Diverse Catalysts Utilized In At Least Two Zones Patents (Class 518/707)
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Patent number: 8921433Abstract: Process for the conversion of carbon oxide(s) and hydrogen containing feedstocks into alcohols in the presence of a particulate catalyst.Type: GrantFiled: June 29, 2006Date of Patent: December 30, 2014Assignee: BP Chemicals LimitedInventors: Peter Simpson Bell, Leslie William Bolton, Benjamin Patrick Gracey, Michael Keith Lee
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Patent number: 8906970Abstract: In a process for converting synthesis gas to higher hydrocarbons in a tubular reactor, reactants are introduced through an inlet of the reactor. The reactants are passed downwardly through at least one tube to an upper surface of a catalyst carrier where they pass into a passage defined by an inner perforated wall of a catalyst container before passing radially through the catalyst bed towards the perforated outer wall. Reaction occurs as the synthesis gas contacts the catalyst. Unreacted reactant and product is passed out of the container through a perforated outer wall thereof and then upwardly between a skirt and an outer wall of the container, followed by being directed over the end of the skirt and downwardly between the skirt and the reactor tube where heat transfer takes place. These steps are repeated for any subsequent catalyst carrier, then product is removed from an outlet of the reactor.Type: GrantFiled: February 6, 2012Date of Patent: December 9, 2014Assignee: Davy Process Technology LimitedInventor: Timothy Douglas Gamlin
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Patent number: 8884089Abstract: The present invention provides a process for producing olefins, comprising: a. cracking an ethane-comprising feed in a cracking zone under cracking conditions to obtain at least olefins and hydrogen; b. converting an oxygenate feedstock in an oxygenate-to-olefin zone to obtain at least olefins; wherein at least part of the oxygenate feedstock is obtained by providing hydrogen obtained in step a) and a feed containing carbon monoxide and/or carbon dioxide to an oxygenate synthesis zone and synthesizing oxygenates. In another aspect the invention provides an integrated system for producing olefins.Type: GrantFiled: November 9, 2010Date of Patent: November 11, 2014Assignee: Shell Oil CompanyInventors: Leslie Andrew Chewter, Jeroen Van Westrenen
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Patent number: 8852539Abstract: A second stage Fischer-Tropsch reaction system to enhance a conversion ratio of a synthetic gas, includes, at least one first reactor that uses a Fe catalyst, receives a first synthetic gas extracted from a coal, biomass or natural gas, and reacts the first synthetic gas with the Fe catalyst to obtain a synthetic fuel, and a second reactor that uses a Fe.Co or Co catalyst, receives a second synthetic gas discharged from the first reactors after reaction, and reacts the second synthetic gas with the Fe.Co or Co catalyst to obtain a synthetic fuel.Type: GrantFiled: July 7, 2011Date of Patent: October 7, 2014Assignee: Korea Institute of Energy ResearchInventors: Ho Tae Lee, Heon Jung, Jung Il Yang, Hak Joo Kim, Dong Hyun Chun, Jung Hoon Yang, Ji Chan Park, Byung Kwon Kim
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Patent number: 8557192Abstract: Improved design of a catalytic method and reactor for the production of methanol at equilibrium conditions, whereby methanol, as it is formed, is separated from the gaseous phase into the liquid phase within the reactor without reducing the catalytic activity of the methanol catalyst. This is achieved by adjusting the boiling point or temperature of a liquid cooling agent being in indirect contact with the catalyst particles and by providing a specific ratio of catalyst bed volume to cooling surface area. Thereby, condensation of methanol as it is formed in the gaseous phase takes place for the most at the cooling surface arranged evenly distributed within the reactor and if at all within a very limited region of the catalyst bed.Type: GrantFiled: June 15, 2012Date of Patent: October 15, 2013Assignee: Haldor Topsoe A/SInventor: Max Thorhauge
