Abstract:
A method of recovering halogen-containing materials from the cyclic catalyst regeneration operation of a catalytic hydrocarbon conversion process is disclosed. The method uses an arrangement of beds of adsorbent to maintain the halogen-containing materials within a circulating regeneration circuit.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to the regeneration of hydrocarbon conversion catalysts in the presence of a halogen-containing material. 
     BACKGROUND OF THE INVENTION 
     Numerous hydrocarbon conversion processes are widely used to alter the structure or properties of hydrocarbon streams. Such processes include isomerization from straight chain paraffinic or olefinic hydrocarbons to more highly branched hydrocarbons, dehydrogenation for producing olefinic or aromatic compounds, reforming to produce aromatics and motor fuels, alkylation to produce commodity chemicals and motor fuels, transalkylation, and others. 
     Many such processes use catalysts to promote hydrocarbon conversion reactions. These catalysts tend to deactivate for a variety of reasons, including the deposition of carbonaceous material or coke upon the catalyst, sintering or agglomeration or poisoning of catalytic metals on the catalyst, and/or loss of catalytic metal promoters such as halogens. Consequently, these catalysts are typically reactivated in a process called regeneration. Reactivation can thus include, for example, removing coke from the catalyst by burning, redispersing catalytic metals such as platinum on the catalyst, oxidizing such catalytic metals, reducing such catalytic metals, replenishing catalytic promoters such as chloride on the catalyst, and drying the catalyst. 
     One of the problems during regeneration of halogen-containing catalysts is loss of halogen itself from the catalyst. This happens when the catalysts are contacted with gases that, while regenerating the catalyst, tend also to remove halogen from the catalyst. 
     U.S. Pat. No. 5,965,473 discloses a method for recovering chlorine-containing materials from the effluent gases during catalyst regeneration in a hydrocarbon conversion process with a cyclic regeneration operation. To prevent loss of chlorine-containing materials, U.S. Pat. No. 5,965,473 uses one of the off-stream catalyst beds. This is an inefficient use of the vessel that contains the off-stream catalyst bed as well as of the catalyst itself, both of which could be better used for promoting hydrocarbon conversion reactions. Therefore, more efficient methods are sought to decrease the loss of halogen during halogen-containing catalyst regeneration. 
     SUMMARY OF THE INVENTION 
     This invention is a catalyst regeneration process that uses a bed of adsorbent first to adsorb halogen-containing materials that are removed from catalyst undergoing regeneration, and then to desorb these halogen-containing materials so they are readsorbed on to catalyst that is undergoing regeneration. The bed of adsorbent, therefore, is contacted with streams and at conditions that are different from those used during hydrocarbon conversion. This invention does not use a reaction vessel and its catalyst to adsorb and desorb the halogen-containing materials. 
     One object of this invention is to improve processes for regeneration of hydrocarbon conversion halogen-containing catalysts. Another object is to recover halogen-containing materials that are present during catalyst regeneration. A third object is to improve the utilization of equipment and catalysts used in hydrocarbon conversion processes, including reforming, isomerization, and dehydrogenation. A fourth object is to improve the efficiency of cyclic catalyst regeneration processes. 
     In a broad embodiment, this invention is a process for the regeneration of a hydrocarbon conversion catalyst in the presence of a halogen-containing material. The process comprises contacting a regeneration inlet stream comprising a first component selected from the group consisting of oxygen, hydrogen, nitrogen, and a C 1 -C 5  hydrocarbon with a catalyst in the presence of a halogen-containing material at regeneration conditions to at least partially regenerate the catalyst and produce a regeneration effluent stream comprising the material and the first component; contacting at least a portion of the regeneration effluent stream with an adsorbent, adsorbing the material on the adsorbent at adsorption conditions, and recovering an adsorption effluent stream comprising the first component and having a reduced concentration of the material relative to the at least a portion of the regeneration effluent stream; contacting a desorption inlet stream comprising a second component selected from the group consisting of oxygen, hydrogen, nitrogen, and a C 1 -C 5  hydrocarbon with the adsorbent, the adsorbent having the material adsorbed thereon, desorbing the material from the adsorbent at desorption conditions, and recovering a desorption effluent stream comprising the material and the second component; and forming the regeneration inlet stream from at least a portion of the desorption effluent stream. 
     Other embodiments and objects are described in the detailed description of the invention. 
     INFORMATION DISCLOSURE 
     U.S. Pat. No. 5,336,834 (Zarchy et al.) discloses an adsorption zone in combination with a catalytic hydrocarbon conversion process that keeps chlorine-containing compounds in the catalyst bed and prevents contamination of product streams with chlorine-containing compounds. The contents of U.S. Pat. No. 5,336,834 are hereby incorporated herein by reference. 
