Patents by Inventor Kevin L. Coy
Kevin L. Coy has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7541310Abstract: This invention relates to catalysts comprising a catalytic metal deposited on a composite support with well-dispersed chemical “anchor” species acting as nucleation centers for catalytic metal crystallites growth. The catalysts have the advantage that the average catalytic metal crystallite size can be controlled by the molar ratio of catalytic metal to chemical “anchor,” and is not limited by the porous structure of the support. A preferred embodiment comprises a cobalt-based catalyst on a silica-alumina support made by a co-gel method, wherein its average pore size can be controlled by the pH. The alumina species in the support most likely serve as chemical “anchors” to control the dispersion of cobalt species, such that the average cobalt crystallite size can be greater than the average pore size.Type: GrantFiled: October 12, 2004Date of Patent: June 2, 2009Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Kandaswamy Jothimurugesan, Kevin L. Coy, James Dale Ortego, Jr., Nithya Srinivasan, Olga P. Ionkina
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Patent number: 7276540Abstract: The present invention relates to thermally stable, high surface area alumina supports and a method of preparing such supports with at least one modifying agent. The method includes adding an aluminum modifying agent to the alumina prior to calcining. The inventive support has thermal stability at temperatures above 800° C. A more specific embodiment of the invention is a catalyst having a high surface area, thermally stable alumina support with at least one group VIII metal or rhenium and an optional promoter loaded onto the support. The present invention further relates to gas-to-liquids conversion processes, more specifically for producing C5+ hydrocarbons.Type: GrantFiled: November 12, 2003Date of Patent: October 2, 2007Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Dan Fraenkel, Kevin L. Coy
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Patent number: 7186757Abstract: An effective catalyst includes an amorphous silica-alumina support having a bimodal pore size-distribution. The support may be prepared by a method that includes the physical mixing of two silica-alumina gels prepared so as to have two different average pore sizes. The catalyst has the advantage that both metal dispersion on the support and product diffusion in the pores are optimized. Further, the catalyst has improved performance in the production of hydrocarbons from synthesis gas.Type: GrantFiled: October 14, 2004Date of Patent: March 6, 2007Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Kandaswamy Jothimurugesan, Kevin L. Coy
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Patent number: 7071239Abstract: A catalyst and method for producing hydrocarbons using a catalyst support having an improved hydrothermal stability, such as under Fischer-Tropsch synthesis conditions. The stabilized support is made by a method comprising treating a boehmite material in contact with at least one structural stabilizer. Contacting the boehmite with at least one structural stabilizer can include forming a mixture comprising the boehmite material and at the least one structural stabilizer. The mixture can be a sol or a slurry. The treating preferably includes drying or spray drying the mixture, and calcining in an oxidizing atmosphere to obtain the stabilized support. Preferred structural stabilizers can include an element, such as cobalt, magnesium, zirconium, boron, aluminum, barium, silicon, lanthanum, oxides thereof, or combinations thereof; or can include precipitated oxides, such as a co-precipitated silica-alumina.Type: GrantFiled: October 16, 2003Date of Patent: July 4, 2006Assignee: ConocoPhillips CompanyInventors: J. Dale Ortego, Jr., Kandaswamy Jothimurugesan, Rafael L. Espinoza, Kevin L. Coy, Beatrice C. Ortego
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Patent number: 7056857Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.Type: GrantFiled: October 14, 2004Date of Patent: June 6, 2006Assignee: ConocoPhillips CompanyInventors: Nithya Srinivasan, Rafael L. Espinoza, Kevin L. Coy, Kandaswamy Jothimurugesan
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Patent number: 7056955Abstract: According to a preferred embodiment, the present invention features a bulk catalyst that includes precipitated cobalt metal. The precipitated cobalt catalyst further includes a textural promoter, a binder and optionally a Group I metal. The method of making the catalyst is optimized so as to enhance attrition resistance and improve activity. According to some embodiments, the present catalyst is made by a method that includes one or a combination of: calcination under optimized temperature conditions; exposure to an acidic solution; and addition of a binder to a suspension of a precipitate. According to some embodiments, a Fischer-Tropsch process includes contacting the present catalyst with a feed stream containing carbon monoxide and hydrogen so as to produce hydrocarbons.Type: GrantFiled: December 22, 2003Date of Patent: June 6, 2006Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Kandaswamy Jothimurugesan, Ajoy P. Raje, Kevin L. Coy, Nithya Srinivasan
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Publication number: 20040259960Abstract: According to a preferred embodiment, the present invention features a bulk catalyst that includes precipitated cobalt metal. The precipitated cobalt catalyst further includes a textural promoter, a binder and optionally a Group I metal. The method of making the catalyst is optimized so as to enhance attrition resistance and improve activity. According to some embodiments, the present catalyst is made by a method that includes one or a combination of: calcination under optimized temperature conditions; exposure to an acidic solution; and addition of a binder to a suspension of a precipitate. According to some embodiments, a Fischer-Tropsch process includes contacting the present catalyst with a feed stream containing carbon monoxide and hydrogen so as to produce hydrocarbons.Type: ApplicationFiled: December 22, 2003Publication date: December 23, 2004Applicant: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Kandaswamy Jothimurugesan, Ajoy P. Raje, Kevin L. Coy, Nithya Srinivasan
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Patent number: 6822008Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.Type: GrantFiled: September 6, 2002Date of Patent: November 23, 2004Assignee: ConocoPhillips CompanyInventors: Nithya Srinivasan, Rafael L. Espinoza, Kevin L. Coy, Kandaswamy Jothimurugesan