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Patent number: 8506910Abstract: A process and system for producing high octane fuel from carbon dioxide and water is disclosed. The feedstock for the production line is industrial carbon dioxide and water, which may be of lower quality. The end product can be high octane gasoline, high cetane diesel or other liquid hydrocarbon mixtures suitable for driving conventional combustion engines or hydrocarbons suitable for further industrial processing or commercial use. Products, such as dimethyl ether or methanol may also be withdrawn from the production line. The process is nearly emission free and reprocesses all hydrocarbons not suitable for liquid fuel to form high octane products. The heat generated by exothermic reactions in the process is fully utilized as is the heat produced in the reprocessing of hydrocarbons not suitable for liquid fuel.Type: GrantFiled: April 20, 2012Date of Patent: August 13, 2013Assignee: CRI EHFInventors: Shwetank Singh, Omar Freyr Sigurbjornsson, Kim-Chinh Tran
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Patent number: 8471076Abstract: In the production of methanol from a synthesis gas containing hydrogen and carbon oxides, the synthesis gas is passed through a first, preferably water-cooled reactor, in which a part of the carbon oxides is catalytically converted to methanol. The obtained mixture containing synthesis gas and methanol vapor is supplied to a second, preferably gas-cooled reactor, in which a further part of the carbon oxides is converted to methanol. Subsequently, methanol is separated from the synthesis gas, and the synthesis gas is recirculated to the first reactor. To achieve a maximum methanol yield even with an aged catalyst, a partial stream of the synthesis gas is guided past the first reactor and introduced directly into the second reactor.Type: GrantFiled: August 18, 2008Date of Patent: June 25, 2013Assignee: Lurgi GmbHInventors: Dierk Müller, Andreas Bormann
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Patent number: 8450381Abstract: The present invention includes a removable microchannel unit including an inlet orifice and an outlet orifice in fluid communication with a plurality of microchannels distributed throughout the removable microchannel unit, and a pressurized vessel adapted have the removable microchannel unit mounted thereto, the pressurized vessel adapted to contain a pressurized fluid exerting a positive gauge pressure upon at least a portion of the exterior of the removable microchannel unit. The invention also includes a microchannel unit assembly comprising a microchannel unit operation carried out within a pressurized vessel, where pressurized vessel includes a pressurized fluid exerting a positive gauge pressure upon an exterior of the microchannel unit operation, and where the microchannel unit operation includes an outlet orifice in fluid communication with an interior of the pressurized vessel.Type: GrantFiled: March 22, 2012Date of Patent: May 28, 2013Assignee: Velocys, Inc.Inventors: William Allen Rogers, Paul William Neagle, Michael Alan Marchiando, Christopher Paul Well, Robert Dwayne Litt, Ronald Chester Pasadyn, G. Bradley Smith, Charles Robert Miele, Thomas Peter Forte, Jimmy Glen Pelham
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Publication number: 20130116349Abstract: A process is described for the conversion of synthesis gas into hydrocarbons including the steps of; (i) passing a synthesis gas comprising hydrogen and carbon monoxide over a cobalt catalyst at elevated temperature and pressure to produce a first reaction product mixture comprising hydrocarbons, steam, carbon monoxide and hydrogen, (ii) condensing and separating water from the first reaction product mixture to produce a de-watered first reaction product mixture, (iii) passing the de-watered first reaction product mixture over a supported ruthenium catalyst at elevated temperature and pressure to produce a second reaction product mixture containing hydrocarbons, and (iv) recovering the hydrocarbons from the second reaction product mixture.Type: ApplicationFiled: December 16, 2010Publication date: May 9, 2013Applicant: JOHNSON MATTHEY PLCInventor: Mark McKenna
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Publication number: 20120322651Abstract: Catalytic process for the preparation of methanol, with a plurality of serial synthesis stages, in which the severity of the reaction conditions, on the basis of the reaction temperature and/or the concentration of carbon monoxide in the synthesis gas, decreases from the first to the last reaction stage in flow direction, the first reaction stage having a first catalyst of low activity but high long-term stability, and the last reaction stage having a second catalyst of high activity but low long-term stability.Type: ApplicationFiled: January 28, 2011Publication date: December 20, 2012Inventors: Holger Schlichting, Philipp Marius Hackel, Thomas Wurzel
