality of compression stages to condense a liquid olefinic hydrocarbon stream rich in propene and butylenes; fractionating uncondensed compressed light hydrocarbons to recover a recycle stream containing at least 90 mole percent ethene; further reacting the condensed liquid olefinic hydrocarbon stream with C 4 + isoparaffin in a secondary alkylation stage with liquid phase acid catalyst to convert at least a portion of C 3 -C 4 olefins to a heavier C 7 + liquid hydrocarbon product stream comprising alkylate gasoline; and further contacting said ethene-rich gaseous stream under conversion conditions with zeolite catalyst in the primary catalyst stage, thereby increasing yield of C 3 + olefins.

Claim 22

The process of claim 18 wherein isobutane is reacted with propene and/or butylene in the secondary stage in the presence of a liquid phase HF acid catalyst at a pressure of about 1500 to 3000 kPa; and wherein primary stage conversion is conducted at a temperature of about 425° C. to 550° C. and pressure of about 100 to 800 kPa over ZSM-5 type catalyst.