Catalytic Processes Patents (Class 48/214A)
  • Patent number: 5653774
    Abstract: A method and nickel-containing catalyst are disclosed for preparing synthesis gas by the reforming of a hydrocarbyl compound using an oxygen-containing compound.
    Type: Grant
    Filed: May 22, 1995
    Date of Patent: August 5, 1997
    Assignee: Amoco Corporation
    Inventors: Alakananda Bhattacharyya, Wen-Dong Chang, Mark S. Kleefisch, Carl A. Udovich
  • Patent number: 5591238
    Abstract: A method and nickel-containing catalyst are disclosed for preparing synthesis gas by the reforming of a hydrocarbyl compound using an oxygen-containing compound.
    Type: Grant
    Filed: December 9, 1994
    Date of Patent: January 7, 1997
    Assignee: Amoco Corporation
    Inventors: Alakananda Bhattacharyya, Wen-Dong Chang, Mark S. Kleefisch, Carl A. Udovich
  • Patent number: 5356845
    Abstract: A process for the reactivation, or rejuvenation of a nickel-alumina catalyst employed in the production of a gas comprised of an admixture of hydrogen and carbon monoxide, or synthesis gas, by the conversion, in a reactor, or reaction zone, of light hydrocarbons in a fluidized bed of the catalyst at elevated temperature, in the presence of steam and oxygen. Catalyst reactivation is accomplished by withdrawing a portion of the catalyst from the fluidized bed of the reactor and treating the catalyst in an oxidation zone at temperature sufficient to oxidize and convert the nickel component of the catalyst to nickel aluminate and disperse said nickel aluminate within the alumina support, and then recycling the treated catalyst to the reactor, or reaction zone, to reactivate and increase the activity of the catalyst.
    Type: Grant
    Filed: May 11, 1993
    Date of Patent: October 18, 1994
    Assignee: Exxon Research and Engineering Company
    Inventors: LeRoy R. Clavenna, Stephen M. Davis, Brent E. Beasley
  • Patent number: 5306481
    Abstract: Resonant tubes of a pulse combustor are immersed in a bed of solid particles in a reaction zone to provide indirect heat from the pulsating combustion gases to the solid particles of the bed. The bed is maintained in an agitated state by a gas or vapor flowing through the bed. Reactant materials are introduced into the agitated bed and undergo reaction at enhanced rates resulting from heat transfer coefficients at least about twice as high as those of steady flow combustors and an intense acoustic pressure level propagated from the pulsating combustor into the reaction zone. The apparatus is useful, for example, to steam reform heavy hydrocarbons and to gasify carbonaceous material, including biomass and black liquor to produce combustible gas at relatively low temperatures, with steam being utilized as the bed fluidizing medium. Black liquor gasification, utilizing sodium carbonate as bed solids, results in liquor energy and chemical content recovery without smelt production.
    Type: Grant
    Filed: July 1, 1991
    Date of Patent: April 26, 1994
    Assignee: Manufacturing and Technology Conversion International, Inc.
    Inventors: Momtaz N. Mansour, Kanda-Swamy Durai-Swamy, David W. Warren
  • Patent number: 5164163
    Abstract: A hydrocarbon reforming apparatus having a furnace casing, a combustion gas passage formed in the furnace casing, a cylindrical reactor which is made up of multi-layered passages arranged concentrically around the combustion gas passage, with the multilayered passages being filled with catalysts, a combustion gas discharge passage communicating with the combustion gas passage, and a feedstock gas intake passage communicating with any one of the multilayered passages, characterized in that the combustion gas discharge passage is arranged on the inside of either of the outer passage of the multilayered passages or the feedstock gas intake passage, so that the combustion gas discharge passage is separated from the furnace casing.
    Type: Grant
    Filed: September 12, 1989
    Date of Patent: November 17, 1992
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Mamoru Aoki, Yohiaki Imoto, Hideki Sugimura, Keiichi Otani
  • Patent number: 5002481
    Abstract: Production of oxides of nitrogen during combustion of liquid fuel can be reduced by burning at relatively low temperatures of about 1400.degree. C., by first producing a special combustible gaseous mixture of superheated steam, fuel vapor, and combustion air. Water is fed (9) to the apparatus in quantities of about 2 to 4 parts for each part of fuel (10). Then the fuel is vaporized (8) in a stream of the superheated steam. This avoids fuel cracking and formation of long-chain hydrocarbons. Preheated air (13,14,15) is added (17) in slightly over stoichiometric proportions. The resulting mixture is burned (2) and the hot effluent is used to heat the evaporator (6,7,8) and the air preheating chamber (15), with a bypass (20) equipped with a throttle (22) being used for regulation of evaporator temperature. For start-up, an external hot air source (23) or electric heat (24) can be used. The remaining heat in the effluent can be captured in a conventional heat exchanger.
