Converting propylene in an oxygenate-contaminated propylene stream to non-polymerization derivative products

Abstract

The invention provides for directing an oxygenate-contaminated propylene-containing stream derived from an oxygenate to olefin reaction system to a derivative non-polymerization reactor for conversion of the propylene to one or more derivative non-polymerization products. Exemplary derivative non-polymerization propylene conversion processes include: oxidation to form acrolein, oxidation to form acrylic acid, ammoxidation to form acrylonitrile, liquid phase oxidation to form acetone, liquid phase hydration to form isopropanol, hydroformylation to form n-butyraldehyde and its subsequent aldol/hydrogenation to form 2-ethylhexanol, direct or indirect oxidation to form propylene oxide, alkylation to form cumene in the presence of phosphoric acid/Kieselguhr or a zeolite and the subsequent selective hydroperoxidation of cumene to form acetone and phenol.

1 . A process for forming a derivative product, the process comprising the steps of: 
 (a) providing a product stream from an oxygenate-to-olefin reaction system, wherein the product stream contains propylene and one or more oxygenate contaminants;    (b) directing the product stream to a derivative process reactor; and    (c) converting the propylene in the derivative process reactor to the derivative product, wherein the derivative product comprises one or more of acrolein, acrylic acid, acrylonitrile, acetone, isopropanol, cumene, n-butyraldehyde, iso-butyraldehyde, 2-ethylhexanol or propylene oxide.    
     
     
         2 . The process of  claim 1 , wherein the oxygenate contaminant comprises one or more of methanol, ethanol, dimethyl ether, ethanal, propanal, acetone, isopropyl alcohol or mixtures thereof.  
     
     
         3 . The process of  claim 1 , wherein the product stream comprises at least about 10 wppm oxygenate contaminants, based on the total weight of the product stream.  
     
     
         4 . The process of  claim 3 , wherein the product stream comprises at least about 1000 wppm oxygenate contaminants, based on the total weight of the product stream.  
     
     
         5 . The process of  claim 4 , wherein the product stream comprises at least about 1 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         6 . The process of  claim 5 , wherein the product stream comprises at least about 2 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         7 . The process of  claim 6 , wherein the product stream comprises at least about 5 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         8 . The process of  claim 1 , wherein the product stream comprises from about 10 wppm to about 10 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         9 . The process of  claim 4 , wherein the product stream comprises less than about 10 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         10 . The process of  claim 6 , wherein the product stream comprises less than about 10 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         11 . The process of  claim 7 , wherein the product stream comprises less than about 10 weight percent oxygenate contaminants, based on the total weight of the product stream.  
     
     
         12 . A process for forming a product from a propylene-containing stream, the process comprising the steps of 
 (a) providing a propylene-containing stream from an oxygenate-to-olefin reaction system; and    (b) contacting propylene in the propylene-containing stream with a catalyst under conditions effective to form the product, wherein the propylene-containing stream comprises at least about 1 weight percent of an oxygenate contaminant, wherein the oxygenate contaminant comprises one or more of methanol, ethanol, dimethyl ether, ethanal, propanal, acetone, isopropyl alcohol or a mixture thereof, based on the total weight of the propylene-containing stream.    
     
     
         13 . The process of  claim 12 , wherein the product is selected from the group consisting of acrolein, acrylic acid, acrylonitrile, acetone, isopropanol, cumene, n-butyraldehyde, iso-butyraldehyde, 2-ethyl hexanol, and propylene oxide.  
     
     
         14 . The process of  claim 12 , wherein the product comprises acrolein, and the catalyst comprises a complex oxide based upon molybdenum and bismuth in combination with one or more of cobalt, iron, phosphorous or nickel.  
     
     
         15 . The process of  claim 12 , wherein the product comprises acrylic acid, and the catalyst comprises an oxide of a metal selected from the group consisting of molybdenum, vanadium optionally with one or more of tungsten, copper, iron or manganese.  
     
     
         16 . The process of  claim 12 , wherein the product comprises acrylonitrile, and the catalyst comprises an oxidic structure of the bismuth molybdate or bismuth ferromolybdate types.  
     
     
         17 . The process of  claim 12 , wherein the product comprises acetone, and the catalyst comprises PdCl 2 .CuCl.H 2 0.  
     
     
         18 . The process of  claim 12 , wherein the product comprises isopropanol and the catalyst is selected from the group consisting of sodium silicotungstate, an ion exchange resin and sulphuric acid.  
     
     
         19 . The process of  claim 12 , wherein the product comprises cumene and the catalyst comprises phosphoric acid/Kieselguhr or a zeolite.  
     
     
         20 . The process of  claim 12 , wherein the product comprises 2-ethylhexanol and the catalyst comprises a cobalt carbonyl salt.  
     
     
         21 . The process of  claim 20 , wherein the cobalt carbonyl salt comprises a phosphine ligand complex.  
     
     
         22 . The process of  claim 21 , wherein the phosphine ligand complex comprises a rhodium phosphine ligand complex.  
     
     
         23 . The process of  claim 12 , wherein the product comprises propylene oxide and the catalyst comprises a molybdenum complex in solution.  
     
     
         24 . The process of  claim 12 , wherein the propylene-containing stream comprises at least about 2 weight percent oxygenate contaminants, based on the total weight of the propylene-containing stream.  
     
     
         25 . The process of  claim 12 , wherein the propylene-containing stream comprises at least about 5 weight percent oxygenate contaminants, based on the total weight of the propylene-containing stream.  
     
     
         26 . The process of  claim 12 , wherein the propylene-containing stream comprises at least about 10 weight percent oxygenate contaminants, based on the total weight of the propylene-containing stream.  
     
     
         27 . The process of  claim 12 , wherein the process further comprises the step of separating a majority of the oxygenate contaminants from the product.