     U.S. Pat. No. 5,965,473 (Sechrist et al.) discloses a method for recovering chlorine-containing materials from the effluent gases during catalyst regeneration in a hydrocarbon conversion process with a cyclic regeneration operation. The contents of U.S. Pat. No. 5,965,473 are hereby incorporated herein by reference. 
     U.S. Pat. No. 6,117,809 (Sechrist et al.) discloses a method for recovering chlorine-containing materials removed from a chloride-containing catalyst undergoing reduction by using a sorption zone which contains catalyst. The contents of U.S. Pat. No. 6,117,809 are hereby incorporated herein by reference. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The drawing is a process flow diagram showing an embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention recovers halogen-containing materials especially chlorine-containing materials removed from hydrocarbon conversion catalysts undergoing cyclic catalyst regeneration. These materials, which are present in the regeneration effluent, are absorbed on an adsorbent contained in at least one adsorption bed. Once the adsorption bed has adsorbed the halogen-containing material, the halogen-containing materials are desorbed from the bed. Desorption takes place using a stream that is then used to regenerate the catalyst. When this regenerant stream contacts catalyst that is undergoing regeneration, it thus returns the halogen-containing materials to catalyst. 
     This invention uses at least one adsorbent. The adsorbent reversibly adsorbs at least one halogen-containing material. Suitable adsorbents include molecular sieves such as zeolites, clays, inorganic polymers such as alumina and activated alumina, zirconia, carbon, activated carbon, organic polymers such as resin adsorbent, etc. Suitable aluminas include gamma, alpha, theta, etc. Suitable adsorbents also include the ion exchanged clinoptilolites described in U.S. Pat. No. 5,336,834. Preferably, the adsorbent is selected so that the conditions at which the adsorbent has a capacity for reversible adsorption correspond to the conditions for cyclic regeneration. In addition, the adsorbent&#39;s select physical properties that affect reversible adsorption preferably do not degrade significantly when the adsorbent is used for adsorption and desorption. For example, while adsorbents with high surface areas are preferred, it is also preferred that the repeated use of the adsorbent for adsorption and desorption does not significantly decrease the adsorbent&#39;s surface area. Thus, while silica gel may be used as the adsorbent, it is not preferred. Although the adsorbent may contain an IUPAC Group 8-10 (VIII A) or noble metal component such as gold, silver, platinum, palladium iridium, rhodium, mercury, ruthenium, or osmium, the adsorbent contains preferably less than 0.1 wt-%, and more preferably none, of the metal, based on the weight of the adsorbent. More than one adsorbent may be used. Multiple adsorbents may be combined into a composite material, or they may be used without compositing, such as in a physical admixture of two adsorbents. 
     In addition to reversibly adsorbing at least one halogen-containing material, the adsorbent may also reversibly adsorb water. Generally, water is present along with the halogen-containing material in the cyclic regeneration stream from which the halogen-containing material is recovered. Generally, the conditions that result in reversible adsorption of the halogen-containing material also result in reversible adsorption of water. However, the presence of water can affect, sometimes adversely, the adsorption of the halogen-containing material, because water can compete with the halogen-containing material for sites on the adsorbent. 
     This invention is believed to be applicable to a wide range of catalytic hydrocarbon conversion processes and the regeneration of their catalysts, including aromatic isomerization, paraffin or olefin isomerization, paraffin dehydrogenation, and alkylation. However, catalytic reforming is the most widely practiced hydrocarbon conversion process which uses cyclic catalyst regeneration and to which this invention applies. Reforming catalysts typically contain a halogen, such as chlorine. Catalytic reforming is described in U.S. Pat. No. 5,965,473, the contents of which are hereby incorporated herein by reference. 
     This invention is applicable to many of the individual regeneration steps that typically comprise a cyclic regeneration operation of a catalytic reforming process. These include coke combustion, redispersion of catalytic metal on the catalyst, rehalogenating of the catalyst, drying of the catalyst, and reduction of catalytic metal on the catalyst. Except for drying, these steps are described in U.S. Pat. No. 5,965,473. Drying can occur by contacting the catalyst with a gas containing oxygen, hydrogen, nitrogen, or a C 1 -C 5  hydrocarbon, or a mixture thereof, under conditions such that water is transferred from the catalyst to the gas. Preferably the gas does not react with the catalyst, any component thereof, or any deposit thereon. Drying conditions usually comprise an elevated temperature and/or a reduced pressure and/or an elevated gas hourly space velocity, including the temperatures, pressures, and gas hourly space described for the other regeneration steps in U.S. Pat. No. 5, 965,473. Usually the water-containing effluent from the drying step is itself dried and then recycled to the catalyst bed to further dry the catalyst. Drying of the effluent usually takes place first by cooling the gas and then condensing the water and/or by contacting the gas with a desiccant. When drying involves cooling the gas, the gas is normally reheated prior to recycling. 
