Process for the aromatization of dilute ethylene

Abstract

Described herein are processes for the conversion of ethylene into CS+ olefins, naphthenics, and aromatics via a dual catalyst reaction utilizing a dearomatization catalyst.

What is claimed is: 
     
         1 . An exothermic process of converting ethylene in a hydrocarbon gas feed, said process comprising:
 a. contacting a hydrocarbon gas feed or portion thereof comprising ethylene with a nitrogen-adsorbing guard bed;   b. introducing the hydrocarbon gas feed into a reactor comprising at least one heterogeneous dehydroaromatization catalyst comprising
 (i) ZSM-5; 
 (ii) amorphous silica, alumina, or a combination thereof; 
 (iii) Zn and/or Cu; and 
 (iv) at least one exchanged metal of Group IA or IIA or lanthanide series; and 
   c. converting ethylene and propylene in the hydrocarbon gas feed to a naphtha boiling-range product comprising at least one aromatic compound.   
     
     
         2 . The process of  claim 1 , wherein the reactor further comprises at least two beds of catalyst, wherein each bed has an independent hydrocarbon gas feedpoint. 
     
     
         3 . The process of  claim 2 , wherein said reactor further comprises a system for controlling the temperature of the hydrocarbon gas feed, wherein said system is located on at least one of the at least 2 feed points. 
     
     
         4 . The process of  claim 1 , further comprising at least one cross-exchanger to transfer heat from an effluent of the reactor or using at least one cross-exchanger to add heat to the hydrocarbon gas feed. 
     
     
         5 . The process of  claim 1 , wherein said heterogeneous catalyst comprises between about 20% and about 85% ZSM-5 by weight. 
     
     
         6 . The process of  claim 1 , wherein the heterogeneous catalyst comprises a second three-dimensional-framework, crystalline, silica/alumina species in an amount less than about 35% weight. 
     
     
         7 . The process of  claim 1 , wherein a dilution feed comprising hydrocarbons substantially free of ethylene is used to dilute the ethylene concentration in the hydrocarbon gas feed. 
     
     
         8 . An exothermic process for the conversion of ethylene in a C2 containing gas feed, said process comprising:
 a. providing at least one C2 containing gas feed, wherein said C2 containing gas feed comprises ethylene, ethane and/or methane, methanol or dimethylether;   b. providing at least one heterogeneous dehydroaromatization catalyst in abed in a reactor, wherein said heterogeneous dehydroaromatization catalyst comprises
 (i) ZSM-5 in a range between 1-100%; 
 (ii) amorphous silica, alumina, or a combination thereof in a range of 1-99%; 
 (iii) Zn and/or Cu in a range between 0.05-3% weight; and 
   (iv) at least one exchanged metal of Group IA or IIA or lanthanide series in a range of 0.05-3% weight;   c. contacting said C2 containing gas feed and said heterogeneous dehydroaromatization catalyst in a bed in a reactor;   d. processing, in the reactor, the hydrocarbon gas to form a naphtha boiling range product, comprising at least one aromatic component.   e. optionally, stopping the C2 containing gas feed, isolating the reactor from the process, using valves, and performing a periodic regeneration of the heterogeneous catalyst to remove carbon deposits, produced from step d., using air, nitrogen, or mixtures thereof.   
     
     
         9 . The process of  claim 8 , further comprising at least two beds of catalyst, wherein each bed has an independent hydrocarbon gas feed point. 
     
     
         10 . The process of  claim 8 , wherein said reactor further comprises a system for controlling the temperature of the C2 containing gas feed, wherein said system is located on at least one of the at least 2 feed points. 
     
     
         11 . The process of  claim 8 , wherein said heterogeneous catalyst has between 20-85% ZSM-5 by weight. 
     
     
         12 . The process of  claim 8 , wherein the heterogeneous catalyst further comprises a second three-dimensional-framework, crystalline, silica/alumina species having a content of less than 35% weight. 
     
     
         13 . The process of  claim 8 , wherein a dilution feed, comprising hydrocarbons substantially free of ethylene, is used to control the temperatures within the reactor. 
     
     
         14 . An exothermic process for the conversion of ethylene in a hydrocarbon gas feed or portion thereof, said process comprising:
 a. providing at least one hydrocarbon gas feed, wherein said hydrocarbon gas feed comprises ethylene and hydrogen;   b. providing at least one heterogeneous dehydroaromatization catalyst in a bed in a reactor, wherein said heterogeneous dehydroaromatization catalyst comprises
 (i) ZSM-5 in a range between 1-98.9%; 
 (ii) amorphous silica, alumina, or a combination thereof in a range of 1-98.9%; 
 (iii) Zn and/or Cu in a range between 0.05-3% weight; and 
 (iv) at least one exchanged metal of Group IA or IIA or lanthanide series in a range of 0.05-3% weight; 
   c. pretreating the heterogeneous dehydroaromatization catalyst to control its hydrogenation activity, by passing a gas stream containing hydrogen sulphide and or an organic sulfur compound over the catalyst, prior to introduction of the hydrocarbon gas feed; and   d. processing, in the reactor, the hydrocarbon gas feed, to form a naphtha boiling-range product, said naphtha boiling-range product comprising at least one aromatic compound.   
     
     
         15 . The process according to  claim 14 , where the organic sulphur compound is a mercaptan, sulphide, or disulphide. 
     
     
         16 . The process according to  claim 14 , where the reactor comprises at least two beds of catalyst, wherein each bed has an independent hydrocarbon gas feedpoint. 
     
     
         17 . The process of  claim 14 , wherein the heterogeneous catalyst further comprises a second three-dimensional-framework, crystalline, silica/alumina species having a content of less than 35% weight. 
     
     
         18 . The process of  claim 17 , wherein the second three-dimensional-framework, crystalline, silica/alumina species is Zeolite Yor Beta zeolite.