    Type: Grant
    Filed: February 16, 1989
    Date of Patent: March 26, 1991
    Assignee: Forschungszentrum Julich GmbH
    Inventor: Siegfried Forster
  • Patent number: 4999133
    Abstract: A process starting from a hydrocarbon feedstock, and aiming to produce a synthesis gas suitable either for methanol synthesis or for other applications requiring a low H.sub.2 /CO ratio.In this process, the feedstock, supposed to be desulfurized, is divided into two fractions; a first fraction undergoes a primary steam reforming at high pressure and moderate temperature; the gas effluent from said primary steam reforming, as well as the second fraction of the feedstock, are combined and subsequently undergo a secondary reforming by reaction with a free-oxygen rich gas in a reactor operating under essentially adiabatic conditions.The synthesis gas, obtained as effluent from said secondary reforming, has a composition adjustable at will in a wide range, and therefore can be made as close as necessary to the stoichiometric composition required for methanol synthesis, or it can be made with a low H.sub.2 /CO ratio for other applications.
    Type: Grant
    Filed: December 7, 1989
    Date of Patent: March 12, 1991
    Assignee: Foster Wheeler USA Corporation
    Inventor: David L. Banquy
  • Patent number: 4888130
    Abstract: A process starting from a hydrocarbon feedstock, and aiming to produce a synthesis gas suitable either for methanol synthesis or for other applications requiring a low H.sub.2 /CO ratio.In this process, the feedstock, supposed to be desulfurized, is divided into two fractions; a first fraction undergoes a primary steam reforming at high pressure and moderate temperature; the gas effluent from said primary steam reforming, as well as the second fraction of the feedstock, are combined and subsequently undergo a secondary reforming by reaction with an oxygen-containing gas in a reactor operating under essentially adiabatic conditions.The synthesis gas, obtained as effluent from said secondary reforming, has a composition adjustable at will in a wide range, and therefore can be made as close as necessary to the stoichiometric composition required for methanol synthesis, or it can be made with a low H.sub.2 /CO ratio for other applications.
    Type: Grant
    Filed: February 24, 1988
    Date of Patent: December 19, 1989
    Assignee: Foster Wheeler USA Corporation
    Inventor: David L. Banquy
  • Patent number: 4830091
    Abstract: Heat is removed from, or supplied to, a vertical pipe of any cross-section, whose internal temperature is above or below the ambient temperature and whose wall temperature must neither exceed nor fall below a predetermined temperature range, by a method in which, in order to maintain the predetermined temperature range, the pipe is provided with a coaxial sheath and gas is passed through the gap between the pipe and the sheath. The invention is particularly directed to maintaining a predetermined temperature range at the outer pipe wall of the vertically oriented, double walled pipes which connect the reaction sections with the collectors in a steam reformer.
    Type: Grant
    Filed: May 19, 1988
    Date of Patent: May 16, 1989
    Assignee: BASF Aktiengesellschaft
    Inventors: Ruediger Dierke, Gottfried Schlichthaerle, Peter Schuchart, Armin Schweitzer
  • Patent number: 4824440
    Abstract: Heterocyclic and O-substituted aromatic species, for example those obtained as a by product of coal gasification, may be gasified by reaction with steam in the presence of a nickel-alumina containing catalyst to produce methane-containing gases. The reforming reaction is carried out at temperatures of not greater than 500.degree. C.
    Type: Grant
    Filed: March 2, 1987
    Date of Patent: April 25, 1989
    Assignee: British Gas plc
    Inventor: Reginald G. S. Banks
  • Patent number: 4690690
    Abstract: A process for producing a product gas stream containing hydrogen and carbon oxides by incomplete catalytic reaction of a hydrocarbon feedstock with steam and/or carbon dioxide. The process involves passing a reactants stream containing the feedstock and steam and/or carbon dioxide over a catalyst disposed in an elongated, externally heated, zone and withdrawing the product gas stream through a tube within that zone and countercurrently to the flow of the reactants stream over the catalyst. Heat exchange between the product gas stream and the reactants stream across the wall of the tube is limited so that the temperature of the product gas stream leaving the tube is less than that of the stream leaving the elongated zone by at most 100.degree. C. Apparatus for carrying out the process is also disclosed.
    Type: Grant
    Filed: February 24, 1986
    Date of Patent: September 1, 1987
    Assignee: Imperial Chemical Industries plc
    Inventors: Sydney P. Andrew, Ralph J. Doy, Antony P. J. Limbach
  • Patent number: 4681701
    Abstract: A process for producing synthesis gas by catalytic reforming of hydrocarbons with steam in a reaction zone which is subjected to heat exchange with a combustion gas and recycling heat exchanged combustion gas to a combustion zone. The invention further relates to an apparatus suitable for said process.
    Type: Grant
    Filed: July 14, 1986
    Date of Patent: July 21, 1987
    Assignee: Shell Oil Company
    Inventor: Swan T. Sie
  • Patent number: 4568583
    Abstract: A shaped solid material to be contacted with a flowing fluid, in the form of tubular units each having a perforated wall and having means to distance that wall from the wall of a container in which they are to be stacked in axial relationship with one another and with the container. The shaped solid material is especially useful as a hydrocarbon steam reforming catalyst, in which event it is made of metal or highly calcined ceramic and carries a coating of for example nickel and alumina.