     The drawing shows a cyclic reforming process using three on-stream reactors  20 ,  36 , and  52 , and a fourth off-stream reactor  64  which is undergoing regeneration. Only the equipment and lines necessary for an understanding of the invention are shown in the drawing. The reactors have inlet lines  18 ,  34 ,  50 , and  63  containing valves  16 ,  32 ,  48 , and  62 , which can be opened or closed to start or stop flow to each reactor. They also have outlet lines  22 ,  38 ,  54 , and  66  containing valves  24 ,  40 ,  56 , and  68 , which can be opened or closed to start or stop flow from each reactor. Well-known equipment and lines (not shown) connect the reactors to each other so that each on-stream reactor can be taken off-stream and regenerated in the place of off-stream reactor  64 , and so that the off-stream reactor  64  can be placed on-stream and function as any of the on-stream reactors. Although this description is mainly in terms of three on-stream reactors and one off-stream reactor, there may of course be more or fewer on-stream reactors or off-stream reactors, and some off-stream reactors may have already undergone regeneration, while others may be awaiting regeneration. 
     A combined feed stream comprising naphtha and hydrogen flows through line  10 , is heated in heater  12 , passes through line  14 , valve  16 , and line  18 , and enters reactor  20 , where reforming reactions occur. Reactor  20  effluent flows through line  22 , valve  24 , and line  26 . Since reforming reactions are generally endothermic the effluent is heated in heater  28 , and the heated effluent flows through line  30 , valve  32 , to and line  34 , and into reactor  36 . Effluent from reactor  36  flows through line  38 , valve  40 , and line  42 , is heated in heater  44 , flows through lines  46 , valve  48 , and line  50 , and enters reactor  52 . Reactor  52  effluent flows through line  54 , valve  56 , and line  58  to conventional product separation and recovery facilities (not shown). 
     The catalyst in off-stream reactor  64  is undergoing regeneration using a recirculating regeneration system that uses two beds containing adsorbent,  80  and  120 . Adsorbent bed  80  operates in adsorption mode and adsorbent bed  120  operates in desorption mode. Adsorption bed  80  has inlet line  78  containing valve  76 , which can be opened or closed to start or stop flow to the bed. Adsorption bed  80  also has outlet line  82  containing valve  84 , which can be opened or closed to start or stop flow from the bed. Desorption bed  120  has an inlet line  118 , another inlet line  117  upstream which contains inlet valve  116 , an outlet line  122 , and another outlet line  124  downstream which contains valve  125 . Desorption bed  120  also has bypass lines  119  and  123  and bypass valve  121 , which can be opened or closed to start or stop bypass flow around desorption bed  120 . Well-known equipment and lines (not shown) connect the beds to each other so that the bed  80  in adsorption mode can be placed in desorption mode, and so that bed  120  in desorption mode can be placed in adsorption mode. 
     The following description is mainly in terms of the regeneration step being coke combustion, but this is not intended to limit the scope of this invention as set forth in the claims. Regenerant gas (also referred to herein as combustion gas) comprising oxygen, nitrogen, and a halogen-containing material (hydrogen chloride or chlorine) flows at an elevated temperature through line  60 , valve  62 , and line  63 , and enters reactor  64 . Since the combustion of coke deposits on the catalyst in reactor  64  is generally exothermic, the reactor  64  effluent gas (also referred to herein as flue gas) is hotter than the combustion gas. More importantly for this invention, the flue gas contains one or more halogen-containing materials that have been removed from the catalyst by the coke combustion, usually because of the combined effect of gas contacting, heat release, and any water produced. The flue gas flows through line  66 , valve  68 , and line  70 , and enters heat exchanger  72 , which cools the flue gas by indirectly transferring heat to the gas stream flowing through line  108 . The cooled flue gas flows through line  73  to cooler  74 . Cooler  74  further cools the gas stream by indirect heat exchange to the desired inlet temperature for adsorption, using water or air as a cooling medium. The further cooled gas stream flows through line  75 , valve  76 , and line  78 , and enters bed  80 , which contains alumina adsorbent. Adsorbent bed  80  is operating in adsorption mode, and the adsorbent adsorbs at least some of the halogen-containing material from the cooled flue gas. 
     The adsorption effluent flows through line  82 , valve  84 , and line  86 , and mixes with a liquid aqueous caustic solution (e.g., aqueous sodium hydroxide) flowing in line  148 . The caustic solution neutralizes halogen-containing materials still present in the adsorption effluent and helps protect downstream equipment (e.g., cooler  90  and separator  94 ) from corrosion. The two-phase mixture of cooled flue gas and aqueous caustic solution flows through line  88  to cooler  90 . Cooler  90  cools the mixture to ambient temperature, using water or air as a cooling medium. Cooler  90  effluent flows through line  92  to vapor-liquid separator  94 . Separator  94  may be empty or it may contain devices such as mesh blankets or baffles that help separate the vapor and liquid phases. The liquid that collects in the bottom of separator  94  and exits through line  137  is primarily aqueous caustic solution containing salts from neutralizing the halogen-containing materials. To prevent salts from accumulating in the recirculating caustic solution, a minor portion of the liquid in line  137  is withdrawn from the process through line  138  and routed to conventional spent caustic recovery facilities (not shown). The remaining portion of the liquid flows through line  140  and combines with a make-up stream of fresh caustic entering in line  142 . Line  144  carries this caustic solution to pump  146 , which discharges into line  148 . 
