Apparatus and process for producing gasoline, olefins and aromatics from oxygenates

A process for converting an oxygenate feedstock to aromatics comprising:

• a. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture in a reactor effluent, wherein the fluid bed reactor comprises:
• i. a catalyst;
• and
• ii. at least one packing layer;
• b. cooling the reactor effluent comprising the hydrocarbon mixture and condensing a portion of the reactor effluent to form a mixed phase effluent;
• c. separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• and
• d. separating aromatics from the hydrocarbon gas phase and the hydrocarbon liquid phase.

A process for converting an oxygenate feedstock to olefins comprising:

• a. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising olefins in a reactor effluent, wherein the fluidized bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• b. cooling the fluidized bed reactor either internally or externally;
• c. transferring spent catalyst comprising coke to an air stream in fluid connection with the fluidized bed reactor and a regenerator;
• d. feeding the air stream containing spent catalyst to the regenerator and burning the coke off of the catalyst to form regenerated catalyst;
• and
• e. transferring the regenerated catalyst from the regenerator to the fluidized bed reactor, wherein the regenerator is in fluid connection with the fluidized bed reactor.

A process for converting an oxygenate feedstock to olefins comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising olefins in a reactor effluent, wherein the fluidized bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to a stabilizer/de-butanizer in fluid connection with the separator, wherein at least olefins are separated;
• h. optionally, recycling a portion of the olefins;
• i. transferring spent catalyst comprising coke to an air stream in fluid connection with the fluidized bed reactor and a regenerator;
• j. feeding the air stream containing spent catalyst to the regenerator and burning the coke off of the catalyst to form regenerated catalyst;
• and
• k. transferring the regenerated catalyst from the regenerator to the fluidized bed reactor, wherein the regenerator is in fluid connection with the fluidized bed reactor.

A process for converting an oxygenate feedstock to olefins comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising olefins in a reactor effluent, wherein the fluidized bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing at least a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to a de-ethanizer in fluid connection with the separator, wherein at least C2− light gas is separated from C3+ product;
• h. transferring the C3+ product to a de-butanizer in fluid connection with the de-ethanizer, wherein at least olefins are separated;
• and
• i. optionally, transferring the olefins to an alkylation unit in fluid connection with the de-butanizer.

A process for converting an oxygenate feedstock to olefins comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising olefins in a reactor effluent, wherein the fluid bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing at least a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to a dividing wall column in fluid connection with the separator, wherein at least streams for a light gas, C2, propylene, propane, butenes, butanes and the C5+ gasoline product are produced;
• h. combining the streams for C2, propylene, and butenes to form an olefin stream in fluid connection with the dividing wall column;
• i. optionally, combining the streams for propane and butanes to form an LPG stream;
• and
• j. optionally, recycling the olefin stream to the fluidized bed reactor, wherein the olefin stream is in fluid connection with the dividing wall column and the fluidized bed reactor.

A process for converting an oxygenate feedstock to aromatics comprising:

• a. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising aromatics in a reactor effluent, wherein the fluidized bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• b. cooling the fluidized bed reactor either internally or externally;
• c. transferring spent catalyst comprising coke to an air stream in fluid connection with the fluidized bed reactor and a regenerator;
• d. feeding the air stream containing spent catalyst to the regenerator and burning the coke off of the catalyst to form regenerated catalyst;
• and
• e. transferring the regenerated catalyst from the regenerator to the fluidized bed reactor, wherein the regenerator is in fluid connection with the fluidized bed reactor.

A process for converting an oxygenate feedstock to aromatics comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising aromatics in a reactor effluent, wherein the fluidized bed reactor comprises:
• i. a catalyst;
• and
• ii. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to a stabilizer/de-butanizer in fluid connection with the separator, wherein at least aromatics are separated;
• h. optionally, recycling olefins;
• i. transferring spent catalyst comprising coke to an air stream in fluid connection with the fluidized bed reactor and a regenerator;
• j. feeding the air stream containing spent catalyst to the regenerator and burning the coke off of the catalyst to form regenerated catalyst;
• and
• k. transferring the regenerated catalyst from the regenerator to the fluidized bed reactor, wherein the regenerator is in fluid connection with the fluidized bed reactor.

A process for converting an oxygenate feedstock to aromatics comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising aromatics in a reactor effluent, wherein the fluidized bed reactor comprises:
• iii. a catalyst;
• and
• iv. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing at least a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to at least one stabilizer in fluid connection with the separator and separating at least aromatics in one or more steps;
• and
• h. optionally, separating olefins and transferring the olefins to an alkylation unit in fluid connection with the stabilizer.

A process for converting an oxygenate feedstock to aromatics comprising:

• a. heating the oxygenate feedstock;
• b. feeding the oxygenate feedstock to a fluidized bed reactor under conditions to convert the oxygenate feedstock to a hydrocarbon mixture comprising aromatics in a reactor effluent, wherein the fluid bed reactor comprises:
• v. a catalyst;
• and
• vi. two packing layers, which separate the fluidized bed reactor into two stages;
• c. cooling the fluidized bed reactor either internally or externally;
• d. transferring the reactor effluent to a set of two stage cyclones for separating reactor vapor from the catalyst and/or transferring the reactor effluent to a fines collection unit for removing catalyst fines, wherein the set of two stage cyclones and the fines collection unit are in fluid connection with the fluidized bed reactor and/or each other;
• e. transferring the reactor effluent to a heat exchanger for cooling the reactor effluent and condensing at least a portion of the reactor effluent against incoming oxygenate feed to form a mixed phase effluent, wherein the heat exchanger is in fluid connection with the fines collection unit or the set of two stage cyclones;
• f. transferring the mixed phase effluent to a separator in fluid connection with the heat exchanger and separating the mixed phase effluent into an aqueous liquid phase, a hydrocarbon gas phase and a hydrocarbon liquid phase;
• g. transferring the hydrocarbon gas phase and the hydrocarbon liquid phase to a dividing wall column in fluid connection with the separator, wherein at least one stream comprising aromatics is produced;
• h. optionally, producing a light gas, C2, propylene, propane, butenes, butanes and C5+ gasoline product streams
• i. optionally, combining the streams for C2, propylene, and butenes to form an olefin stream in fluid connection with the dividing wall column;
• j. optionally, combining the streams for propane and butanes to form an LPG stream;
• and
• k. optionally, recycling an olefin stream to the fluidized bed reactor, wherein the olefin stream is in fluid connection with the dividing wall column and the fluidized bed reactor.