Process for production of ethylbenzene from toluene and methane

A process for making ethylbenzene and styrene comprising:

• reacting toluene and methane in one or more reactors to form a first product stream comprising ethylbenzene and styrene and one or more of benzene, toluene, and methane;
• sending the first product stream to a first separation apparatus that separates the stream into at least benzene;
• removing at least a portion of the benzene from the first separation apparatus;
• reacting the benzene with ethylene in an alkylation reactor to form ethylbenzene;
• and
• dehydrogenating the ethylbenzene to thereby form styrene;
• wherein at least a portion of one or more of the separation, alkylation, and dehydrogenation processes are performed utilizing the facilities of an existing styrene production facility;
• wherein the one or more reactors comprise a reaction zone capable of dissipating heat to maintain the reaction zone within a desired temperature range for reacting toluene and methane to form ethylbenzene and styrene;
• wherein the reaction zone comprises one or more catalyst sites comprising a catalyst selected from the group consisting of X zeolite, Y zeolite, mordenite, silicalite, and combinations thereof;
• wherein the catalyst is modified with molybdenum, sodium or other basic ion.