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Publication number: 20120136076Abstract: The present invention relates to a multistage adiabatic process for performing the Fischer-Tropsch synthesis at low temperatures, in which the synthesis is performed in 5 to 40 series-connected reaction zones under adiabatic conditions.Type: ApplicationFiled: December 4, 2009Publication date: May 31, 2012Applicant: BAYER TECHNOLOGY SERVICES GMBHInventors: Ralph Schellen, Leslaw Mleczko, Evin Hizaler Hoffmann, Stephan Schubert, Rushikesh Apte
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Publication number: 20120108682Abstract: Disclosed is a process for converting synthesis gas to liquid hydrocarbon mixtures useful in the production of fuels and petrochemicals. The synthesis gas is contacted with at least two layers of synthesis gas conversion catalyst wherein each synthesis gas conversion catalyst layer is followed by a layer of hydrocracking catalyst and hydroisomerization catalyst or separate layers of hydrocracking and hydroisomerization catalysts. The process can occur within a single reactor, at an essentially common reactor temperature and an essentially common reactor pressure. The process provides a high yield of naphtha range liquid hydrocarbons and a low yield of wax.Type: ApplicationFiled: August 11, 2011Publication date: May 3, 2012Applicant: Chevron U.S.A. Inc.Inventors: Robert J. Saxton, Charles L. Kibby, Kandaswamy Jothimurugesan, Tapan Das
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Patent number: 7790775Abstract: A process for use in equilibrium exothermic gas phase reactions comprising the steps of (a) providing a recycle stream with the addition of make-up gas, to form a feed gas stream; (b) heating the feed gas stream; (c) passing the heated feed gas stream to a first reactor containing a catalyst for the exothermic gas phase reactions at conditions suitable for the reaction; (d) removing a product stream comprising product and unreacted gases from the first reactor; (e) cooling and partially condensing the product stream to form a gas phase and a liquid phase; (f) separating the liquid phase containing the desired product from the product stream and removing said liquid phase; (g) separating the gas phase from the product stream to form a gas stream; (h) optionally mixing the gas stream from the product stream with additional make-up gas; (i) heating the gas stream; (j) passing the heated gas stream to a final reactor containing a catalyst for the exothermic gas phase reactions at conditions suitable for the reactType: GrantFiled: August 10, 2005Date of Patent: September 7, 2010Assignee: Davy Process Technology LimitedInventor: Simon Robert Early
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Patent number: 7288689Abstract: The present invention provides various processes for producing C1 to C4 alcohols, optionally in a mixed alcohol stream, and optionally converting the alcohols to light olefins. In one embodiment, the invention includes directing a first portion of a syngas stream to a methanol synthesis zone wherein methanol is synthesized. A second portion of the syngas stream is directed to a fuel alcohol synthesis zone wherein fuel alcohol is synthesized. The methanol and at least a portion of the fuel alcohol are directed to an oxygenate to olefin reaction system for conversion thereof to ethylene and propylene.Type: GrantFiled: November 19, 2003Date of Patent: October 30, 2007Assignee: ExxonMobil Chemical Patents Inc.Inventors: Marcel Johannes Janssen, Cornelis F. Van Egmond, Luc R. M. Martens, Jaimes Sher
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Patent number: 7247281Abstract: A methanation assembly for use with a water supply and a gas supply containing gas to be methanated in which a reactor assembly has a plurality of methanation reactors each for methanating gas input to the assembly and a gas delivery and cooling assembly adapted to deliver gas from the gas supply to each of said methanation reactors and to combine water from the water supply with the output of each methanation reactor being conveyed to a next methanation reactor and carry the mixture to such next methanation reactor.Type: GrantFiled: April 6, 2004Date of Patent: July 24, 2007Assignee: FuelCell Energy, Inc.Inventors: Fred C. Jahnke, Sanjay C. Parab