     A gas stream from separator  94  flows through line  96 . Since this stream contains carbon dioxide byproduct from coke combustion, a minor portion of these vapors is vented from the process through a line  98 . The remaining portion of these vapors flows through line  100  and combines with an oxygen-containing make-up stream (usually air) in line  102 . Line  104  carries this gas stream to compressor  106 , which discharges into line  108 . The gases in line  108  are heated by indirect heat transfer in exchanger  72 , flow through line  110 , and are further heated to the desired inlet temperature for desorption in heater  112 . After heating, the gases flow through line  111  and combines with a make-up stream (if any) in line  113 . The make-up stream can be used to add water (or a compound that forms water) to the gases in order to help halogen desorption. The gases flowing in line  114  flows through valve  116 , line  117 , and line  118 , and enter bed  120 , which contains alumina adsorbent containing halogen-containing materials. Bed  120  operates in desorption mode, and halogen-containing materials on the alumina adsorbent are desorbed and exit with the effluent of adsorption bed  120 . When desired, a portion of the gases flowing through line  117  may be made to bypass desorption bed  120  through lines  119  and  123 , provided that bypass valve  121  is open. 
     The desorption effluent flows through line  122  combines with any bypass flow in line  123 , and flows through line  124 , valve  125 , and line  126 , and combines with a make-up stream (if any) in line  128 . The make-up stream can be used to add additional halogen to the stream flowing in line  126  to produce the gas stream flowing in line  130 . Averaged over time, the amount of halogen added through line  128  is approximately equal to the amount of halogen neutralized by the contact of the caustic solution flowing in line  148  with the gases flowing in line  86 . But at any particular point in time, the amount of halogen added through line  128  is usually what is needed to attain the desired molar ratio of water to halogen at the inlet of the off-stream reactor  64  for regeneration purposes. 
     The gas flowing in line  130  combines with another make-up stream (if any) in line  132 . The make-up stream in line  132  can be used to add additional water (or a compound that forms water after being added, such as an alcohol) to the stream flowing in line  130  to produce the combustion gas (regeneration gas) flowing in line  134 . The amount of water (or compound that forms water) added through line  132  is usually what is needed to attain the desired molar ratio of water to halogen at the inlet of the off-stream reactor  64  for regeneration purposes. As a final step prior to entering the off-stream reactor  64 , the combustion gas may be cooled, or possibly even heated if necessary, using exchanger  136  to achieve the desired inlet temperature for off-stream reactor  64 . Whether or not exchanger  136  is needed depends on the outlet temperature of desorption bed  120  and the inlet temperature of off-stream reactor  64 . 
     Prior to being placed in adsorption mode, the bed of adsorbent  80  had operated in desorption mode in the position of bed of adsorbent  120 . While the bed  80  was in desorption mode, the halogen-containing materials on the alumina adsorbent were desorbed and passed to the off-stream reactor that was undergoing regeneration at the time. This desorption depleted the alumina adsorbent in bed  80  of halogen-containing materials, and thereby prepared the alumina adsorbent in bed  80  for use in adsorption mode. Conversely, prior to being placed in desorption mode the bed  120  had operated in adsorption mode in the position of bed  80 . While the bed  120  was in adsorption mode, the halogen-containing materials from the off-stream reactor that was undergoing regeneration at the time were adsorbed on the alumina adsorbent. This adsorption added halogen-containing materials to the alumina adsorbent in bed  120 , and thereby prepared the alumina adsorbent in bed  120  for use in desorption mode. 
     The operating conditions for the process of this invention are determined by many factors, but a primary factor is the regeneration conditions of the off-stream reactor. The regeneration conditions for the off-stream reactor  64  usually include an inlet temperature, an inlet gas hourly space velocity, an inlet oxygen concentration, and an inlet molar ratio of water to halogen of the combustion gases flowing in line  63 , a peak or maximum temperature of the catalyst bed in off-stream reactor  64 , and an outlet temperature of the flue gases flowing in line  66 . In practice, when the halogen is chlorine the molar ratio of water to halogen is the molar ratio of water to chloride. Of course, the specific target values of each of these regeneration variables depends on the composition and nature of the catalyst being regenerated, on the process and mechanical details of the off-stream reactor  64  and other associated equipment (such as exchangers  136  and  72 ), and on the regeneration step that is actually taking place. A person of ordinary skill in the art is able to determine the values of these regeneration variables. 