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Publication number: 20040147619Abstract: The present invention discloses synthesis gas catalysts, and methods for making such catalysts, that are active for promoting partial oxidation of light hydrocarbons to CO and H2. The catalysts comprise a support and an active metal. The catalysts may further comprise a promoter and halide or a rare earth oxyhalide. The present invention further discloses a method for producing synthesis gas by net partial oxidation of light hydrocarbons by contacting O2 and light hydrocarbons in the presence of a synthesis gas catalyst as previously described. The present invention also describes a method for extending the life of a synthesis gas catalyst by contacting the catalyst with a halide. A method for making middle distillates from light hydrocarbons by partial oxidation of light hydrocarbons over a synthesis gas catalyst as previously described and Fischer-Tropsch reaction is also disclosed.Type: ApplicationFiled: January 23, 2003Publication date: July 29, 2004Applicant: ConocoPhillips CompanyInventors: Tianyan Niu, Kevin L. Coy, David M. Minahan, Harold A. Wright
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Publication number: 20040138317Abstract: The present invention relates to thermally stable, high surface area alumina supports and method of preparing such supports with at least one modifying agent. The method includes adding the modifying agent to the alumina prior to calcining. More particularly, the invention relates to the use of such catalysts for the catalytic partial oxidation of light hydrocarbons (e.g., methane or natural gas) to produce primarily synthesis gas. The present invention further relates to gas-to-liquids conversion processes, more specifically for producing C5+ hydrocarbons.Type: ApplicationFiled: November 12, 2003Publication date: July 15, 2004Applicant: ConocoPhillips CompanyInventors: Shuibo Xie, Mary E. Wolf, Harold A. Wright, Rafael L. Espinoza, Tianyan Niu, David M. Minahan, Kevin L. Coy
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Publication number: 20040132832Abstract: The present invention relates to thermally stable, high surface area alumina supports and a method of preparing such supports with at least one modifying agent. The method includes adding an aluminum modifying agent to the alumina prior to calcining. The inventive support has thermal stability at temperatures above 800° C. A more specific embodiment of the invention is a catalyst having a high surface area, thermally stable alumina support with at least one group VIII metal or rhenium and an optional promoter loaded onto the support. The present invention further relates to gas-to-liquids conversion processes, more specifically for producing C5+ hydrocarbons.Type: ApplicationFiled: November 12, 2003Publication date: July 8, 2004Applicant: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Dan Fraenkel, Kevin L. Coy
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Publication number: 20040132834Abstract: A catalyst and method for producing hydrocarbons using a catalyst support having an improved hydrothermal stability, such as under Fischer-Tropsch synthesis conditions. The stabilized support is made by a method comprising treating a boehmite material in contact with at least one structural stabilizer. Contacting the boehmite with at least one structural stabilizer can include forming a mixture comprising the boehmite material and at the least one structural stabilizer. The mixture can be a sol or a slurry. The treating preferably includes drying or spray drying the mixture, and calcining in an oxidizing atmosphere to obtain the stabilized support. Preferred structural stabilizers can include an element, such as cobalt, magnesium, zirconium, boron, aluminum, barium, silicon, lanthanum, oxides thereof, or combinations thereof; or can include precipitated oxides, such as a co-precipitated silica-alumina.Type: ApplicationFiled: October 16, 2003Publication date: July 8, 2004Applicant: ConocoPhillips CompanyInventors: J. Dale Ortego, Kandaswamy Jothimurugesan, Rafael L. Espinoza, Kevin L. Coy, Beatrice C. Ortego
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Patent number: 6730708Abstract: A process is disclosed for the hydrogenation of carbon monoxide. The process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst system in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream, preferably comprising hydrocarbons. In accordance with this invention the catalyst system used in the process includes at least one catalytic material for Fischer-Tropsch reactions (e.g., iron, cobalt, nickel and/or ruthenium), preferably comprising cobalt, and a support comprising aluminum borate. The catalyst system can be prepared by impregnating alumina with a boron-containing composition to form an aluminum borate support and applying a Fischer-Tropsch catalytically active material to the aluminum borate to form a supported catalyst system.Type: GrantFiled: July 3, 2001Date of Patent: May 4, 2004Assignee: ConocoPhillips CompanyInventors: Ajoy P. Raje, Joe D. Allison, Kevin L. Coy
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Publication number: 20040048937Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.Type: ApplicationFiled: September 6, 2002Publication date: March 11, 2004Applicant: Conoco Inc.Inventors: Nithya Srinivasan, Rafael L. Espinoza, Kevin L. Coy, Kandaswamy Jothimurugesan
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Publication number: 20020037937Abstract: A process is disclosed for the hydrogenation of carbon monoxide. The process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst system in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream, preferably comprising hydrocarbons. In accordance with this invention the catalyst system used in the process includes at least one catalytic material for Fischer-Tropsch reactions (e.g., iron, cobalt, nickel and/or ruthenium), preferably comprising cobalt, and a support comprising aluminum borate. The catalyst system can be prepared by impregnating alumina with a boron-containing composition to form an aluminum borate support and applying a Fischer-Tropsch catalytically active material to the aluminum borate to form a supported catalyst system.Type: ApplicationFiled: July 3, 2001Publication date: March 28, 2002Inventors: Ajoy P. Raje, Joe D. Allison, Kevin L. Coy