Ethylene-to-liquids systems and methods

Abstract

Integrated systems are provided for the production of higher hydrocarbon compositions, for example liquid hydrocarbon compositions, from methane using an oxidative coupling of methane system to convert methane to ethylene, followed by conversion of ethylene to selectable higher hydrocarbon products. Integrated systems and processes are provided that process methane through to these higher hydrocarbon products.

1 .- 20 . (canceled) 
     
     
         21 . A method for generating a catalyst, comprising:
 (a) providing a catalyst base material having a first set of pores, wherein said catalyst base material comprises an active component that facilitates the conversion of olefins to a first set of hydrocarbons, at least some of which is in liquid form at room temperature and atmospheric pressure;   (b) introducing a second set of pores into said catalyst base material, said second set of pores having an average diameter of at least about 10 nanometers (nm) as measured by Brunauer-Emmett-Teller (BET) isotherms; and   (c) providing one or more dopants on one or more surfaces of said catalyst base material, wherein said one or more dopants facilitate the conversion of olefins to a second set of hydrocarbons, at least some of which are in liquid form at room temperature and atmospheric pressure, wherein said second set of hydrocarbons has a different product distribution than said first set of hydrocarbons.   
     
     
         22 . The method of  claim 21 , wherein said first set of pores has an average diameter from about 4 Angstroms to 10 Angstroms. 
     
     
         23 . The method of  claim 21 , wherein said catalyst base material comprises a zeolite. 
     
     
         24 . The method of  claim 23 , wherein said zeolite comprises ZSM-5, ZSM-11, ZSM-22, Y, beta, mordenite, L, ferrierite, MCM-41, SAPO-34, SAPO-11, TS-1, SBA 15, or any combination thereof. 
     
     
         25 . The method of  claim 21 , wherein (a) comprises modifying a functionality of said catalyst base material by subjecting said catalyst base material to chemical treatment. 
     
     
         26 . The method of  claim 25 , wherein said chemical treatment includes desilication (de-Si) or dealumination (de-Al). 
     
     
         27 . The method of  claim 21 , wherein (b) is prior to (c). 
     
     
         28 . The method of  claim 21 , wherein (b) and (c) are performed simultaneously. 
     
     
         29 . The method of  claim 21 , wherein said catalyst base material has a surface area from about 100 m 2 /g to 1000 m 2 /g. 
     
     
         30 . The method of  claim 21 , wherein (b) comprises introducing said one or more dopants to said catalyst base material using vapor phase deposition. 
     
     
         31 . The method of  claim 21 , wherein (c) comprises providing said one or more dopants selected from the group consisting of Ga, Zn, Al, In, Ni, Mg, B, Pd, Pt, Be, Ca, Sr and Ag. 
     
     
         32 . The method of  claim 21 , wherein said catalyst base material is H—Al-ZSM-5, H—Ga-ZSM-5, H—Fe-ZSM-5, H—B-ZSM-5, or any combination thereof. 
     
     
         33 . The method of  claim 21 , wherein said second set of hydrocarbons has a narrower product distribution than said first set of hydrocarbons. 
     
     
         34 . A method of producing a plurality of hydrocarbon products, comprising:
 (a) directing ethylene to an ethylene-to-liquids (ETL) reactor, wherein said ETL reactor is configured to convert hydrocarbon compounds with two or more carbon atoms (C 2+  compounds) into higher hydrocarbons;   (b) in said ETL reactor, converting said ethylene into said higher hydrocarbons; and   (c) separating said higher hydrocarbons into at least two product streams, at least one of which product streams is characterized by at least five of:
 (1) no more than 1.30 vol % benzene; 
 (2) no more than 50 vol % aromatics; 
 (3) no more than 25 vol % olefins; 
 (4) a motor octane number (MON) of at least 82; 
 (5) a total octane number of at least 87; 
 (6) a Reid vapor pressure (RVP) of no more than 15 pounds per square inch (psi); 
 (7) a 10% boiling point of no more than 70° C.; 
 (8) a 50% boiling point of no more than 121° C.; 
 (9) a 90% boiling point of no more than 190° C.; 
 (10) a final boiling point (FBP) of no more than 221° C.; and 
 (11) an oxidative induction time of at least 240 minutes. 
   
     
     
         35 . The method of  claim 34 , wherein said ETL reactor is operated at a temperature greater than or equal to about 200° C. 
     
     
         36 . The method of  claim 34 , wherein said ETL reactor is operated at a pressure greater than or equal to about 200 psi. 
     
     
         37 . The method of  claim 34 , wherein said at least one of said product streams is characterized by at least six of (1)-(11). 
     
     
         38 . The method of  claim 37 , wherein said at least one of said product streams is characterized by at least seven of (1)-(11). 
     
     
         39 . The method of  claim 38 , wherein said at least one of said product streams is characterized by at least eight of (1)-(11). 
     
     
         40 . The method of  claim 34 , wherein said ethylene is from an oxidative coupling of methane (OCM) unit.