    Type: Grant
    Filed: May 30, 1984
    Date of Patent: February 4, 1986
    Assignee: Imperial Chemical Industries PLC
    Inventor: Martyn V. Twigg
  • Patent number: 4553981
    Abstract: Effluent gas streams for steam reforming, partial oxidation or coal gasification operations are advantageously treated in shift conversion, scrubbing and pressure swing adsorption units for recovery of a purified, hydrogen-containing product gas stream. By recycling a portion of the waste gas removed from the pressure swing adsorption system to the shift conversion unit and/or to the effluent gas generation operation, enhanced product recovery is achieved without the necessity for employing low temperature shift or for achieving essentially complete removal of the carbon dioxide content of the gas being treated prior to its passage to said pressure swing adsorption system.
    Type: Grant
    Filed: February 7, 1984
    Date of Patent: November 19, 1985
    Assignee: Union Carbide Corporation
    Inventor: Andrija Fuderer
  • Patent number: 4541841
    Abstract: Converting carbon-containing raw material, particularly coal, wood or crude oil, into a combustible product gas by a gasification reaction in the presence of a catalyst which is dissolved in the steam intended for the gasification reaction, forming a homogeneous gaseous solution. The ash-containing gasification residue is separated and the catalyst is extracted from the separated gasification residue by the steam intended for the gasification reaction at a temperature and a pressure, at which a homogeneous gaseous solution of the catalyst in steam is formed.
    Type: Grant
    Filed: June 15, 1983
    Date of Patent: September 17, 1985
    Assignee: Kraftwerk Union Aktiengesellschaft
    Inventor: Dieter Reinhardt
  • Patent number: 4500323
    Abstract: An increased reaction velocity is achieved when gasifying a raw carboniferous material with H.sub.2 O. The raw material is suspended or emulsified in a liquid aqueous solution of a catalytically active salt, and the amount of the catalytically active salt and the pressure are such that the aqueous solution is maintained in the liquid phase.
    Type: Grant
    Filed: July 29, 1982
    Date of Patent: February 19, 1985
    Assignee: Kraftwerk Union Aktiengesellschaft
    Inventors: Peter Siegfried, Martin Wenger
  • Patent number: 4483693
    Abstract: Hydrogen sulfide replaces a portion of the water required to suppress the formation of carbon in gas phase catalytic reforming and hydrocracking of hydrocarbons, particularly aromatics. Hydrogen is present to prevent carbon formation from the aromatic hydrocarbons. The support used for the catalyst is a gamma alumina, delta alumina, theta alumina or mixtures thereof.
    Type: Grant
    Filed: May 20, 1982
    Date of Patent: November 20, 1984
    Assignee: The Ralph M. Parsons Co.
    Inventors: Gerald A. White, Theodore R. Roszkowski, Harold W. Fleming
  • Patent number: 4483691
    Abstract: In coal gasification processes for the production of synthetic natural gas by the reaction of coal with steam and oxygen under pressure to form a gasifier synthesis gas and a liquid hydrocarbon by-product, the liquid hydrocarbon by-product is treated for solids and metal removal and is then passed to a catalytic partial oxidation zone containing a monolithic platinum-palladium catalyst. The hydrocarbon by-product liquids are converted to secondary synthesis gas by being reacted with steam and oxygen. Optionally, the effluent from the catalytic partial oxidation zone may be passed through a second, steam reforming catalyst to react residual hydrocarbons with water to produce hydrogen and carbon oxides. The gasifier and secondary synthesis gases may be treated to remove acid gases therefrom and then methanated to provide a product synthetic natural gas.
    Type: Grant
    Filed: February 13, 1984
    Date of Patent: November 20, 1984
    Assignee: Engelhard Corporation
    Inventors: William T. McShea, III, Robert M. Yarrington
  • Patent number: 4436532
    Abstract: A process for converting solid wastes to gases suitable for use as a town gas comprising the steps of (1) pyrolyzing solid wastes at 550.degree. C. or higher in a pyrolyzing furnace to produce pyrolysis gases containing hydrogen, carbon monoxide and dioxide, methane and other hydrocarbons as well as chlorine-containing compounds, sulphur-containing compounds and other impurities, (2) washing the pyrolysis gases with an aqueous alkaline solution or the like, (3) refining the washed pyrolysis gases with the hydrogen contained in the pyrolysis gases, (4) reforming the refined pyrolysis gases by steam reforming, CO conversion and/or methanation and (5) separating the excess steam and carbonic acid gas from the reformed gases. In one embodiment, the washing (2) and refining (3) may be substituted by the high-temperature steam reforming of the pyrolysis gases in hot state supplied directly from the pyrolyzing furnace.
    Type: Grant
    Filed: March 9, 1982
    Date of Patent: March 13, 1984
    Assignees: JGC Corporation, Tsukishima Kikai Co., Ltd.