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Patent number: 7226954Abstract: The invention relates to an integrated process for producing liquid fuels, the process comprising the steps of: a) subjecting syngas with a hydrogen/carbon monoxide ratio between about 0.5 to 2.0 to Fischer-Tropsch reaction conditions in the presence of a first catalyst; b) optionally removing water and/or heavy hydrocarbons from the product stream; and c) subjecting the product from step a) or b) together with syngas of a hydrogen/carbon monoxide ratio higher than that of step a) or hydrogen to Fischer-Tropsch reaction conditions at higher temperatures than during step a) in the presence of a second catalyst, said second catalyst being selected such as to provide a higher activity than said first catalyst; wherein said first catalyst is selected such as to provide low methane selectivity and high olefins and heavy hydrocarbons selectivity. According to the invention, a third synthesis step or additional synthesis steps is added subsequent to the synthesis step c).Type: GrantFiled: October 3, 2005Date of Patent: June 5, 2007Assignee: Research Institute Petroleum Industry (RIPI)Inventors: Ahmad Tavasoli, Ali Karimi, Kambiz Sadagiani Zadeh, Abas Ali Kodadadi, Yadollah Mortazavi, Shahram Sharifnia
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Patent number: 7214721Abstract: A reactor system, plant and a process for the production of methanol from synthesis gas is described in which the reactor system comprises: (a) a first reactor adapted to be maintained under methanol synthesis conditions having inlet means for supply of synthesis gas and outlet means for recovery of a first methanol-containing stream, said first reactor being charged with a first volume of a methanol synthesis catalyst through which the synthesis gas flows and on which in use, partial conversion of the synthesis gas to a product gas mixture comprising methanol and un-reacted synthesis gas will occur adiabatically; and (b) a second reactor adapted to be maintained under methanol synthesis conditions having inlet means for supply of the gaseous first methanol-containing stream, outlet means for recovery of a second methanol-containing stream and cooling means, said second reactor being charged with a second volume of a methanol synthesis catalyst through which the gaseous first methanol-containing stream flowsType: GrantFiled: February 18, 2004Date of Patent: May 8, 2007Assignee: Davy Process Technology LimitedInventor: Philip Henry Donald Eastland
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Controlling the ratio of ethylene to propylene produced in an oxygenate to olefin conversion process
Patent number: 7199276Abstract: The present invention provides various processes for producing methanol and ethanol, preferably in a mixed alcohol stream. In one embodiment, the invention includes directing syngas to a synthesis zone wherein the syngas contacts a methanol synthesis catalyst and an ethanol synthesis catalyst (either a homologation catalyst or a fuel alcohol synthesis catalyst) under conditions effective to form methanol and ethanol. The methanol and ethanol, in a desired ratio, are directed to an oxygenate to olefin reaction system for conversion thereof to ethylene and propylene in a desired ratio. The invention also relates to processes for varying the weight ratio of ethylene to propylene formed in an oxygenate to olefin reaction system.Type: GrantFiled: November 19, 2003Date of Patent: April 3, 2007Assignee: ExxonMobil Chemical Patents Inc.Inventors: Jaimes Sher, Cornelis F. Van Egmond, Luc R. M. Martens, Mechilium Johannes Janssen, James R. Lattner, Teng Xu -
Patent number: 7196239Abstract: The present invention provides various processes for producing light olefins from methanol and ethanol, optionally in a mixed alcohol stream. In one embodiment, the invention includes directing a first syngas stream to a methanol synthesis zone to form methanol and directing a second syngas stream and methanol to a homologation zone to form ethanol. The methanol and ethanol are directed to an oxygenate to olefin reaction system for conversion thereof to ethylene and propylene.Type: GrantFiled: November 19, 2003Date of Patent: March 27, 2007Assignee: ExxonMobil Chemical Patents Inc.Inventors: Cornelis F. Van Egmond, Andrew Argo, Teng Xu, Marcel Johannes Janssen, Jaimes Sher
