CPC C10G 29/04 (2013.01) [C10G 25/003 (2013.01); C10G 31/06 (2013.01)] | 26 Claims |
1. A multi-stage hydrocarbon upgrading process, comprising:
(I) contacting a hydrocarbon-containing feed with a first catalyst comprising a Group 8-10 element disposed on a support within a first conversion zone to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of a portion of the hydrocarbon-containing feed to produce a first conversion zone effluent comprising one or more upgraded hydrocarbons, molecular hydrogen, and unconverted hydrocarbon-containing feed;
(II) contacting the first conversion zone effluent with a second catalyst comprising a Group 8-10 element disposed on a support within a second conversion zone to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the unconverted hydrocarbon-containing feed to produce a second conversion zone effluent comprising an additional quantity of one or more upgraded hydrocarbons and molecular hydrogen; wherein:
the hydrocarbon-containing feed comprises one or more of C2-C16 linear or branched alkanes, one or more of C4-C16 cyclic alkanes, one or more of C8-C16 alkyl aromatic hydrocarbons, or a mixture thereof;
the hydrocarbon-containing feed and the first catalyst are contacted for a time period in a range from 0.1 seconds to 3 hours, under a hydrocarbon partial pressure of at least 20 kPa-absolute, wherein the hydrocarbon partial pressure is the total partial pressure of any C2-C16 alkanes and any C8-C16 alkyl aromatic hydrocarbons in the hydrocarbon-containing feed;
the first conversion zone effluent and the second catalyst are contacted for a time period in a range from 0.1 seconds to 3 hours, under a hydrocarbon partial pressure of at least 20 kPa-absolute, wherein the hydrocarbon partial pressure is the total partial pressure of any C2-C16 alkanes and any C8-C16 alkyl aromatic hydrocarbons in the first conversion zone effluent;
the first conversion zone effluent has a temperature in a range from 300° C. to 850° C.;
the second conversion zone effluent has a temperature in a range from 350° C. to 900° C.;
the temperature of the second conversion zone effluent is greater than the temperature of the first conversion zone effluent;
the first catalyst and the second catalyst have the same composition or a different composition;
the first catalyst and the second catalyst each comprise from 0.001 wt % to 6 wt % of the Group 8-10 element based on the weight of the support;
the one or more upgraded hydrocarbons comprise a dehydrogenated hydrocarbon, a dehydroaromatized hydrocarbon, a dehydrocyclized hydrocarbon, or a mixture thereof; and
at least one of the following is met:
(a) in step (I), the hydrocarbon-containing feed and the first catalyst are contacted in the presence of steam at an amount from 0.1 vol % to 50 vol %, based on a total volume of any C2-C16 alkanes, any C4-C16 cyclic alkanes, and any C8-C16 alkyl aromatics in the hydrocarbon-containing feed; and
(b) in step (II), the first conversion zone effluent and the second catalyst are contacted in the presence of steam at an amount from 0.1 vol % to 50 vol %, based on a total volume of any C2-C16 alkanes, any C4-C16 cyclic alkanes, and any C8-C16 alkyl aromatics in the first conversion zone effluent.
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