    Inventors: Katsunobu Yamaguchi, Seiichi Matsuoka, Takayuki Hayashida, Tomio Hayase
  • Patent number: 4417905
    Abstract: Methane-containing gases are produced by passing a hydrocarbon feedstock having a boiling point of not greater than 350.degree. C. and steam over a catalyst at an elevated pressure and at a temperature of from 350.degree. C. to 550.degree. C. at the inlet of the catalyst and an exit of temperature of at least 450.degree. C., the catalyst comprising a reduced catalyst precursor which is resistant to deactivation by polymer formation or by sintering, the catalyst precursor containing (1) from 0 to not more than 0.43% K and from 0 to not more than 0.1% Na, (2) the combined weights of Na+ K does not exceed 0.011 gm atoms/100 gm of catalyst precursor, (3) the ratio of Na:K falls within the area defined by ABCDEO in FIG. 1 of the drawings, and (3) at combined Na+ K weights of from 0 to 0.05% the water loss is not more than 11.2%.
    Type: Grant
    Filed: July 30, 1980
    Date of Patent: November 29, 1983
    Assignee: British Gas Corporation
    Inventors: Reginald G. S. Banks, Alan Williams
  • Patent number: 4414001
    Abstract: A method for thermally decomposing and gasifying either liquid or solid combustible material in a single reactor filled with working medium in a high active fluidization, said reactor being provided with two partitions, one of which is extended downwards upto the lower portion of the reactor, while the other is vertically extended at the lower and middle portions thereof substantially at a right angle to the first partition, whereby the reactor is divided into two sections, that is, thermal decomposition and gasification section and combustion and heating section, so that thermal decomposing and gasifying are performed by way of supplying the combustible raw material into the downwardly travelling working medium and at the same time supplying steam thereinto for generating and maintaining the high active fluidization of the working medium in the thermal decomposition and gasification section, while burning and heating are performed by way of supplying air or steam mixture gas of oxygen and steam into the upwa
    Type: Grant
    Filed: January 21, 1982
    Date of Patent: November 8, 1983
    Inventor: Daizo Kunii
  • Patent number: 4400182
    Abstract: Heavy hydrocarbon feedstocks, e.g. gas oils, are vaporized and subsequently gasified at high temperatures without pyrolytic degradation by first admixing the hydrocarbon with a hot gaseous reactant, e.g. product gas or steam, to bring the temperature of the mixture above that of the dew point of the hydrocarbon and thereafter raising the temperature of the mixture to above that at which pyrolysis of the hydrocarbon begins to be significant by admixture with further quantities of the reactant which are superheated thereby to bring the temperature of the resultant mixture to that required for effecting a catalytic gasification reaction.
    Type: Grant
    Filed: July 19, 1982
    Date of Patent: August 23, 1983
    Assignee: British Gas Corporation
    Inventors: Haydn S. Davies, James H. Garstang, Cyril Timmins
  • Patent number: 4371452
    Abstract: Disclosed is a process for reforming hydrocarbon which comprises heating up to 800.degree. C. or higher a gaseous mixture of sulfur containing hydrocarbon with an oxidizing agent for reforming such as steam or a mixture of steam and carbon dioxide, while passing the gaseous mixture through an alkaline solid packing bed containing alkali metal and/or alkaline earth metal followed by bringing into contact thereof with a nickel containing catalyst at a temperature of 800.degree. C. or higher to produce a mixed gas containing hydrogen and carbon monoxide. An apparatus for the practice of the process is also disclosed.
    Type: Grant
    Filed: December 9, 1981
    Date of Patent: February 1, 1983
    Assignee: Toyo Engineering Corporation
    Inventors: Kozo Ohsaki, Kazuo Hirokawa, Goro Fukuda, Kozi Otsuka, Tadayoshi Tomita
  • Patent number: 4367077
    Abstract: Process for converting a relatively high boiling point crude oil fraction, such as a 500.degree.+F. initial boiling point topped crude to synthetic natural gas. In the process, a lower boiling point fraction of the feedstock is hydrogasified while a residual oil fraction of the feedstock is partially oxidized to produce hydrogen for use in the process. A mid-cut fraction between the gasification fraction and the partial oxidation fraction is converted in a combined steam reforming-methanation stage, along with some by-product aromatics, to produce additional synthetic natural gas products.
    Type: Grant
    Filed: April 20, 1981
    Date of Patent: January 4, 1983
    Assignee: Air Products and Chemicals, Inc.
    Inventor: John C. Tao
  • Patent number: 4340501
    Abstract: A process and apparatus for contacting a fluid with the walls of a vessel are characterized by flow of the fluid alternatingly (a) through a structure within the vessel and having passages angled to the general direction of flow in the vessel and (b) through a space between the structure and the vessel walls. The structure can be for example a cross flow ceramic or metal honeycomb or a stack of profiled plates or of apertured plates such as expanded metal. The structure can carry a catalytic coating and then affords high activity and low pressure drop. The process and apparatus are especially suitable for endothermic tubular steam hydrocarbon reforming.
