A process for converting a feed stream having carbon to C.sub.2 to C.sub.5 olefins, includes introducing a feed stream including methane and oxygen to a first reaction zone, reacting the methane and oxygen in the first reaction zone to form a first reaction zone product stream having a mixture of C.sub.2 to C.sub.5 alkanes, transporting the mixture of C.sub.2 to C.sub.5 alkanes to a second reaction zone, introducing a fresh stream of at least one of ethane and propane to the second reaction zone, converting the C.sub.2 to C.sub.5 alkanes to C.sub.2 to C.sub.5 olefins in the second reaction zone, producing one or more product streams in the second reaction zone, where a sum of the one or more product streams includes C.sub.2 to C.sub.5 olefins, and producing a recycle stream comprising hydrogen in the second reaction zone, where the recycle stream is transported to the first reaction zone.

Provided are systems and methods for obtaining ethylene and propylene products from, for example, shale gas and shale gas condensate feedstocks. These systems and method operate by utilizing a hydrocracker train to crack C4 and C5 hydrocarbons to a product stream of propane and ethane or using a hydrogenolysis train to process C4 and C5 hydrocarbons to a product stream of propane and ethane that is provided to a cracker for an efficient conversion to ethylene and propylene. The disclosed systems are configured to reduce the amount of offsite hydrogen needed and also provide product streams that include a well-defined set of products as compared to existing approaches.

Provided are systems and methods for obtaining ethylene and propylene products from, for example, shale gas and shale gas condensate feedstocks. These systems and method operate by utilizing a hydrocracker train to crack C4 and C5 hydrocarbons to a product stream of propane and ethane or using a hydrogenolysis train to process C4 and C5 hydrocarbons to a product stream of propane and ethane that is provided to a cracker for an efficient conversion to ethylene and propylene. The disclosed systems are configured to reduce the amount of offsite hydrogen needed and also provide product streams that include a well-defined set of products as compared to existing approaches.

A system for oxidative conversion of a mixed hydrocarbon feed stream to a product stream containing at least one olefin is provided. The system includes a plurality of reactors each capable of oxidatively dehydrogenating at least a portion of a hydrocarbon in the mixed hydrocarbon feed, and each reactor able to operate at different set of reaction conditions from other reactors in the plurality of reactors. All of the reactors use the same oxygen transfer agent to produce at least one olefin. In some embodiments, at least one reactor is optimized to oxidatively couple methane to produce ethylene, while other reactors are optimized to oxidatively dehydrogenate ethane to ethylene or to oxidatively dehydrogenate propane to ethylene and/or propylene. All of the reactors feed into a single regeneration unit for the oxygen transfer agent. A method of oxidatively converting the mixed hydrocarbon feed to an olefin is also provided.

A system for oxidative conversion of a mixed hydrocarbon feed stream to a product stream containing at least one olefin is provided. The system includes a plurality of reactors each capable of oxidatively dehydrogenating at least a portion of a hydrocarbon in the mixed hydrocarbon feed, and each reactor able to operate at different set of reaction conditions from other reactors in the plurality of reactors. All of the reactors use the same oxygen transfer agent to produce at least one olefin. In some embodiments, at least one reactor is optimized to oxidatively couple methane to produce ethylene, while other reactors are optimized to oxidatively dehydrogenate ethane to ethylene or to oxidatively dehydrogenate propane to ethylene and/or propylene. All of the reactors feed into a single regeneration unit for the oxygen transfer agent. A method of oxidatively converting the mixed hydrocarbon feed to an olefin is also provided.

A system for oxidative conversion of a mixed hydrocarbon feed stream to a product stream containing at least one olefin is provided. The system includes a plurality of reactors each capable of oxidatively dehydrogenating at least a portion of a hydrocarbon in the mixed hydrocarbon feed, and each reactor able to operate at different set of reaction conditions from other reactors in the plurality of reactors. All of the reactors use the same oxygen transfer agent to produce at least one olefin. In some embodiments, at least one reactor is optimized to oxidatively couple methane to produce ethylene, while other reactors are optimized to oxidatively dehydrogenate ethane to ethylene or to oxidatively dehydrogenate propane to ethylene and/or propylene. All of the reactors feed into a single regeneration unit for the oxygen transfer agent. A method of oxidatively converting the mixed hydrocarbon feed to an olefin is also provided.

Aspects of the invention relate to producing olefins and other products by oxidative dehydrogenation cracking of a hydrocarbon feed. In one embodiment, the method includes oxidative cracking a hydrocarbon feed comprised of plastic waste. Methods of the present invention employ dual functional catalyst comprising solid acids and metal oxides, which are capable of selectively oxidizing hydrogen to water rather than combustion of the hydrocarbon feeds or products. Additional aspects of the invention demonstrate catalyst synthetic methods for encapsulating metal oxides in the internal channels and cages of solid acids, thereby improving the selective oxidation of hydrogen to water and decreasing feed and product oxidation. The re-oxidation of the thus reduced metal oxide transfer agents supplies heat to drive the endothermic cracking of the feed.

Integrated systems are provided for the production of higher hydrocarbon compositions, for example liquid hydrocarbon compositions, from methane using an oxidative coupling of methane system to convert methane to ethylene, followed by conversion of ethylene to selectable higher hydrocarbon products. Integrated systems and processes are provided that process methane through to these higher hydrocarbon products.

Integrated systems are provided for the production of higher hydrocarbon compositions, for example liquid hydrocarbon compositions, from methane using an oxidative coupling of methane system to convert methane to ethylene, followed by conversion of ethylene to selectable higher hydrocarbon products. Integrated systems and processes are provided that process methane through to these higher hydrocarbon products.

Systems and processes herein improve the conversion of propylene to ethylene via metathesis. On a mass basis, embodiments herein may be used to convert greater than 40% propylene, on a mass basis, to ethylene, such as 43% to 75%, on a mass basis. In one aspect, processes for the conversion of propylene to ethylene herein may include introducing a propylene feed stream to a metathesis reactor, and contacting the propylene with a metathesis catalyst in the metathesis reactor to convert the propylene to ethylene and 2-butene. An effluent from the metathesis reactor may be recovered, the effluent including ethylene, 2-butene, and unconverted propylene. The effluent may then be separated in a fractionation system to recover an ethylene fraction, a propylene fraction, a c4 fraction, and a C5+ fraction. The propylene fraction and the C4 fraction may then be fed to the metathesis reactor to produce additional ethylene.