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.

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.

The present disclosure provides natural gas and petrochemical processing systems including oxidative coupling of methane reactor systems that integrate process inputs and outputs to cooperatively utilize different inputs and outputs of the various systems in the production of higher hydrocarbons from natural gas and other hydrocarbon feedstocks.

The present disclosure provides natural gas and petrochemical processing systems including oxidative coupling of methane reactor systems that integrate process inputs and outputs to cooperatively utilize different inputs and outputs of the various systems in the production of higher hydrocarbons from natural gas and other hydrocarbon feedstocks.

An H.sub.2-rich fuel gas stream can be advantageously produced by reforming a hydrocarbon/steam mixture in to produce a reformed stream, followed by cooling the reformed stream in a waste-heat recovery unit to produce a high-pressure steam stream, shifting the cooled reformed stream a first shifted stream, cooling the first shifted stream, shifting the cooled first shifted stream to produce a second shifted stream, cooling the second shifted stream, abating water from the cooled second shifted stream to obtain a crude gas mixture stream comprising H.sub.2 and CO.sub.2, and recovering a CO.sub.2 stream from the crude gas mixture stream. The H.sub.2-rich stream can be advantageously combusted to provide thermal energy needed for residential, office, and/or industrial applications including in the H.sub.2-rich fuel gas production process. The H.sub.2-rich fuel gas production process can be advantageously integrated with an olefins production plant comprising a steam cracker.

A process to produce 1-octene and 1-decene includes (a) separating a composition containing an oligomer product—which contains from 15 to 80 mol % C.sub.6 olefins, from 20 to 80 mol % C.sub.8 olefins, and from 5 to 20 mol % C.sub.10+ olefins—into a first oligomer composition containing C.sub.6 alkanes and at least 85 mol % C.sub.6 olefins (e.g., 1-hexene), a second oligomer composition containing at least 85 mol % C.sub.8 olefins (e.g., 1-octene), and a heavies stream containing C.sub.10+ olefins, then (b) contacting a metathesis catalyst system with the first oligomer composition to form a first composition comprising C.sub.10 linear internal olefins, (c) contacting the C.sub.10 linear internal olefins with an isomerization hydrofunctionalization catalyst system to form a second composition containing a functionalized alkane, (d) retro-hydrofunctionalizing the functionalized alkane to form a third composition containing 1-decene, and (e) purifying the third composition to isolate a fourth composition containing at least 90 mol % 1-decene. Processes to produce 1-hexene and 1-decene also are described, as well as related manufacturing systems.

A process to produce 1-octene and 1-decene includes (a) separating a composition containing an oligomer product—which contains from 15 to 80 mol % C.sub.6 olefins, from 20 to 80 mol % C.sub.8 olefins, and from 5 to 20 mol % C.sub.10+ olefins—into a first oligomer composition containing C.sub.6 alkanes and at least 85 mol % C.sub.6 olefins (e.g., 1-hexene), a second oligomer composition containing at least 85 mol % C.sub.8 olefins (e.g., 1-octene), and a heavies stream containing C.sub.10+ olefins, then (b) contacting a metathesis catalyst system with the first oligomer composition to form a first composition comprising C.sub.10 linear internal olefins, (c) contacting the C.sub.10 linear internal olefins with an isomerization hydrofunctionalization catalyst system to form a second composition containing a functionalized alkane, (d) retro-hydrofunctionalizing the functionalized alkane to form a third composition containing 1-decene, and (e) purifying the third composition to isolate a fourth composition containing at least 90 mol % 1-decene. Processes to produce 1-hexene and 1-decene also are described, as well as related manufacturing systems.

A catalyst composition includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for the catalytic cracking of hydrocarbons includes contacting in a reactor system a carbon-containing feedstock with at least one catalyst in the presence of oxygen to generate olefinic and/or aromatic compounds; and collecting the olefinic and/or aromatic compounds; wherein: the at least one catalyst includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for preparing the catalyst includes mixing metal catalyst precursors selected from transition metal compounds and rare-earth metal compounds and a eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides and heating it. A use of the catalyst in the catalytic cracking process of hydrocarbons.

A process for producing propylene in which a first material stream is provided using a steam cracking method and one or more fractionations and is rich in ethylene, in which a second material stream containing carbon monoxide and hydrogen is provided using a synthesis gas production method, and in which at least a part of the ethylene from the first material stream is reacted with at least a part of the carbon monoxide and the hydrogen from the second material stream to form an aldehyde using a hydroformylation to obtain a third material stream, and in which at least a part of the aldehyde in the third material stream is converted to the propylene, wherein the ethylene is provided by means of the steam cracking method in a first component mixture, wherein the propylene is provided in a second component mixture.

A process for producing propylene in which a first material stream is provided using a steam cracking method and one or more fractionations and is rich in ethylene, in which a second material stream containing carbon monoxide and hydrogen is provided using a synthesis gas production method, and in which at least a part of the ethylene from the first material stream is reacted with at least a part of the carbon monoxide and the hydrogen from the second material stream to form an aldehyde using a hydroformylation to obtain a third material stream, and in which at least a part of the aldehyde in the third material stream is converted to the propylene, wherein the ethylene is provided by means of the steam cracking method in a first component mixture, wherein the propylene is provided in a second component mixture.