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Patent number: 6992113Abstract: CO2 emissions from syngas conversion processes are reduced by use of a multi-stage Fischer-Tropsch reaction system. A process for the conversion of syngas using a Fischer-Tropsch reactor comprises forming a first syngas and reacting at least a portion of the first syngas in a Fischer-Tropsch reactor to form a first hydrocarbonaceous product and a second syngas. The second syngas is mixed with a hydrogen-containing stream to provide an adjusted syngas, at least a portion of which is reacted in a dual functional syngas conversion reactor to form a second hydrocarbonaceous product and a third syngas comprising a reduced amount of CO2 than was present in the adjusted syngas.Type: GrantFiled: November 25, 2003Date of Patent: January 31, 2006Assignee: Chevron U.S.A. Inc.Inventors: Dennis J. O'Rear, Charles L. Kibby
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Patent number: 6903140Abstract: Process for the conversion of synthesis gas to a product comprising liquid hydrocarbons and oxygenates. The process includes contacting synthesis gas at an elevated temperature and pressure with a mixed particulate catalyst comprising a mixture of a particulate Fischer-Tropsch catalyst and a particulate oxygenate synthesis catalyst.Type: GrantFiled: May 17, 2002Date of Patent: June 7, 2005Assignees: BP Exploration Operating C Company Limited, Davy Process Technology LimitedInventors: Josephus Johannes Helena Maria Font Freide, Stephen Anthony Leng, David Charles Griffiths
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Patent number: 6897246Abstract: A process for reducing C2-C9 olefin formation by recycling them to a Fischer-Tropsch hydrocarbon synthesis process and promoting recycled olefins chain growth comprises contacting a gas feed comprising a mixture of H2 and CO with a catalyst in a reactor system at conditions effective to produce a hydrocarbon product stream including C2-C9 olefins, separating a C2-C9 olefins-rich stream from the hydrocarbon product stream to form a light olefin recycle stream and recycling the light olefin recycle stream to the reactor system at a point in the reactor system where the H2:CO ratio is low relative to the H2:CO ratio in the rest of the reactor system. Depending on whether the initial H2:CO ratio is greater or less than the usage ratio of the selected catalyst, the recycled olefins can be returned to the system up- or downstream of the reactor system.Type: GrantFiled: November 12, 2002Date of Patent: May 24, 2005Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Ajoy P. Raje, Doug S. Jack
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Patent number: 6627666Abstract: A process is described in which the waste gas from the production of acetylene is employed in the Fischer-Tropsch synthesis of hydrocarbon liquids. The process consists of the steps of collecting the waste gas, compressing it to the proper pressure, passing the compressed gas into a reactor containing a Fischer-Tropsch catalyst under the proper conditions of temperature, pressure, and space velocity, and collecting the liquid products thereby formed from the waste gas stream.Type: GrantFiled: August 8, 2001Date of Patent: September 30, 2003Assignee: Rentech Inc.Inventor: Peter S. Pedersen
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Patent number: 6613949Abstract: This invention is directed towards an improved process for the selective gas phase oxidation of a organic reactant using a metal oxide redox catalyst, wherein the organic reactant and air feeds are at a substantially continuous level, the improvement comprising adding a fluctuating flow of oxygen at alternating relatively high and relatively low levels. The invention also teaches means by which a gas may be provided to a reaction process on a fluctuating basis.Type: GrantFiled: March 10, 1997Date of Patent: September 2, 2003Assignee: Praxair Technology, Inc.Inventors: Matthew Lincoln Wagner, Donald Walter Welsh Kirkwood, Kazuo Kiyonaga
