# US 2025/0154080 A1 · Process for converting c2-c5 hydrocarbons to gasoline and diesel fuel blendstocks

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2025/0154080 A1
- Document ID: US20250154080A1
- Status: Published application
- Kind: A1
- Application number: 19/019,651
- Filed: 2025-01-14
- Published: 2025-05-15
- Earliest claimed: 2020-03-31
- Assignees: Swift Fuels, LLC
- Applicants: Swift Fuels, LLC
- Inventors: Chris D'Acosta; Jeffery Miller; Kurtis Sluss; Benjamin Wegenhart
- Web page: https://patentgrep.com/patent/US20250154080A1

## CPC

- C07C 2/12: with crystalline alumino-silicates {or with catalysts comprising} molecular sieves
- C10G 57/02: with polymerisation
- C07C 5/327: Formation of non-aromatic carbon-to-carbon double bonds only
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES

## Abstract

A process for converting C2-5 alkanes to higher value C5-24 hydrocarbon fuels and blendstocks. The C2-5 alkanes are converted to olefins by thermal olefination, without the use of a dehydrogenation catalyst and without the use of steam. The product olefins are fed to an oligomerization reactor containing a zeolite catalyst to crack, oligomerize and cyclize the olens to the fuel products which are then recovered. Optionally, hydrogen and methane are removed from the product olefin stream prior to oligomerization. Further optionally, C2-5 alkanes are removed from the product olefin stream prior to oligomerization.

## Claims

### Claim 1

A method for converting C2-5 alkanes to a broad-range of fuel products constituting higher-value C5-24 hydrocarbon fuels or fuel blendstocks, comprising:
passing a fresh, C2-5 alkane-rich feedstream through a thermal olefination reactor, the fresh, C2-5 alkane-rich feedstream having any one or more of the C2-5 alkanes and containing at least 90 wt % C2-5 feed alkanes, the thermal olefination reactor operating without a dehydrogenation catalyst and without steam, the thermal olefination reactor converting the C2-5 feed alkanes to product olefins in an effluent olefination stream;
passing at least a portion of the effluent olefination stream to an oligomerization reactor containing a zeolite catalyst and operating at a temperature, pressure and space velocity to crack, oligomerize and cyclize the product olefins to form an effluent oligomerization stream comprising the fuel products, unconverted C2-4 alkanes and methane;
separating C2-4 alkanes and methane from the effluent oligomerization stream;
passing a recycle stream comprising the separated C2-4 alkanes and methane from the effluent oligomerization stream directly back through the thermal olefination reactor, separating C5 alkanes from the effluent oligomerization stream;
passing a recycle stream comprising the separated C5 alkanes from the effluent oligomerization stream directly back through the thermal olefination reactor,
the olefination reactor operating at a temperature, pressure and space velocity to convert at least 80 wt % of the C2-5 feed alkanes to product olefins in the effluent olefination stream; and
recovering the fuel products from the effluent oligomerization stream.

### Claim 2 (depends on 1)

The method of claim 1 in which the effluent olefination stream undergoes membrane separation of inert gases.

### Claim 3 (depends on 1)

The method of claim 1 in which the fresh, C2-5 alkane-rich feedstream comprises 80-100% ethane and 0-20% propane.

### Claim 4 (depends on 1)

The method of claim 1 in which the fresh, C2-5 alkane-rich feedstream comprises at least about 90 wt % ethane.

### Claim 5 (depends on 1)

The method of claim 1 and which further comprises passing a recycle stream comprising methane from the effluent oligomerization stream back through the oligomerization reactor.

### Claim 6 (depends on 1)

The method of claim 1 in which the fresh, C2-5 alkane-rich feedstream comprises at least 95 wt % C2-5 alkanes.

### Claim 7 (depends on 1)

The method of claim 1 in which the effluent olefination stream has at least 95 wt % of the C2-5 feed alkanes converted to product C2-5 olefins.