Abstract: The present invention relates to processes and continuous processes for preparing gaseous products, and in particular, methane via the catalytic gasification of carbonaceous feedstocks in the presence of steam. In one aspect of the invention, the processes comprise at least partially combusting a first carbonaceous feedstock with an oxygen-rich gas stream in an oxygen-blown gasifier, under suitable temperature and pressure, to generate a first gas stream comprising hydrogen, carbon monoxide and superheated steam; and reacting a second carbonaceous feedstock and the first gas stream in a catalytic gasifier in the presence of a gasification catalyst under suitable temperature and pressure to form a second gas stream comprising a plurality of gaseous products comprising methane, carbon dioxide, hydrogen, carbon monoxide and hydrogen sulfide.

Abstract: The invention provides processes for generating a methane-enriched gas from a gas mixture comprising carbon monoxide and hydrogen such as gas streams generated by gasification of an alkali metal catalyst-loaded carbonaceous feedstock, and a char methanation catalyst useful in such processes.

Abstract: Processes for the generation of steam are provided for use in an integrated catalytic gasification process for converting carbonaceous materials to combustible gases, such as methane. Generally, the exhaust gas from a steam generating reactor is provided along with steam, a carbonaceous feedstock, and a gasification catalyst, to a catalytic gasifier, wherein under appropriate temperature and pressure conditions, the carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, and carbon dioxide. As substantially all the carbon dioxide produced from the steam generation process and the gasification process are subsequently directed though gas purification and separation processes, substantially all the carbon dioxide may be recovered, yielding a process having a near zero carbon footprint.

Abstract: Processes are provided for capturing and recycling carbonaceous fines generated during a gasification process. In particular, the recycled fines are processed into a particulate composition which is useable as a carbonaceous feedstock and is conversion into a gas stream comprising methane.

Abstract: The present invention relates to processes for preparing gaseous products, and in particular, methane via the catalytic gasification of carbonaceous feedstocks in the presence of steam and an oxygen-rich gas stream. The processes comprise using at least one catalytic methanator to convert carbon monoxide and hydrogen in the gaseous products to methane and do not recycle carbon monoxide or hydrogen to the catalytic gasifier.

Abstract: The present invention relates to processes for hydromethanating a carbonaceous feedstock to a methane-enriched synthesis gas and a char by-product, with catalyst recovery from the by-product char to generate a spent char, and with treatment of the spent char to generate a carbon rich portion which is ultimately recycled to the hydromethanation reactor to increase overall carbon utilization and increase yields of product gas (per unit of feedstock).

Abstract: The present invention relates to processes for preparing gaseous products, and in particular methane, via the catalytic hydromethanation of a carbonaceous feedstock in the presence of steam, syngas and an oxygen-rich gas stream.

Abstract: The present invention relates to processes and continuous processes for preparing gaseous products, and in particular, methane via the catalytic gasification of carbonaceous feedstocks in the presence of steam. In one aspect of the invention, the processes comprise at least partially combusting a first carbonaceous feedstock with an oxygen-rich gas stream, a recycle steam stream, and an aqueous make-up stream in an oxygen-blown gasifier, under suitable temperature and pressure, to generate a first gas stream comprising hydrogen, carbon monoxide and superheated steam; and reacting a second carbonaceous feedstock and the first gas stream in a catalytic gasifier in the presence of a gasification catalyst under suitable temperature and pressure to form a second gas stream comprising a plurality of gaseous products comprising methane, carbon dioxide, hydrogen, carbon monoxide and hydrogen sulfide.

Abstract: Processes for the catalytic conversion of a carbonaceous composition into a gas stream comprising methane are provided, where a sour shift reaction is used to remove carbon monoxide gas stream produced by the gasification process. The incorporation of the sour shift reaction provides an efficient and cost-effective means of eliminating carbon monoxide from the gas stream. In addition, the sour shift reaction also generates additional hydrogen, thus increasing the amount of hydrogen produced from the gasification process.

Abstract: The present invention relates to processes for hydromethanating a carbonaceous feedstock to a methane-enriched synthesis gas, where an oxygen-rich gas stream and the carbonaceous feedstock are fed into a fluidized-bed hydromethanation reactor at a specified zone in order to assist in heat management within the hydromethanation reactor.

Abstract: The present invention relates to processes for hydromethanating a carbonaceous feedstock to a methane-enriched synthesis gas, where an oxygen-rich gas stream and the carbonaceous feedstock are fed into a fluidized-bed hydromethanation reactor, and where the carbonaceous feedstock as fed into the hydromethanation reactor has an elevated moisture content in order, for example, to assist in heat management within the hydromethanation reactor.

Abstract: The present invention relates to processes for hydromethanating a carbonaceous feedstock to a fines-depleted methane-enriched synthesis gas, with recycle of recovered particulate fines back into a specified portion of a hydromethanation reactor.

Abstract: The present invention provides processes for making syngas-derived products. For example, one aspect of the present invention provides a process for making a syngas-derived product, the process comprising (a) providing a carbonaceous feedstock; (b) converting the carbonaceous feedstock in a syngas formation zone at least in part to a synthesis gas stream comprising hydrogen and carbon monoxide; (c) conveying the synthesis gas stream to a syngas reaction zone; (d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and heat energy, a combustible tail gas mixture, or both; (e) recovering the syngas-derived product; and (f) recovering the heat energy formed from the reaction of the synthesis gas stream, burning the combustible tail gas mixture to form heat energy, or both.

Abstract: The present invention relates to processes and apparatuses for generating light olefins, methane and other higher-value gaseous hydrocarbons from “liquid” heavy hydrocarbon feedstocks.

Abstract: The present invention relates to processes and apparatuses for generating electrical power from certain non-gaseous carbonaceous feedstocks through the integration of catalytic hydromethanation technology with fuel cell technology.

Abstract: A method and apparatus for reacting a hydrocarbon containing feed stream by steam methane reforming reactions to form a synthesis gas. The hydrocarbon containing feed is reacted within a reactor having stages in which the final stage from which a synthesis gas is discharged incorporates expensive high temperature materials such as oxide dispersed strengthened metals while upstream stages operate at a lower temperature allowing the use of more conventional high temperature alloys. Each of the reactor stages incorporate reactor elements having one or more separation zones to separate oxygen from an oxygen containing feed to support combustion of a fuel within adjacent combustion zones, thereby to generate heat to support the endothermic steam methane reforming reactions.

Abstract: The present invention relates to processes for preparing gaseous products, and in particular methane and/other value added gases such as hydrogen, via the catalytic hydromethanation of a carbonaceous feedstock in the presence of steam and syngas, wherein a hydromethanation reactor is combined with a syngas generator in a particular combination.

Abstract: The present invention relates to processes for preparing gaseous products, and in particular methane, via the hydromethanation of a carbonaceous feedstock in the presence of steam, syngas, a hydromethanation catalyst and an oxygen-rich gas stream.

Abstract: The present invention relates to processes for preparing gaseous products, and in particular methane, via the catalytic hydromethanation of a carbonaceous feedstock in the presence of steam, syngas and an oxygen-rich gas stream.

Abstract: The present invention relates to processes for preparing gaseous products, and in particular methane, via the hydromethanation of carbonaceous feedstocks in the presence of steam, carbon monoxide, hydrogen and a hydromethanation catalyst.