An integrated process for producing C3-C4 olefins or C3-C4 di-olefins comprising the steps of:
- (1)(a) contacting, in a fluidized dehydrogenation reactor,
- (i) a C3-C4 hydrocarbon feed and
- (ii) a catalyst feed comprising a catalyst;
- under conditions such that a step (1)(a) product mixture, comprising a C3-C4 target olefin or di-olefin, hydrogen and unreacted C3-C4 hydrocarbon feed, is formed;
- and
- the catalyst has coke deposited thereon and is at least partially deactivated such that it forms an at least partially deactivated catalyst;
- and
- (b) transferring the step (1)(a) product mixture and the at least partially deactivated catalyst from the fluidized dehydrogenation reactor to a cyclonic separation system, and
- under conditions such that the step (1)(a) product mixture is converted to form a step (1)(b) product mixture;
- and
- thereafter substantially separating the step (1)(b) product mixture and the at least partially deactivated catalyst from each other;
- (c) transferring at least a portion of the at least partially deactivated catalyst to a regenerator vessel and heating the at least partially deactivated catalyst therein to a combustion temperature of from about 660° C. to about 850° C. in order to combust the coke deposited on the at least partially deactivated catalyst therein,
- the heating forming a heated, further deactivated catalyst which has an activity for dehydrogenating the C3-C4 hydrocarbon feed that is less than that of the at least partially deactivated catalyst, and,
- (d) subjecting the heated, further deactivated catalyst to a conditioning step, comprising maintaining the heated, further deactivated catalyst at a temperature of at least 660° C. under a flow of an oxygen-containing gas for more than 2 minutes,
- to form an oxygen-containing, at least partially reactivated catalyst that has an activity for dehydrogenating the C3-C4 hydrocarbon feed that is greater than that of the at least partially deactivated catalyst;
- and
- (e) transferring the at least partially reactivated catalyst back to the fluidized dehydrogenation reactor;
- (2) transferring the step (1)(b) product mixture to a compressor, wherein the step (1)(b) product mixture is compressed at least one to form a step (2) product mixture;
- (3) transferring the step (2) product mixture to a product recovery area, wherein the step (2) product mixture is separated into recovered products comprising a light gas fraction and at least one or more target C3-C4 olefin or di-olefin fractions;
- and
- (4) recycling at least a portion of the step (3) light gas fraction to the regenerator vessel, wherein the step (3) light gas fraction is combusted to heat the at least partially deactivated catalyst.