    Type: Grant
    Filed: September 2, 1980
    Date of Patent: July 20, 1982
    Assignee: Imperial Chemical Industries Limited
    Inventor: Peter J. Davidson
  • Patent number: 4337170
    Abstract: The hot effluent from the catalytic steam reforming of a major portion of a fluid hydrocarbon feed stream in the reformer tubes of a primary reformer, or said effluent after secondary reforming thereof, is mixed with the hot effluent from the catalytic steam reforming of the remaining portion of the feed discharged from the reformer tubes of a primary reformer-exchanger. The combined gas steam is passed on the shell side of the reformer-exchanger countercurrently to the passage of feed in the reformer tubes thereof, thus supplying the heat for the reforming of the portion of the feed passed through the reformer tubes of the reformer-exchanger. At least about 2/3 of the hydrocarbon feed stream is passed to the reformer tubes of said primary reformer, heated by radiant heat transfer and/or by contact with combustion gases, at a steam/hydrocarbon mole ratio of about 2-4/1.
    Type: Grant
    Filed: January 23, 1980
    Date of Patent: June 29, 1982
    Assignee: Union Carbide Corporation
    Inventor: Andrija Fuderer
  • Patent number: 4331449
    Abstract: A process of producing a town-gas-grade fuel gas having a calorific value below 18,000 kJ/standard m.sup.3 (4,300 kcal/standard m.sup.3) by a catalytic reaction of methanol and water vapor under a pressure of 10 to 50 bars is disclosed wherein 80 to 95 percent of the mixed feedstock (methanol and water vapor) is fed in a water vapor to methanol weight ratio of 0.5 to 1.5 to a first reaction zone where it is maintained at a temperature of 300.degree. to 700.degree. C. in contact with a nickel catalyst containing 25 to 50 weight percent nickel, the remainder of the mixed feedstock being mixed with the effluent gas from the first reaction zone and together passed to a second reaction zone at a temperature of 200.degree. to 400.degree. C. and therein contacted with a copper catalyst containing 40 to 70 percent by weight copper.
    Type: Grant
    Filed: September 12, 1980
    Date of Patent: May 25, 1982
    Assignee: Metallgesellschaft Aktiengesellschaft
    Inventors: Heinz Jockel, Friedrich W. Moller, Hans J. Renner, Gerd Siebert
  • Patent number: 4331451
    Abstract: A process for catalytic gasification of heavy oil of a specific gravity of higher than 0.7 with steam or steam/oxygen-containing gas characterized in that the heavy oil is contacted with chromium oxide catalyst or a catalyst comprising a mixture of chromium oxide and one or more of alkaline earth metal oxides, aluminum oxide, zirconium oxide, nickel oxide and cobalt oxide.More particularly, the present invention relates to a process for catalytic gasification of heavy oil of a specific gravity of higher than 0.7 characterized in that the heavy oil is contacted with a gasification catalyst comprising calcium aluminate, an alkali aluminate or tungsten-containing nickel and then the heavy oil is further contacted with said chromium oxide catalyst or chromium oxide-containing catalyst.
    Type: Grant
    Filed: February 4, 1980
    Date of Patent: May 25, 1982
    Assignees: Mitsui Toatsu Chemicals, Inc., Toyo Engineering Corporation
    Inventors: Kazuyoshi Isogaya, Eiiti Sugiyama, Kenji Yoshida, Katsutoshi Kikuchi
  • Patent number: 4309359
    Abstract: In a process in which, after product recovery, an off-gas containing hydrogen and/or carbon monoxide is produced, energy economy is improved by reacting the off-gas in a fuel cell. The resulting electricity is preferably used for driving small machines in the process. The process is especially useful for producing methanol from natural gas feedstock and then includes the steps of methanating the off-gas and letting it down in an engine before passing it to a fuel cell.
    Type: Grant
    Filed: December 12, 1977
    Date of Patent: January 5, 1982
    Assignee: Imperial Chemical Industries Limited
    Inventor: Alwyn Pinto
  • Patent number: 4308167
    Abstract: A process for gasifying liquid and solid hydrocarbons by contact at elevated temperature with a novel hydrocarbon gasifying catalyst comprising K.sub.2 O--CaO--Al.sub.2 O.sub.3 containing from about 5 to 15% by weight K.sub.2 O, from about 0.1 to 7% CaO, and from about 78 to 94.9% Al.sub.2 O.sub.3.
    Type: Grant
    Filed: July 14, 1980
    Date of Patent: December 29, 1981
    Assignees: Idemitsu Kosan Co., Ltd., Kyusyu Refractories Co., Ltd.
    Inventors: Hiroshi Sugiyama, Tsuyoshi Mitani
  • Patent number: 4300999
    Abstract: Hydrocarbon oils, particularly oils which have a high boiling temperature, are treated to remove organic sulphur compounds by subjecting a mixture of a hydrogenating gas, e.g. a gas containing at least 90% v/v hydrogen and is substantially free from carbon oxides, and partially vaporized oil to a hydrogenation reaction over a known hydrogenation catalyst and thereafter passing the resulting liquid/vapor mixture which also contains hydrogen sulphide over zinc oxide, thereby to remove the hydrogen sulphide.
