Systems and methods for using and regenerating a catalyst for producing acetic acid from ethane are disclosed. Feed stream comprising ethane and an oxidant including oxygen is flowed to a reactor, in which a catalyst comprising MoVNbPd oxide is disposed. The ethane and the oxidant are reacted in presence of the catalyst under reaction conditions sufficient to produce acetic acid. When the catalyst's ability to catalyze the reaction between the ethane and the oxidant is reduced by a predetermined percentage, the flow of the feed stream to the reactor is ceased. A regenerating gas stream is flowed through the reactor to contact the regenerating gas stream with the catalyst under operating conditions to increase the catalyst's ability to catalyze the reaction between the ethane and the oxidant.

Systems and methods for using and regenerating a catalyst for producing acetic acid from ethane are disclosed. Feed stream comprising ethane and an oxidant including oxygen is flowed to a reactor, in which a catalyst comprising MoVNbPd oxide is disposed. The ethane and the oxidant are reacted in presence of the catalyst under reaction conditions sufficient to produce acetic acid. When the catalyst's ability to catalyze the reaction between the ethane and the oxidant is reduced by a predetermined percentage, the flow of the feed stream to the reactor is ceased. A regenerating gas stream is flowed through the reactor to contact the regenerating gas stream with the catalyst under operating conditions to increase the catalyst's ability to catalyze the reaction between the ethane and the oxidant.

A catalyst is regenerated by an inventive process using a heat exchange fluid such as superheated steam to remove heat during the process relying on efficient heat transfer (e.g., enabled by the microchannel reactor construction) in comparison with prior art heat exchange relying on a phase change, e.g. between water and (partial or complete vaporization) steam, allows simplification of the protocols to enable transition at higher temperatures between steps which translates in reduced duration of the regeneration process and avoids potential water hammering risks.

A catalyst is regenerated by an inventive process using a heat exchange fluid such as superheated steam to remove heat during the process relying on efficient heat transfer (e.g., enabled by the microchannel reactor construction) in comparison with prior art heat exchange relying on a phase change, e.g. between water and (partial or complete vaporization) steam, allows simplification of the protocols to enable transition at higher temperatures between steps which translates in reduced duration of the regeneration process and avoids potential water hammering risks.

An oxygen gas stream is distributed to a spent catalyst stream through an oxygen nozzle of an oxygen gas distributor and a fuel gas stream is distributed to the spent catalyst stream through a fuel nozzle of a fuel gas distributor. An oxygen gas jet generated from said oxygen nozzle and a fuel gas jet generated from said fuel gas nozzle have the same elevation in the regenerator. In a regenerator, an oxygen gas distributor and a fuel gas distributor may be located in a mixing chamber. A fuel outlet of a fuel nozzle of the fuel gas distributor may be within a fifth of the height of the mixing chamber from an oxygen outlet of an oxygen nozzle of the oxygen gas distributor. In addition, clear space is provided between a fuel gas nozzle on a fuel gas distributor and a closest oxygen nozzle on an oxygen gas distributor.

An oxygen gas stream is distributed to a spent catalyst stream through an oxygen nozzle of an oxygen gas distributor and a fuel gas stream is distributed to the spent catalyst stream through a fuel nozzle of a fuel gas distributor. An oxygen gas jet generated from said oxygen nozzle and a fuel gas jet generated from said fuel gas nozzle have the same elevation in the regenerator. In a regenerator, an oxygen gas distributor and a fuel gas distributor may be located in a mixing chamber. A fuel outlet of a fuel nozzle of the fuel gas distributor may be within a fifth of the height of the mixing chamber from an oxygen outlet of an oxygen nozzle of the oxygen gas distributor. In addition, clear space is provided between a fuel gas nozzle on a fuel gas distributor and a closest oxygen nozzle on an oxygen gas distributor.

Disclosed are processes for rejuvenating catalysts comprising at least one Group 10 metal and a microporous crystalline metallosilicate, and hydrocarbon conversion processes including such rejuvenation processes. In an aspect, the rejuvenation process comprises contacting a deactivated catalyst comprising at least one Group 10 metal and a microporous crystalline metallosilicate with an oxygen-containing gaseous stream under conditions comprising a temperature ranging from about 250° C. to about 375° C. and a pressure of up to about 100 bar. In a further aspect, the rejuvenation process comprises contacting a deactivated catalyst comprising at least one Group 10 metal, at least one rare earth metal, and a microporous crystalline metallosilicate with an oxygen-containing gaseous stream under conditions comprising a temperature ranging from about 250° C. to about 500° C. and a pressure of up to about 100 bar.

Disclosed are processes for rejuvenating catalysts comprising at least one Group 10 metal and a microporous crystalline metallosilicate, and hydrocarbon conversion processes including such rejuvenation processes. In an aspect, the rejuvenation process comprises contacting a deactivated catalyst comprising at least one Group 10 metal and a microporous crystalline metallosilicate with an oxygen-containing gaseous stream under conditions comprising a temperature ranging from about 250° C. to about 375° C. and a pressure of up to about 100 bar. In a further aspect, the rejuvenation process comprises contacting a deactivated catalyst comprising at least one Group 10 metal, at least one rare earth metal, and a microporous crystalline metallosilicate with an oxygen-containing gaseous stream under conditions comprising a temperature ranging from about 250° C. to about 500° C. and a pressure of up to about 100 bar.

A catalyst is regenerated by an inventive process using a heat exchange fluid such as superheated steam to remove heat during the process relying on efficient heat transfer (e.g., enabled by the microchannel reactor construction) in comparison with prior art heat exchange relying on a phase change, e.g. between water and (partial or complete vaporization) steam, allows simplification of the protocols to enable transition at higher temperatures between steps which translates in reduced duration of the regeneration process and avoids potential water hammering risks.

A catalyst is regenerated by an inventive process using a heat exchange fluid such as superheated steam to remove heat during the process relying on efficient heat transfer (e.g., enabled by the microchannel reactor construction) in comparison with prior art heat exchange relying on a phase change, e.g. between water and (partial or complete vaporization) steam, allows simplification of the protocols to enable transition at higher temperatures between steps which translates in reduced duration of the regeneration process and avoids potential water hammering risks.