     In a first embodiment, the desired inlet conditions of off-stream reactor  64  are the same, or substantially the same, as the outlet conditions of desorption bed  120 . In that case, the bypass valve  121  would be closed, and there would be neither halogen addition through line  128 , nor water addition through line  132 , nor heat exchange by heat exchanger  136 . For example, when there is no heat transfer between the desorption bed and the off-stream reactor, then the desorption outlet temperature is about the same as the regeneration inlet temperature. To achieve those outlet conditions for the desorption bed  120  without undue experimentation, a person of ordinary skill in the art can monitor the desorption conditions and adjust the inlet conditions of the desorption bed  120  as necessary. The inlet temperature is set by the heater  112 . Generally, the desorption temperature is higher than the adsorption temperature and above about 66° C. (150° F.). The desorption temperature is usually from about 260° C. (500° F.) to about 538° C. (1000° F.). The inlet gas hourly space velocity is set by the compressor  106 , and the inlet oxygen concentration is set by the air addition via line  102 . The inlet molar ratio of water to halogen is preferably extremely high (i.e., little or no halogen in the inlet gas) since any halogen in the inlet gas to desorption bed  120  would deter desorption. Such low halogen concentrations are achieved by scrubbing the inlet gas with aqueous caustic solution, as shown in the drawing. 
     In this first embodiment, with the bed  120  in desorption mode, the outlet conditions of desorption bed  120  will change over time and no longer be the same, or substantially the same, as the desired inlet conditions of off-stream reactor  64 . This might happen because the adsorbent in desorption bed  120  has become depleted of halogen, resulting in a gradual and ultimately unacceptable increase in the molar ratio of water to halogen in the desorption outlet gas. When this occurs in this first embodiment, the positions of desorption bed  120  and adsorption bed  80  are switched, so that desorption bed  120  is used for adsorption, and adsorption bed  80  is used for desorption. 
     The duration of time that a bed of adsorbent is in desorption mode and the frequency at which the bed is switched from desorption mode depends on many factors. In this first embodiment, and in all other embodiments of this invention as well, these factors include the desorption conditions, the type and amount of adsorbent, the type of halogen-containing materials, the residual or minimum capacity of the adsorbent for halogen at desorption conditions, the halogen content of the adsorbent, the molar ratio of water to halogen in the stream entering the bed of adsorbent, and the halogen concentration in the effluent of the bed of adsorbent. The halogen content in the desorption effluent is usually at least 1 wt-%, and more commonly at least 10 wt-%, greater than the halogen concentration in the desorption inlet. If less halogen is desorbed from a bed of adsorbent, the bed is removed from desorption mode and replaced with another bed. In this first embodiment, it may be and usually is desirable to extend the time that a bed of adsorbent is in desorption mode while still maintaining the outlet conditions of the desorption bed the same, or substantially the same, as the desired inlet conditions of the off-stream reactor. One possible way of simultaneously achieving these two objectives is to add water (or a compound that forms water after being added, such as an alcohol) to the gases that enter the desorption bed  120 . Water in the inlet gases to desorption bed  120  helps desorb halogen from the adsorbent, and this is beneficial when the halogen content of the desorption outlet gases declines as the desorption bed  120  becomes depleted of halogen. Although the point of water introduction to the process could be anywhere downstream of separator  94  and upstream of desorption bed  120 , it is preferred to add water at a point where the process temperature is relatively high, such as through line  113  downstream of heater  112 . 
     Another way of not only extending the time that a bed of adsorbent is in desorption mode but also maintaining desirable outlet conditions of the desorption bed is to use two beds containing adsorbent in a parallel flow arrangement for desorption. Initially, only one bed of adsorbent is being desorbed, and all of the desorption gases flow to that one bed. However, as that desorption bed becomes depleted of halogen, the halogen content in that bed&#39;s effluent declines. When the composition of the desorption effluent is no longer the same, or substantially the same, as the desired composition of the regeneration inlet, a second bed of adsorbent is placed in a parallel flow arrangement with the first bed, and some of the desorption gases are routed to the second bed. While both beds are being desorbed, the flow rate of the desorption gases to the two beds is split so that a greater portion of the desorption gases flows to the first, more-depleted bed and a smaller portion of the desorption gases flows to the second, less depleted bed. In this way, the increase in halogen contributed by desorption of the second bed makes up for the decline in halogen contribution from the first bed, so that the total amount of halogen to the off-stream reactor is constant. Accordingly, the first bed of adsorbent may remain in desorption mode for a longer period of time than it could have remained if it alone was used to achieve the desired inlet conditions of the off-stream reactor. When the first bed is sufficiently depleted of halogen, the second desorption bed functions as the first desorption bed, and a third desorption bed replaces and functions as the second desorption bed. 