    Type: Grant
    Filed: January 28, 1980
    Date of Patent: November 17, 1981
    Assignee: British Gas Corporation
    Inventors: Haydn S. Davies, James H. Garstang, Cyril Timmins
  • Patent number: 4280820
    Abstract: Methane-containing gases are produced by the catalytic-stream-reforming of hydrocarbon feedstocks using a catalyst which includes a Group VIII metal such as nickel and alumina, and which in its calcined but unreduced precursor form has a pore size distribution defined as follows:(i) at least 55% of the pore volume of pores having a pore radius between 12 and 120 Angstrom Units is in the range of 12-30 Angstrom Units, and(ii) the ratio of the pore volume contained in pores of 10-50 A to the pore volume contained in pores 50-300 A is at least 5:1.
    Type: Grant
    Filed: February 8, 1980
    Date of Patent: July 28, 1981
    Assignee: British Gas Corporation
    Inventors: Reginald G. S. Banks, Alan Williams
  • Patent number: 4272399
    Abstract: Carbon-containing materials are gasified to produce synthesis gas, a mixture of hydrogen and carbon monoxide, in a three zone unified system (oxidizer, reducer and gasifier) using a metal oxide as the oxygen and heat source for the gasification with steam and carbon dioxide. Synthesis gas contacts the metal oxide prior to the gasification to release the oxygen and convert the synthesis gas to steam and carbon dioxide as the gasification medium.
    Type: Grant
    Filed: September 21, 1979
    Date of Patent: June 9, 1981
    Assignee: Monsanto Company
    Inventors: George D. Davis, James C. Hill, Talmage D. McMinn, Charles W. Rooks
  • Patent number: 4240805
    Abstract: A process is disclosed for making hydrogen from a hydrocarbon feedstock and steam using heat stored in a vessel, and the vessel is then regenerated to restore the heat. Regeneration is done by preheating, separately and within the vessel, an oxygen containing gas and a hydrogen purge gas, and mixing these preheated gases so that they combust within the vessel and heat material disposed in the vessel. This is the heat which is used in converting the hydrocarbon feedstock to hydrogen.
    Type: Grant
    Filed: March 16, 1979
    Date of Patent: December 23, 1980
    Assignee: United Technologies Corporation
    Inventor: Richard A. Sederquist
  • Patent number: 4239499
    Abstract: Methanol is passed over a catalyst at an elevated temperature and pressure to produce a fuel gas containing a high proportion of methane in a one-step catalytic conversion process. Removal of water and carbon dioxide from the fuel gas produces a synthetic natural gas. For example, methanol with water is passed over a precious metal catalyst such as ruthenium on alumina at a temperature in the range of about 350.degree. C. to 500.degree. C. and a pressure in the range of about 800 to 2500 psig to produce a gaseous mixture comprising methane, carbon dioxide, minor amounts of hydrogen and essentially no carbon monoxide. Upon condensing the water vapor and scrubbing out the carbon dioxide, synthetic natural gas is obtained having a methane content above 90% by volume.
    Type: Grant
    Filed: November 15, 1977
    Date of Patent: December 16, 1980
    Assignee: Engelhard Minerals and Chemicals Corporation
    Inventor: William C. Pfefferle
  • Patent number: 4233179
    Abstract: A process is provided for the steam reforming of normally liquid hydrocarbons to produce carbon monoxide and hydrogen, which does not promote the deposition of carbonacious materials upon catalytic surfaces. The catalyst consists of nickel promoted with the oxides of iron and manganese within a specific manganese to iron ratio, said metal and metal oxides being supported upon a refractory support. The support is preferably aluminum oxide in its alpha phase having a surface area of more than 0.5 m.sup.2 /gm but no more than 10 m.sup.2 /gm. The metallic constituents are impregnated onto said refractory low surface area support as salts and are calcined at sufficiently high temperature to convert the salts to the oxide but at a sufficiently low temperature that they do not chemically react with the support.
    Type: Grant
    Filed: December 8, 1975
    Date of Patent: November 11, 1980
    Assignee: United Catalysts Inc.
    Inventors: Karl J. Russ, Donald R. Broughton
  • Patent number: 4224298
    Abstract: A process and apparatus for reforming hydrocarbons utilizing a fluidized bed furnace through which pass reformer tubes, the pressure in the fluidized bed and in the tubes being substantially the same and in excess of 50 atmospheres absolute. For hydrocarbons which have been steam reformed, the reformed high pressure product can be converted to synthesis gas for use in the high pressure catalytic synthesis of ammonia.
    Type: Grant
    Filed: April 11, 1978
    Date of Patent: September 23, 1980
    Inventor: Lee F. Robinson
  • Patent number: 4215998
    Abstract: A catalyst for production of methane-containing gases which is formed from a catalyst precursor composed of a mixed precipitate of hydroxides and/or carbonates of nickel and/or cobalt, lanthanum and/or cerium and aluminum, which is obtained by stepwise addition of solutions of alkaline substances to a solution of an aluminum salt, to a solution of a lanthanum salt and/or a cerium salt and to a nickel salt and/or a cobalt salt is disclosed.
