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 molecular sieve has a silica/alumina molar ratio of 100-300, and has a mesopore structure. One closed hysteresis loop appears in the range of P/P.sub.0=0.4-0.99 in the low temperature nitrogen gas adsorption-desorption curve, and the starting location of the closed hysteresis loop is in the range of P/P.sub.0=0.4-0.7. The catalyst formed from the molecular sieve as a solid acid not only has a good capacity of isomerization to reduce the freezing point, but also can produce a high yield of the product with a lower pour point. The process for preparing the catalyst involves steps including crystallization, filtration, calcination, and hydrothermal treatment.

A process to produce 1-octene and 1-decene includes (a) separating a composition containing an oligomer product—which contains 15 to 80 mol % C.sub.6 olefins, 20 to 80 mol % C.sub.8 olefins, and 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 20 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 a catalytic isomerization catalyst system in the presence of photochemical irradiation to form a second composition comprising 1-decene, and (d) purifying the second composition to isolate a third composition comprising at least 90 mol % 1-decene. Processes to produce 1-hexene and 1-decene also are described, as well as related manufacturing systems and processes to produce higher carbon number normal alpha olefins from lower carbon number normal alpha olefins.

A process to produce 1-octene and 1-decene includes (a) separating a composition containing an oligomer product—which contains 15 to 80 mol % C.sub.6 olefins, 20 to 80 mol % C.sub.8 olefins, and 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 20 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 a catalytic isomerization catalyst system in the presence of photochemical irradiation to form a second composition comprising 1-decene, and (d) purifying the second composition to isolate a third composition comprising at least 90 mol % 1-decene. Processes to produce 1-hexene and 1-decene also are described, as well as related manufacturing systems and processes to produce higher carbon number normal alpha olefins from lower carbon number normal alpha olefins.

Methanol-to-gasoline conversion may be performed using a heavy gasoline treatment, followed by a separation operation. Methanol may be converted into a first product mixture comprising dimethyl ether (DME) under DME formation conditions. In a methanol-to-gasoline (MTG) reactor, the first product mixture may be converted under MTG conversion conditions to produce a second product mixture comprising light gasoline hydrocarbons and untreated heavy gasoline hydrocarbons. The untreated heavy gasoline hydrocarbons may be separated from the light gasoline hydrocarbons and transferred to a heavy gasoline treatment (HGT) reactor. The untreated heavy gasoline hydrocarbons may be catalytically reacted in the HGT reactor to form a third product mixture. A heavy hydrocarbon fraction may be separated from the third product mixture. The heavy hydrocarbon fraction includes heavy gasoline hydrocarbons having a lower boiling endpoint than does the untreated heavy gasoline hydrocarbons.

Processes for the hydrogenolysis of butane are described. A process can include (a) introducing a butane feed and hydrogen to a first hydrogenolysis reactor comprising a hydrogenolysis catalyst, and (b) contacting the butane feed and hydrogen with the hydrogenolysis catalyst at conditions sufficient to produce a first hydrogenolysis product stream. The introduction of the butane feed stream and hydrogen to the first hydrogenolysis reactor can be controlled to maintain a hydrogen to butane molar ratio in the reactor inlet of 0.3:1 to 0.8:1.

A method of producing a fuel additive includes passing a feed stream comprising C4 hydrocarbons through a butadiene extraction unit producing a first process stream; passing the first process stream through a methyl tertiary butyl ether unit producing a second process stream and a methyl tertiary butyl ether product; passing the second process stream through a hydration unit producing the fuel additive and a recycle stream; passing the recycle stream through a hydrogenation unit; and recycling the recycle stream to a steam cracker unit and/or to the feed stream

A method of producing a fuel additive includes passing a feed stream comprising C4 hydrocarbons through a butadiene extraction unit producing a first process stream; passing the first process stream through a methyl tertiary butyl ether unit producing a second process stream and a methyl tertiary butyl ether product; passing the second process stream through a hydration unit producing the fuel additive and a recycle stream; passing the recycle stream through a hydrogenation unit; and recycling the recycle stream to a steam cracker unit and/or to the feed stream

A hydrocarbon isomerization system for an iC4 feed stream that provides for removal of C3s from an isomerization reactor feed stream by the addition of a depropanizer column to remove C3s from the reactor effluent stream after it has passed through a stabilizer column. This configuration prevents a buildup of C3s in the system and provides significant savings by reducing the size of the chloride treaters that are used to remove chlorides from off gas, increasing chlorides recovered to the hydrocarbon feed stream for use in combination with the isomerization catalyst. Significant utility savings are provided as well as a reduction in the amount of perchloroethane (PERC) and adsorbent that are required.

Processes for the hydrogenolysis of butane are described. A process can include (a) introducing a butane feed and hydrogen to a first hydrogenolysis reactor comprising a hydrogenolysis catalyst, and (b) contacting the butane feed and hydrogen with the hydrogenolysis catalyst at conditions sufficient to produce a first hydrogenolysis product stream. The introduction of the butane feed stream and hydrogen to the first hydrogenolysis reactor can be controlled to maintain a hydrogen to butane molar ratio in the reactor inlet of 0.3:1 to 0.8:1.