Processes for upgrading a hydrocarbon. The process can include contacting a hydrocarbon-containing feed with fluidized catalyst particles that can include a Group 8-10 element or a compound thereof disposed on a support to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the hydrocarbon-containing feed to produce coked catalyst particles and an effluent. The process can also include contacting at least a portion of the coked catalyst particles with an oxidant to effect combustion of at least a portion of the coke to produce regenerated catalyst particles. The process can also include contacting at least a portion of the regenerated catalyst particles with a reducing gas to produce regenerated and reduced catalyst particles. The process can also include contacting an additional quantity of the hydrocarbon-containing feed with fluidized regenerated and reduced catalyst particles to produce additional effluent and re-coked catalyst particles.

Disclosed herein are methods of preparing dehydrogenation catalysts using non-halogen containing metal sources. The methods generally comprise the steps of providing a first solution comprising anions of a first metal selected from Group 14 of the Periodic Table of Elements, and impregnating an inorganic support with the first solution to obtain a first impregnated inorganic support, wherein the first solution has a pH value of less than the isoelectric point of the inorganic support. The dehydrogenation catalysts prepared in accordance with the methods of the present disclosure are typically free or substantially free of halogen species. Such catalysts may be particularly useful in the dehydrogenation of a feed comprising cyclohexane and/or methylcyclopentane.

A process for preparing a catalyst for selective hydrogenation of acetylene to ethylene, comprises: mixing palladium, gallium, and gold sources, silica, and a solvent to form a suspension, which is then subjected to filtration and drying so as to obtain a catalyst precursor; subjecting the catalyst precursor obtained to a calcination treatment; and subjecting a calcinated product obtained to a reduction reaction in a reducing atmosphere so as to obtain the catalyst. The catalyst prepared according to this process exhibits a high stability and high catalytic performance, and has a large number of active sites uniformly distributed.

A method for operating an acetylene hydrogenation unit in an integrated steam cracking-fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from a steam cracking system and an FCDh effluent from an FCDh system into a hydrogenation feed and an acetylene-depleted stream, the hydrogenation feed comprising at least hydrogen, CO, and acetylene. During normal operating conditions, at least 20% of the CO in the hydrogenation feed is from the cracked gas. The method may include contacting the hydrogenation feed with an acetylene hydrogenation catalyst to hydrogenate at least a portion of the acetylene in the hydrogenation feed to produce a hydrogenated effluent. The steam cracking is operated under conditions that increase CO production such that a concentration of CO in the cracked gas is great enough that when a flowrate of the FCDh effluent is zero, a CO concentration in the hydrogenation feed is at least 100 ppmv.

Processes for upgrading a hydrocarbon. In some embodiments, the process can include contacting a hydrocarbon-containing feed with a first catalyst that can include a Group 8-10 element disposed on a support within a first conversion zone to effect dehydrogenation, dehydroaromatization, and/or dehydrocyclization of a portion of the feed to produce first conversion zone effluent that includes one or more upgraded hydrocarbons, molecular hydrogen, and unconverted feed. The process can also include contacting the first conversion zone effluent with a second catalyst that can include a Group 8-10 element disposed on a support within a second conversion zone to effect dehydrogenation, dehydroaromatization, and/or dehydrocyclization of at least a portion of the unconverted feed to produce a second conversion zone effluent that includes an additional quantity of upgraded hydrocarbon(s) and molecular hydrogen. A temperature of the second conversion zone effluent can be greater than a temperature of the first conversion zone effluent.

Methods of preparing unsaturated compounds or analogs through dehydrogenation of corresponding saturated compounds and/or hydrogenation of aromatic compounds are disclosed.

According to one or more embodiments described herein, a method for dehydrogenating hydrocarbons may include passing a hydrocarbon feed comprising one or more alkanes or alkyl aromatics into a fluidized bed reactor, contacting the hydrocarbon feed with a dehydrogenation catalyst in the fluidized bed reactor to produce a dehydrogenated product and hydrogen, and contacting the hydrogen with an oxygen-rich oxygen carrier material in the fluidized bed reactor to combust the hydrogen and form an oxygen-diminished oxygen carrier material. In additional embodiments, a dual-purpose material may be utilized which has dehydrogenation catalyst and oxygen carrying functionality.

A process for dehydrogenating alkane or alkylaromatic compounds comprising contacting the given compound and a dehydrogenation catalyst in a fluidized bed. The dehydrogenation catalyst is prepared from an at least partially deactivated platinum/gallium catalyst on an alumina-based support that is reconstituted by impregnating it with a platinum salt solution, then calcining it at a temperature from 400° C. to 1000° C., under conditions such that it has a platinum content ranging from 1 to 500 ppm, based on weight of catalyst; a gallium content ranging from 0.2 to 2.0 wt %; and a platinum to gallium ratio ranging from 1:20,000 to 1:4. It also has a Pt retention that is equal to or greater than that of a fresh catalyst being used in a same or similar catalytic process.

A method for processing a chemical stream includes contacting a feed stream with a catalyst in a reactor portion of a reactor system that includes a reactor portion and a catalyst processing portion. The catalyst includes platinum, gallium, or both and contacting the feed stream with the catalyst causes a reaction which forms an effluent stream. The method includes separating the effluent stream from the catalyst, passing the catalyst to the catalyst processing portion, and processing the catalyst in the catalyst processing portion. Processing the catalyst includes passing the catalyst to a combustor, combusting a supplemental fuel in the combustor to heat the catalyst, treating the heated catalyst with an oxygen-containing gas to produce a reactivated catalyst, and passing the reactivated catalyst from the catalyst processing portion to the reactor portion. The supplemental fuel may include a molar ratio of hydrogen to other combustible fuels of at least 1:1.

Processes for upgrading a hydrocarbon. The process can include introducing, contacting, and halting introduction of a hydrocarbon-containing feed into a reaction zone. The feed can be contacted with a catalyst within the reaction zone to effect dehydrogenation, dehydroaromatization, and/or dehydrocyclization of the feed to produce a coked catalyst and an effluent. The process can include introducing, contacting, and halting introduction of an oxidant into the reaction zone. The oxidant can be contacted with the coked catalyst to effect combustion of the coke to produce a regenerated catalyst. The process can include introducing, contacting, and halting introduction of a reducing gas into the reaction zone. The reduction gas can be contacted with the regenerated catalyst to produce a regenerated and reduced catalyst. The process can include introducing and contacting an additional quantity of the feed with the regenerated and reduced catalyst to produce a re-coked catalyst and additional first effluent.