    Type: Grant
    Filed: October 20, 1978
    Date of Patent: August 5, 1980
    Inventor: Hideo Futami
  • Patent number: 4216123
    Abstract: Steam reforming catalyst having good sinter and polymer resistance and which include a Group VIII metal such as nickel and alumina, have in their calcined but unreduced precursor form pore size distributions defined in the following relationships:(i) at least 55% of the pore volume of pores having a pore radius between 12 and 120 Angstrom Units is in the range 12-30 Angstrom Units, and(ii) the ratio of the pore volume contained in pores of 10-50 A to the pore volume contained in pores of 50-300 A is at least 5:1.These catalysts are prepared by coprecipitation at temperatures of not greater than 60.degree. C. wherein a solution of an alkali precipitating agent is added to a solution of the catalytic components.
    Type: Grant
    Filed: July 11, 1978
    Date of Patent: August 5, 1980
    Assignee: British Gas Corporation
    Inventors: Reginald G. S. Banks, Alan Williams
  • Patent number: 4211669
    Abstract: A high purity chemical synthesis gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. F. and about 1500.degree. F.
    Type: Grant
    Filed: November 9, 1978
    Date of Patent: July 8, 1980
    Assignee: Exxon Research & Engineering Co.
    Inventors: James M. Eakman, Harry A. Marshall, Theodore Kalina
  • Patent number: 4211538
    Abstract: An intermediate Btu gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. F. and about 1500.degree. F. and a pressure in excess of about 100 psia to produce an effluent or raw product gas consisting essentially of equilibrium quantities, at reaction temperature and pressure, of methane, steam, carbon dioxide, carbon monoxide and hydrogen; recovering at least a portion of the effluent or raw product gas from the gasifier as an intermediate Btu product gas; contacting a carbon-containing material with steam in a steam reforming zone under conditions such that at least a portion of the carbon-containing material reacts with the steam to produce carbon monoxide and hydrogen; and passing the effluent from the reforming zone into the gasifier, thereby supplying the added hydrogen and carbon monoxide required in the gasifier.
    Type: Grant
    Filed: June 28, 1978
    Date of Patent: July 8, 1980
    Assignee: Exxon Research & Engineering Co.
    Inventors: James M. Eakman, Nicholas C. Nahas, Charles A. Euker, Jr.
  • Patent number: 4209305
    Abstract: A process, having high thermal efficiency, is provided for the production of substitute natural gas from fossil fuels such as crude oil, by non-catalytic hydrogenation. High thermal efficiency is obtained by using cryogenic systems for separating hydrogen from (a) the product of the hydrogenation reaction and (b) from products produced by partial oxidation in the production of hydrogen required for the hydrogenation reactions. Other products from the partial oxidation reaction may be used either as fuel or as feedstocks for catalytic steam reforming to produce SNG.
    Type: Grant
    Filed: November 11, 1977
    Date of Patent: June 24, 1980
    Assignee: British Gas Corporation
    Inventors: Henry L. Conway, John A. Hargis, Henry J. F. Stroud
  • Patent number: 4207211
    Abstract: A catalyst is provided for the steam reforming of normally liquid hydrocarbons to produce carbon monoxide and hydrogen, which does not promote the deposition of carbonaceous materials upon the catalytic surfaces. The catalyst consists of nickel promoted with the oxides of iron and manganese within a specific manganese to iron ratio, said metal and metal oxides being supported upon a refractory support. The support is preferably aluminum oxide in its alpha phase having a surface area of less than 15 m.sup.2 /gm. The metallic constituents are impregnated onto said refractory low surface area support as salts and are calcined at sufficiently high temperature to convert the salts to the oxide but at a sufficiently low temperature that they do not chemically react with the support.
    Type: Grant
    Filed: May 19, 1978
    Date of Patent: June 10, 1980
    Assignee: United Catalysts Inc.
    Inventors: Karl J. Russ, Donald R. Broughton
  • Patent number: 4185967
    Abstract: Steam reforming catalysts which are suitable for the gasification of hydrocarbons, particularly heavier hydrocarbons such as kerosene and gas oils, consist of calcined and reduced forms of a basic mixed carbonate of nickel, aluminium and chromium produced by coprecipitation. The catalysts are further characterized in that they have a pore size distribution such that at least 55% by volume of the pores of the calcined but unreduced catalyst which have a pore radius of 12-120A is in the range 12-30A. The catalysts are produced by coprecipitation, preferably at temperatures of not more than 60.degree. C., by using an alkali carbonate as the precipitant and by adding the precipitant to a mixed solution of alumium, nickel and chromium III compounds. The catalysts which have good sinter and polymer resistance may be used for the production of methane-containing gases, e.g., for the production of substitute natural gas.
