Claims
- 1. A process to produce an alkylbenzenes comprising the steps of:
(a) producing a synthetic crude by Fischer-Tropsch reaction of synthesis gas; (b) fractionating the synthetic crude at least into a naphtha stream, a light Fischer-Tropsch liquid, and a heavy Fischer-Tropsch liquid; (c) fractionating light Fischer-Tropsch liquid into at least a naphtha cut and a remaining light Fischer-Tropsch liquid stream; (d) reacting at least a part of the remaining light Fischer-Tropsch liquid stream over an alumina catalyst to dehydrate alcohols in the remaining light Fischer-Tropsch liquid stream to corresponding alpha- and internal-olefins and forming a dehydrated light Fischer-Tropsch liquid; (e) reacting the dehydrated light Fischer-Tropsch liquid with benzene to produce an alkylbenzene.
- 2. The process of claim 1 further comprising the step of:
(f) separating the alkylbenzene from unreacted hydrocarbons and benzene.
- 3. The process of claim 1 further comprising the step of:
(g) sulfonating the alkylbenzene.
- 4. The process of claim 1 wherein all or part of the benzene is produced from a process comprising the steps of:
(1) catalytically reforming the naphtha to form a mixture of aromatics; and (2) processing the product of step (1) and recovering a benzene fraction.
- 5. The process of claim 1 wherein all or part of the benzene is produced from a process comprising the steps of:
(i) fractionating a natural gas liquid to recover a C6-C10 fraction; (ii) catalytically reforming the C6-C10 fraction to form a mixture of aromatics; and (iii) processing the product of step (ii) and recovering a benzene fraction.
- 6. The process of claim 1 wherein the synthesis gas is prepared from a gas comprising methane.
- 7. The process of claim 6 wherein the synthesis gas is produced by autothermal reformation.
- 8. The process improvement of claim 7 wherein the synthesis gas comprises between about 10% and about 60% N2.
- 9. The process improvement of claim 6 wherein the gas is natural gas.
- 10. The process improvement of claim 6 wherein the gas is coal gas.
- 11. The process of claim 1 wherein at least 95 wt % of alcohols present in the light Fischer-Tropsch liquid are converted to olefins in step (d).
- 12. The process improvement of claim 1 wherein the dehydrated light Fischer-Tropsch liquid contains substantially no alcohols.
- 13. The process improvement of claim 1 wherein the dehydrated light Fischer-Tropsch liquid contains substantially no oxygenates.
- 14. The process of claim 1 wherein the dehydration is conducted over a moving bed of alumina catalyst and further comprising continuous catalyst regeneration.
- 15. The process of claim 14 wherein the moving bed is selected from the group of ebullating beds, slurry bed and a fluidized bed.
- 16. The process of claim 1 wherein the alumina catalyst is silica-alumina.
- 17. The process of claim 1 further comprising the step of: vaporizing all or part of the light Fischer-Tropsch liquid before step (d).
- 18. The process of claim 1 further comprising the steps of:
(I) condensing a dehydrated product; (II) separating aqueous and organic phases of the dehydrated product; between steps (d) and (e).
- 19. The process of claim 1 wherein the reaction temperature of dehydration in step (c) is between about 400° and about 800° F.
- 20. The process of claim 1 wherein the alumina catalyst is gamma-alumina.
- 21. The process of claim 1 wherein the alumina catalyst is passivated alumina.
- 22. The process of claim 1 wherein the reaction temperature of dehydration in step (c) is between about 500° and about 700° F.
- 23. The process of claim 1 wherein the reaction temperature of dehydration in step (c) is between about 550° and about 675° F.
- 24. The process of claim 1 wherein the light Fischer-Tropsch liquid comprises from about 0 wt % to about 95 wt % olefins.
- 25. The process of claim 1 wherein the light Fischer-Tropsch liquid comprises from about 0.5 to about 40 wt % oxygenates.
- 26. The process of claim 1 wherein at least 80 wt % of the oxygenates are primary and internal alcohols.
- 27. The process of claim 2 further comprising the steps of:
(f2) separating and recovering the unreacted benzene from the unreacted paraffins; and (f3) reacting the recovered benzene with olefins to produce an alkylbenzene.
- 28. The process of claim 2 further comprising the step of:
(f4) separating and recovering the unreacted paraffins from the unreacted benzene.
- 29. An alkylbenzene produced by the process of claim 1.
- 30. An alkylbenzene sulfonate produced by the process of claim 3.
- 31. An alkylbenzene produced by the process of claim 4.
- 32. An alkylbenzene produced by the process of claim 5.
- 33. The process of claim 28 further comprising the step of dehydrogenating the unreacted paraffins.
- 34. An alkylbenzene produced by the process of claim 28.
- 35. The process of claim 28 further comprising the step of:
(f5) isomerically distilling the recovered paraffins to produce a stream comprised of 97+% normal paraffins.
- 36. The process of claim 28 further comprising the step of:
(f6) isomerically distilling the recovered paraffins to produce a stream comprised of isoparaffins wherein between about 20% and about 70% of the isoparaffins are terminal monomethyl branched.
- 37. The process of claim 36 further comprising the step of dehydrogenating the 97+% normal paraffins to produce linear internal olefins.
- 38. The process of claim 37 further comprising the step of dehydrogenating the terminal monomethyl paraffin stream to produce terminal monomethyl branched internal olefins.
- 39. The process of claim 37 further comprising the step of reacting the olefins with benzene to form alkylbenzenes.
- 40. The process of claim 38 further comprising the step of reacting the branched olefins with benzene to form alkylbenzenes.
- 41. A feedstock for use in producing a linear alkylbenzene comprising:
at least about 5 wt % olefins; at least about 5 wt % n-paraffins; and between about 2 and 80 wt % branched paraffins wherein substantially all of the branch groups are monomethyl and wherein the ratio of terminal monomethyl branching to internal monomethyl branching is at least about 1:1.5.
- 42. The feedstock of claim 41 wherein the ratio of terminal monomethyl branching to internal monomethyl branching is at least about 1:1.
- 43. The feedstock of claim 41 wherein the n-paraffins are present in an amount of at least about 20 wt % and wherein the ratio of terminal monomethyl branching to internal monomethyl branching is at least about 1.5:1.
- 44. The feedstock of claim 41 wherein the n-paraffins are present in an amount of at least about 40 wt % and wherein the ratio of terminal monomethyl branching to internal monomethyl is at least about 2:1.
- 45. The feedstock of claim 41 wherein the feedstock is a product of a Fischer-Tropsch reaction.
- 46. The feedstock of claim 45 wherein the Fischer-Tropsch reaction incorporates feed syngas having between about 10% N2 and about 60% N2.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Serial No. 60/453,274, filed on Mar. 7, 2003.
Provisional Applications (1)
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Number |
Date |
Country |
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60453274 |
Mar 2003 |
US |