     In this first embodiment, and also in all other embodiments of this invention, the adsorption conditions are selected in order to recover a target or desired fraction of the total amount of the halogen that exits the off-stream reactor  64  in line  66 . In the embodiment shown in the drawing, that total amount of halogen is equal to the amount of halogen that enters the adsorption bed  80  in line  78 , and the amount of halogen that is lost (i.e., not recovered) is the amount of halogen in the gas stream that exits the adsorption bed  80  in line  82  and is then neutralized. Since the flow rates and halogen concentrations of the streams entering and leaving the adsorption bed  80  may vary with time, halogen recovery is determined by time-averaging the amount of halogen entering and exiting the adsorption bed  80 . Thus, the amount of halogen entering the adsorption bed  80  can be computed by measuring the flow rates and halogen concentrations of the inlet stream at specified times, plotting a curve representing the product of each flow-rate-concentration data pair versus time, and then integrating the area under the curve. The amount of halogen leaving the adsorption bed  80  can be computed in a similar way, and the halogen recovery is the quotient of the amount leaving divided by the amount entering, expressed as a percentage and subtracted from 100%. Halogen recovery is generally greater than about 80 wt-% and preferably greater than 90 wt-%. 
     The halogen recovery is determined by many factors. The molar ratio of water to halogen of the inlet gas to the adsorption bed  80  certainly affects the recovery, but this operating variable is not one that a person of ordinary skill in the art practicing this invention would typically control. This is because this ratio is essentially the same as that of the flue gas exiting the off-stream reactor  64 , which in turn is determined in large part by the previously-mentioned inlet conditions to off-stream reactor  64  and by the regeneration reactions that take place in the off-stream reactor  64 . Generally, as the molar ratio of water to halogen increases, halogen recovery decreases. The molar ratio of water to hydrogen halide in the stream entering the adsorbent bed being used for adsorption is usually more than about 5:1, and depending on the catalyst being regenerated in the reactor as well as other factors, this molar ratio could conceivably be as high as about 50:1 or 100:1. 
     A second factor affecting halogen recovery is the halogen content of the adsorbent at the start of the adsorption step. Generally, as the initial halogen content increases, the halogen recovery decreases. This initial halogen content is the same as the final halogen content of the adsorbent used for desorption, since the bed of adsorbent that is used for adsorption had previously been used for desorption. For this reason, the extent to which halogen is desorbed during the desorption step can influence the halogen recovery in the adsorption step. But, for the same reason, this variable cannot be independently controlled once the desorption step is finished and the adsorption step begins. 
     A third variable that can be independently adjusted to affect halogen recovery during adsorption is the adsorption temperature. Adsorption temperature can be controlled by regulating exchangers  72  and  74 . Generally, recovery increases as adsorption temperature decreases. Thus, if during adsorption, the halogen recovery drops below the desired target, the adsorption temperature may be decreased to the low end of the range of adsorption temperatures. 
     The operating temperature for adsorption mode is generally lower than that for desorption mode. The adsorption temperature is usually above about 66° C. (150° F.). The adsorption temperature is usually no higher than the outlet temperature of the reactor that is undergoing regeneration, but usually it is lower than that by at least 55° C. (100° F.) due to heat exchange between the outlet of the off-stream reactor  64  and the inlet of the desorption bed  80 . Only rarely, would the adsorption temperature exceed 482° C. (900° F.). The adsorption temperature is generally maintained above the dew point temperature of the flue gas in order to minimize the possibility of condensing corrosive acidic liquid in the adsorption equipment. Also, the adsorption temperature is preferably maintained above the capillary condensation temperature of the flue gas, which is the temperature at which condensation from the flue gas occurs in the capillaries of the adsorbent. The capillary condensation temperature is usually higher than the dew point temperature of the bulk flue gas. 
     The capillary condensation temperature depends on many factors, including not only the composition of the flue gas but also the chemical and physical properties of the adsorbent, such as the distribution of pore size and volume. When there are differences in the physical dimensions and chemical components of individual pores of the adsorbent, capillary condensation will occur over a range of temperatures. The greater the amount of capillary condensation during adsorption, the greater is the amount of water present on the adsorbent at the start of the desorbent step. To the extent that this greater amount of water is desorbed during the desorption step, the greater is the amount of water withdrawn from the reactor undergoing regeneration and returned or recycled to the reactor. 
