Patent ID: 8173852

Claim:
A method for producing styrene, the method comprising the steps of: introducing ethylbenzene to a first dehydrogenation reactor containing a first high activity dehydrogenation catalyst that has a relative activity of about 1.5 or greater at a first predetermined inlet temperature of from about 550 to about 620° C. to form a first intermediate effluent stream that comprises styrene, ethylbenzene, and hydrogen; adding oxygen to the first intermediate effluent stream to form a first oxygenated intermediate effluent stream; and introducing the first oxygenated intermediate effluent stream to a first oxidation-reheat dehydrogenation reactor at a second predetermined inlet temperature of about 510° C. or less to form styrene, wherein the first oxidation-reheat dehydrogenation reactor contains a first oxidation catalyst and a second high activity dehydrogenation catalyst that has a relative activity of about 1.5 or greater, wherein the step of introducing the first oxygenated intermediate effluent stream includes contacting the first oxygenated intermediate effluent stream with the first oxidation catalyst contained in an oxidation bed to form a first heated hydrogen-lean intermediate effluent stream, and contacting the first heated hydrogen-lean intermediate effluent stream with the second high activity dehydrogenation catalyst contained in a dehydrogenation bed to form styrene.