Higher temperature regenerated dehydrogenation catalyst is mixed with the lower temperature spent dehydrogenation catalyst from a dehydrogenation reaction to heat the spent catalyst. Air or other oxygen containing gas may be introduced to facilitate mixing. The mixing of hot regenerated catalyst with cooler spent catalyst increases the temperature of the spent catalyst and makes the coke on catalyst and in the supplemental fuel gas instantly ready to combust without the delay necessary to heat up the spent catalyst to combustion temperature. The regenerated dehydrogenation catalyst may be mixed with the spent dehydrogenation catalyst before the mixture of catalyst is contacted with the supplemental fuel gas. Combustion with fuel gas should be conditioned to avoid generation of a flame.

Higher temperature regenerated dehydrogenation catalyst is mixed with the lower temperature spent dehydrogenation catalyst from a dehydrogenation reaction to heat the spent catalyst. Air or other oxygen containing gas may be introduced to facilitate mixing. The mixing of hot regenerated catalyst with cooler spent catalyst increases the temperature of the spent catalyst and makes the coke on catalyst and in the supplemental fuel gas instantly ready to combust without the delay necessary to heat up the spent catalyst to combustion temperature. The regenerated dehydrogenation catalyst may be mixed with the spent dehydrogenation catalyst before the mixture of catalyst is contacted with the supplemental fuel gas. Combustion with fuel gas should be conditioned to avoid generation of a flame.

A fluidized bed reactor, a device, and a method for producing low-carbon olefins from oxygen-containing compound are provided. The fluidized bed reactor includes a reactor shell, a reaction zone, a coke control zone and a delivery pipe, where there are n baffles arranged in the coke control zone, and the n baffles divide the coke control zone into n sub-coke control zones which include a first sub-coke control zone, a second sub-coke control zone, and an nth sub-coke control zone; at least one catalyst circulation hole is provided on each of the n-1 baffles, so that the catalyst flows in an annular shape in the coke control zone, where n is an integer. The device and method can be adapted to a new generation of DMTO catalyst, and the unit consumption of production ranges from 2.50 to 2.58 tons of methanol/ton of low-carbon olefins.

A coke control reactor, and a device and method for preparing low-carbon olefins from an oxygen-containing compound are provided. The coke control reactor includes a coke control reactor shell, a reaction zone I, and a coke controlled catalyst settling zone; a cross-sectional area at any position of the reaction zone I is less than that of the coke controlled catalyst settling zone; n baffles are arranged in a vertical direction in the reaction zone I; the n baffles divide the reaction zone I into m reaction zone I subzones; and a catalyst circulation hole is formed in each of the baffles, such that a catalyst flows in the reaction zone I in a preset manner. A catalyst charge in the present coke control reactor can be automatically adjusted, and an average residence time of a catalyst in the coke control reactor can be controlled by changing process operating conditions.

A fluidized catalytic reactor connected to a start-up heater is provided. The start-up heater provides sufficient heat to a catalyst containing stream to gradually increase the feed temperature. This allows for a critical volumetric flow rate to be achieved so that catalyst can be recovered from product instead of being entrained in product.

A process for preventing hazardous conditions at startup and shutdown of a reactor by sending an inert gas such as nitrogen to strip entrained oxygen from the catalyst when reactor temperatures are below about 240° C. During normal operation the entrained oxygen reacts with hydrocarbons to produce oxides but at the lower temperatures that are present at startup or shutdown these reactions do not occur sufficiently leaving oxygen that can cause hazardous conditions as temperatures increase upon startup. When the temperature is in the safe operating zone above 240° C., the nitrogen gas is stripped by air or other oxygen containing gas.

Processes and apparatuses for regenerating catalysts used in a hydrocarbon conversion process. The catalyst is separated into a bypass portion and an adsorption portion. The bypass portion is passed to a regeneration zone where coke may be removed. A vent gas from the regeneration zone may include an active additive from the catalyst, like a halogen. The vent gas is sent to an adsorption zone which also receives the adsorption portion. In the adsorption zone, the catalyst will contact and adsorb the active additive and then pass to the regeneration zone. The amount of active additive in the vent gas from the regeneration zone and the adsorption zone is reduced.

Processes and apparatuses for regenerating catalysts used in a hydrocarbon conversion process. The catalyst is separated into a bypass portion and an adsorption portion. The bypass portion is passed to a regeneration zone where coke may be removed. A vent gas from the regeneration zone may include an active additive from the catalyst, like a halogen. The vent gas is sent to an adsorption zone which also receives the adsorption portion. In the adsorption zone, the catalyst will contact and adsorb the active additive and then pass to the regeneration zone. The amount of active additive in the vent gas from the regeneration zone and the adsorption zone is reduced.

An active material useful in an oxidative dehydrogenation reactor system has an active phase, a support phase, and an intermediate composite phase. The active phase includes a transition metal oxide such as manganese oxide, which is reversibly oxidizable and/or reducible between oxidized and reduced states. The support phase includes an oxide of a IUPAC Group 2-14 element. The composite phase is a mixed metal oxide of the transition metal and the Group 2-14 element. The active phase can also include a promoter such as Na-W04 and/or a selectivity modifier such as A1 or ceria. Also, a reactor including the active material in a reactor, a method of making the active material, and a method of using the active material in a regenerative reaction process.

An active material useful in an oxidative dehydrogenation reactor system has an active phase, a support phase, and an intermediate composite phase. The active phase includes a transition metal oxide such as manganese oxide, which is reversibly oxidizable and/or reducible between oxidized and reduced states. The support phase includes an oxide of a IUPAC Group 2-14 element. The composite phase is a mixed metal oxide of the transition metal and the Group 2-14 element. The active phase can also include a promoter such as Na-W04 and/or a selectivity modifier such as A1 or ceria. Also, a reactor including the active material in a reactor, a method of making the active material, and a method of using the active material in a regenerative reaction process.