     The capillary condensation temperature can be approximately determined from a graph of the weight of water adsorbed on the adsorbent as a function of adsorption temperature of the flue gas. As temperature is decreased from above the range of capillary condensation temperatures into the range of temperatures where capillary condensation occurs, the slope of the graph increases dramatically. While the change in slope may occur over a range of temperatures rather than at one particular temperature, the change is nevertheless apparent to a person of ordinary skill in the art. For example, if the upper end of the range of capillary condensation temperature is 149° C. (300° F.), the change in the weight of water adsorbed may be only about 1.5 wt-% as the temperature is decreased from about 427° C. (800° F.) to about 149° C. (300° F.), but may be about 4 wt-% as the temperature is further decreased from about 149° C. (300° F.) to about 121° C. (250° F.). In addition, a person of ordinary skill in the art can estimate the capillary condensation temperature by estimating the difference between the dew point temperature of the bulk flue gas and the capillary condensation temperature using well-known correlations and theoretical techniques that take into account the dimensions of the adsorbent&#39;s capillaries and other factors, and then adding that difference to the measured dew point temperature. 
     Despite decreasing the adsorption temperature to increase halogen recovery, halogen recovery may nevertheless be unacceptably low, because of frequent or excessive breakthrough of halogen into the outlet of the adsorption bed  80 . In this case, other embodiments of this invention can be used to further improve halogen recovery. Instead of, or subsequent to, operating the desorption bed  120  so that the outlet conditions of desorption bed  120  are the same as, or substantially the same as, the desired inlet conditions of off-stream reactor  64 , the desorption operating variables may be selected somewhat independently of the regeneration conditions. In these other embodiments of this invention, desorption operating conditions are selected with the objective of decreasing the final halogen content of the adsorbent at the end of the desorption step. This objective can be met in several ways. First, the desorption temperature can be increased to a temperature above the desired regeneration inlet temperature. Heater  112  can heat the gases entering desorption bed  120 , and exchanger  136  can cool the exiting gases to the desired inlet temperature for off-stream reactor  64 . Second, the desorption step can be prolonged beyond the point when the outlet molar ratio of water to halogen increases above the desired inlet molar ratio for regeneration. In that case, line  128  may be used to add halogen to the gases exiting desorption bed  120 , thereby lowering the molar ratio to the desired range. 
     Even if halogen recovery is within the desired range, the outlet conditions of the desorption bed  120  may not be the same, or substantially the same, as the desired inlet conditions of the off-stream reactor  64 . For example, the molar ratio of water to halogen in the gases flowing through line  122  may be lower than the desired molar ratio at the inlet of the off-stream reactor  64 . This can happen if too much halogen is being desorbed too rapidly from the desorption bed  120 , such as when desorption is starting on a bed of adsorbent that adsorbed an excessive amount of halogen or when the gas is flowing through the bed at an excessive rate. In these situations, a surge of halogen may be desorbed from the bed, resulting in an unacceptably low molar ratio of water to halogen in the gases flowing through line  122 . In these circumstances, either or both of two other embodiments of this invention are useful. First, line  132  may be used to add water to the gases exiting desorption bed  120 , thereby raising the molar ratio to the desired range. Second, valve  121  may be opened to bypass desorption gases around desorption bed  120 , thereby decreasing the amount of halogen that is desorbed from the adsorbent in desorption bed  120  and effectively raising the molar ratio of the gases flowing through line  126  to the desired range. In either event, once the molar ratio of water to halogen in the gases flowing through line  122  increases to the desired range, the water addition or the desorption gas bypassing may be decreased or stopped. 
     When halogen breakthrough occurs in the effluent of the bed of adsorbent that is being used for adsorption, the bed is removed from adsorption mode, and is subsequently used for desorption. The duration of time that the bed is in adsorption mode and the frequency at which the bed is removed from adsorption mode depends on many factors. These factors include the adsorption conditions, the type and amount of adsorbent, the type of halogen-containing materials, the maximum capacity of the adsorbent for halogen at adsorption conditions, the halogen content of the adsorbent, the molar ratio of water to halogen in the stream entering the bed of adsorbent, and the halogen concentration in the adsorbent bed. A bed of adsorbent used in adsorption mode adsorbs usually at least 90 wt-%, and preferably at least 99 wt-%, of the halogen in the stream entering the bed of adsorbent. If less halogen than that is adsorbed by the bed of adsorbent, the bed is removed from adsorption mode and replaced with another bed. 
     Although the description of this invention has been mainly in terms of two beds of adsorbent, one in use for adsorption and the other in use for desorption, there may of course be more beds of adsorbent, and at any given time some of these other beds might be in use for adsorption, desorption, or neither. One or more beds of adsorbent may have already been used for adsorption and are awaiting desorption, while others have been used for desorption and are awaiting adsorption. Such additional adsorbent beds may be desirable for several reasons. First, one or more additional beds may be useful if there is a heating step between the adsorption and desorption steps, to preheat the relatively cool adsorbent after adsorption and prior to desorption. Also, additional beds may be used if there is a cooling step after desorption and prior to adsorption. Third, additional beds may be used if the adsorbent beds have a relatively small capacity for halogen relative to the amount of halogen that may be removed from the off-stream reactor bed  64 . Fourth, additional beds could function as a “reservoir” for halogen that had been removed from the off-stream reactor but which had not yet been returned to the reactor. Such a situation may arise when the regeneration conditions do not require that halogen removed from the catalyst be returned immediately to the off-stream reactor. 