    Type: Grant
    Filed: February 15, 1978
    Date of Patent: January 29, 1980
    Assignee: British Gas Corporation
    Inventors: Costa Komodromos, Alan Williams, Norman Parkyns
  • Patent number: 4181503
    Abstract: In the hydrotreating and steam reforming of an oxygen and sulfur bearing hydrocarbon fuel the oxygen is first removed in an oxidizer containing a bed of platinum catalyst, the inlet temperature being well below 1000.degree. F. and preferably on the order of 300.degree. F. The sulfur in the fuel does not harm the oxidizer catalyst and may be removed downstream by known hydrodesulfurization techniques prior to reforming.
    Type: Grant
    Filed: October 30, 1978
    Date of Patent: January 1, 1980
    Assignee: United Technologies Corporation
    Inventors: Roger R. Lesieur, Herbert J. Setzer, James R. Hawkins
  • Patent number: 4160649
    Abstract: A multiple-stage steam reforming process for producing a substitute natural gas from kerosene boiling range hydrocarbons. Initially, a lower-boiling feedstock is steam reformed and a portion of the effluent is subjected to hydrogen-producing conditions to provide a vaporous phase enriched in hydrogen content. This vaporous phase is utilized throughout the reaction zone circuit to decrease the extent to which carbon becomes deposited upon the various catalytic composites, and especially with respect to those reaction zones in which the kerosene boiling range hydrocarbons are processed. Gasification of the kerosene fractions is effected at a minimum catalyst temperature of about 840.degree. F. (448.9.degree. C.) and a maximum catalyst temperature of about 1,000.degree. F. (537.8.degree. C.).
    Type: Grant
    Filed: August 25, 1978
    Date of Patent: July 10, 1979
    Assignee: UOP Inc.
    Inventor: Dennis J. Ward
  • Patent number: 4147660
    Abstract: A method for reactivation of a platinum group metal catalyst which comprises treating the platinum group metal catalyst lowered in catalytic activity as the result of having been used for the catalytic reaction of hydrocarbons optionally containing an oxygen atom with at least one agent selected from an inorganic alkaline substance and a reducing substance in an aqueous medium.
    Type: Grant
    Filed: December 16, 1977
    Date of Patent: April 3, 1979
    Assignee: Osaka Gas Company, Ltd.
    Inventors: Kiaki Yamauchi, Yukihiko Morimoto, Toshikatu Sasaki, Katsumi Nakai
  • Patent number: 4140493
    Abstract: A catalyst consisting essentially of nickel, a promoter selected from the group consisting of barium and uranium and a calcium phosphate support having a Ca:P atomic ratio in the range of 1.4:1 to 2.3:1, is formed by impregnating a calcium phosphate gel with suitable compounds of nickel and either barium or uranium. The resulting catalysts are useful for reacting carbon monoxide and steam and in steam reforming processes for producing methane.
    Type: Grant
    Filed: October 21, 1977
    Date of Patent: February 20, 1979
    Assignee: Phillips Petroleum Company
    Inventors: Marvin M. Johnson, Gerhard P. Nowack
  • Patent number: 4118204
    Abstract: An intermediate Btu gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. and about 1500.degree. F. and a pressure in excess of about 100 psia to produce a raw product gas consisting essentially of equilibrium quantities, at reaction temperature and pressure, of methane, steam, carbon dioxide, carbon monoxide and hydrogen; withdrawing the raw product gas from the gasifier and treating it for the removal of acid gases to produce a treated gas; withdrawing a portion of the treated gas as an intermediate Btu product gas; mixing the remainder of the treated gas with steam; passing the resultant mixture into a steam reforming furnace where the methane in the gas reacts with the steam to produce additional amounts of carbon monoxide and hydrogen; and passing the effluent from the reforming furnace into the gasifier.
    Type: Grant
    Filed: February 25, 1977
    Date of Patent: October 3, 1978
    Assignee: Exxon Research & Engineering Co.
    Inventors: James M. Eakman, Nicholas C. Nahas, Charles A. Euker, Jr.
  • Patent number: 4115075
    Abstract: A slurry of particulate carbonaceous material such as coal and a liquid hydrocarbon solvent formed from liquefaction of the carbonaceous material in the presence of hydrogen are combined with hydrogen in a liquefaction zone operated at temperatures from 700.degree. to 1000.degree. F, and pressures up to about 2500 psi. There is generated vapor and liquid hydrocarbons and solid residue. Light liquid hydrocarbons may be recovered as a product or ultimately converted to methane. Another portion of the liquid is recycled as the hydrocarbon solvent. The higher boiling liquid hydrocarbons and the solid residue are subjected to gasification to yield a synthesis gas which serves as a stripping gas stream used for separating the products of liquefaction into useful constituents. Preferably, all of the synthesis gas formed in the process, hydrocarbon vapor, and the light liquid hydrocarbons are converted by a combination of reforming and methanation operations to methane.
    Type: Grant
    Filed: March 21, 1977
    Date of Patent: September 19, 1978
    Assignee: The Ralph M. Parsons Company
    Inventors: Gerald P. McNamee, Theodore R. Roszkowski, David W. Stanbridge, Gerald A. White