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Patent number: 6608114Abstract: A process is set forth for producing DME by dehydrating the effluent stream from a methanol reactor where the methanol reactor is a slurry bubble column reactor (SBCR) containing a methanol synthesis catalyst that converts a synthesis gas stream comprising hydrogen and carbon monoxide into an effluent stream comprising methanol. A key to the process is that the SBCR methanol can produce a relatively low water content methanol stream, thereby avoiding an intervening water removal unit between the SBCR methanol unit and the dehydration unit and/or an incremental increase in the water that must be processed by the dehydration unit.Type: GrantFiled: March 13, 2002Date of Patent: August 19, 2003Assignee: Air Products and Chemicals, Inc.Inventors: Edward C. Heydorn, Bharat Lajjaram Bhatt, Barry W. Diamond
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Patent number: 6479557Abstract: A process for the preparation of at least two organic products from a synthesis gas by (i) converting a first synthesis gas feed to a first organic product and a first by-product; (ii) converting a second synthesis gas feed to a second organic product and a second by-product; (iii) separating the first and/or second by-product from, respectively, the first and/or second organic product, and (iv) mixing the separated first and/or second by-product with, respectively, the second and/or first organic product. Preferably, the first organic product is paraffinic hydrocarbons or oxygenates and the second organic product is olefinic hydrocarbons or oxygenates.Type: GrantFiled: February 14, 2000Date of Patent: November 12, 2002Assignee: Shell Oil CompanyInventors: Jean-Paul Lange, Ian Ernest Maxwell, Bob Scheffer
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Patent number: 6299849Abstract: A Method for in-situ modernization of a heterogeneous exothermic synthesis reactor, comprising the steps of providing at least a first and at least a second catalytic bed (12, 13) in an upper (2a) respectively lower (2b) portion of the reactor, providing additionally a lowermost catalytic bed (14) in the lower portion (2b) of the reactor having a reaction volume smaller than the reaction volume of the second catalytic bed (13), and loading the lowermost catalytic bed (14) with a catalyst having an activity higher that the activity of the catalyst loaded in the other beds (12, 13). Thanks to the above steps, the present method allows to obtain a reactor with high conversion yield.Type: GrantFiled: March 19, 1998Date of Patent: October 9, 2001Assignee: Ammonia Casale S.A.Inventors: Giorgio Pagani, Ermanno Filippi
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Patent number: 6255357Abstract: A process for the production of methanol comprises converting a hydrocarbon feedstock at a pressure above the desired synthesis pressure into a synthesis gas mixture containing hydrogen, carbon oxides and steam at an elevated temperature and pressure, cooling said mixture to condense water from the mixture, separating the condensed water, and passing the resultant gas mixture, with no further compression and no recycle of unreacted gas, at an elevated temperature through a series of at least two methanol synthesis stages with separation of synthesised methanol from the gas mixture after each stage is disclosed. The hydrocarbon feedstock is converted into the synthesis gas mixture by a catalytic steam reforming process wherein the heat required for reforming is supplied by the products of combustion of the unreacted gas remaining after separation of synthesised methanol, and, preferably also by the reformed gas after it has left the reforming catalyst.Type: GrantFiled: December 13, 1999Date of Patent: July 3, 2001Assignee: Imperial Chemical Industries PLCInventor: Peter Edward James Abbott
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Patent number: 6191175Abstract: An improved process for the production of a methanol and dimethyl ether mixture rich in DME from essentially stoichiometrically balanced synthesis gas by a novel combination of synthesis steps.Type: GrantFiled: January 25, 2000Date of Patent: February 20, 2001Assignee: Haldor Topsoe A/SInventors: Jesper Haugaard, Bodil Voss
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Patent number: 5827901Abstract: Methanol is catalytically produced from a synthesis gas containing hydrogen and carbon oxides on copper-containing catalysts at pressures in the range from 20 to 120 bar and temperatures in the range from 130.degree. to 350.degree. C. The synthesis gas is first of all passed through a first synthesis reactor, in which the catalyst is provided in tubes surrounded by water as a coolant which is boiling at an elevated pressure. From the first reactor a first mixture containing gases and methanol vapor is withdrawn and passed through a second synthesis reactor. In the second reactor the catalyst is cooled with synthesis gas.Type: GrantFiled: January 31, 1997Date of Patent: October 27, 1998Assignee: Metallgesellschaft AktiengesellschaftInventors: Peter Konig, Hermann Gohna