     A fifth reason that additional beds may be desirable is that the additional beds may be used to maximize halogen recovery. In one example, a bed that is being used for adsorption could be replaced with a fresh bed either long before any halogen breaks through at the outlet of the bed or well prior to when the halogen content of the adsorbent in the bed in adsorption mode has reached its maximum content. By not operating the adsorption bed to the point of maximum possible halogen loading, the full halogen capacity of the adsorbent may not be utilized, but since the risk of halogen breakthrough is minimized, halogen recovery is maximized. In another example, two beds containing adsorbent could be used in a series flow arrangement for a “lead-lag” adsorption operation. The first bed in the series, or the “lead” bed, could be used for adsorption up to or even after either halogen breaks through at the outlet of the “lead” bed, or the halogen content of the adsorbent in the “lead” bed has reached its maximum. The second bed in the series, or the “lag” bed, could adsorb any halogen that breaks through the “lead” bed. By operating the “lead” bed to the point of its maximum possible halogen loading, the full halogen capacity of the adsorbent in the “lead” bed is utilized while still maximizing halogen recovery. When halogen breakthrough has occurred in the outlet of the “lead” bed, the “lead” bed is removed from adsorption mode and replaced with the “lag” bed, and the “lag” bed is replaced with a bed that has been used for desorption. 
     As previously described, halogen recovery is affected by the difference between the halogen content of the adsorbent prior to adsorption (i.e., after desorption) and the halogen content of the adsorbent after adsorption (i.e., prior to desorption). Generally, the greater the difference in halogen contents, the greater is the halogen recovery. Suitable halogen recoveries are achieved when the difference between the halogen content of the adsorbent prior to adsorption (i.e., after desorption) and the halogen content of the adsorbent after adsorption (i.e., prior to desorption) is from about 0.2 to about 2.0 wt-% halogen, and preferably from about 0.5 to about 1.0 wt-% halogen, based on the weight of the adsorbent. 
     The difference in halogen contents of the adsorbent depends on many factors, including the flow rates and compositions of the gases flowing through the adsorption and desorption beds, the adsorbent, the quantities of adsorbent used for adsorption and desorption, and other adsorption and desorption conditions, especially the difference between the adsorption and desorption temperatures. As long as there is some difference in the adsorption and desorption temperatures, then some adsorption of halogen will generally occur. With all other conditions being the same, the greater the difference in adsorption and desorption temperatures, the greater is the recovery of halogen. This increased recovery is due to either an increase in halogen pickup during adsorption (due to a lower adsorption temperature) or an increase in halogen removal during desorption (due to a higher desorption temperature). The difference in the adsorption and desorption temperatures is usually more than about 55° C. (100° F.). The difference in halogen contents also depends on the molar ratios of water to halogen during adsorption and desorption. The ratio of the molar ratio of water to halogen during adsorption to the molar ratio of water to halogen during desorption is generally from about 0 to about 2. 
     The relationship between, on the one hand, halogen recovery and, on the other hand, the flow rates and halogen concentrations of the streams during adsorption and desorption and the amount of adsorbent used for adsorption and desorption is that of a halogen material balance. Thus, assuming that the adsorbent in the adsorption bed has adequate capacity to adsorb a desired amount of halogen, it is possible to adsorb that amount either by using a relatively high flow rate of the gas at a relatively low inlet concentration of halogen or by using a relatively low flow rate of the gas at a relatively high concentration of halogen. Similarly, a desired amount of halogen can be desorbed from the desorption bed with either a relatively high or low flow rate of gas or with a relatively low or high concentration of halogen. 
     As used herein, the term “halogen” includes “halogen” or “halide.” Thus, the term “halogen” includes an IUPAC Group 17 (VII B) element component such as fluorine, fluoride, chlorine, chloride, bromine, bromide, iodine, iodide, etc. The term “halogen-containing material” includes molecules or compounds containing halogen, regardless whether they are present on the catalyst, on the adsorbent, or in a fluid stream. But, in the case of molecules or compounds present on the catalyst or the adsorbent, the term “halogen-containing material” means the halogen or halide itself, rather than the catalyst or the adsorbent. That is, even when a catalyst or an adsorbent contains halogen, referring to the “halogen-containing material” on the catalyst or adsorbent does not refer to the catalyst or the adsorbent itself as a whole, but rather to the halogen or halide present on the catalyst or adsorbent. 
     All references herein to groups of elements are to the Periodic Table of the Elements, “CRC Handbook of Chemistry and Physics,” CRC Press, 80 th  Edition, 1999-2000.