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Patent number: 5770630Abstract: An improved process for the manufacture of organic liquids from gases containing hydrogen and carbon monoxide which avoids the build-up of nitrogen content through the use of a se ies of organic liquid reactors.Type: GrantFiled: February 1, 1995Date of Patent: June 23, 1998Assignee: Foster Wheeler Energy LimitedInventors: Wieslaw Mark Kowal, Geoffrey Frederick Skinner
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Patent number: 5712313Abstract: A process for carrying out a chemical equilibrium reaction is disclosed in which, in a first stage, one or more reactants are contacted with a fixed arrangement of a catalyst under conditions such that the reactants and the products of the reaction are gaseous, the unconverted reactants and products of the first stage being passed to a second stage, in which they are contacted with a fixed arrangement of a catalyst and the reaction allowed to proceed in the presence of an absorbent capable of absorbing a product of the reaction.Type: GrantFiled: February 26, 1996Date of Patent: January 27, 1998Assignee: Shell Oil CompanyInventors: Gert Jan Kramer, Jean Paul Lange
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Patent number: 5703133Abstract: The invention provides for a method of making isoalcohols using syngas-to-alcohol catalyst and method of making it. The catalyst is a highly dispersed, alkali promoted, La stabilized, microcrystalline Cu.sub.2 O having a particle size of .ltoreq.6 nm in the presence of an alumina structural promoter, wherein on a mole % alkali free metals-only basis Cu is present in from 45 to 55%, Zn from 10 to 20%, Al from 10 to 25%, La from 5 to 15%, and wherein the alkali is from 0.01 to 0.91% K and from 3 to 6.5% Cs. The method of making it involves coprecipitation at a constant pH from a solution of soluble metal salts of copper, zinc, lanthanum and aluminum with an alkali hydroxide, washing the coprecipitate in the essential absence of CO.sub.2, drying and calcining it, then contacting it with K and Cs to form the promoted catalyst. The promoted catalyst is dried and recalcining to produce a catalyst precursor with highly dispersed CuO crystallites. The catalyst is activated in flowing hydrogen.Type: GrantFiled: December 8, 1995Date of Patent: December 30, 1997Assignee: Exxon Research and Engineering CompanyInventors: Thomas Henry Vanderspurt, Russell John Koveal
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Patent number: 5624964Abstract: A process for integration of a steam reforming unit and a cogeneration power plant in which said steam reforming unit comprises two communicating fluid beds; the first fluid bed comprising a reformer containing catalyst and which is used to react steam and light hydrocarbons at conditions sufficient to produce a mixture comprising synthesis gas hydrogen, carbon monoxide, and carbon dioxide, the second fluid bed comprising a combustor-regenerator which receives spent catalyst from the first fluid bed and which provides heat to heat the catalyst and balance the reaction endotherm, by combusting fuel gas in direct contact with the catalyst producing hot flue gas; said cogeneration power plant comprises a gas turbine equipped with an air compressor and a combustor; said integration which comprises drawing off a portion of compressed air from the power plant gas turbine air compressor leaving remainder compressed air; introducing the drawn off compressed air to the combustor-regenerator; mixing the hot flue gas frType: GrantFiled: June 6, 1995Date of Patent: April 29, 1997Assignee: Mobil Oil CorporationInventors: Ronald J. Cimini, David O. Marler, Reuel Shinnar, Gerald J. Teitman
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Patent number: 5498638Abstract: High conversion, substantially once-through hydrocarbon synthesis is achieved by reacting H.sub.2 and CO in a first stage(s) in the presence of a non-shifting catalysts, separating liquid products and reacting the remaining gas streams in the presence of hydrocarbon synthesis catalysts having shifting activity.Type: GrantFiled: April 29, 1994Date of Patent: March 12, 1996Assignee: Exxon Research & Engineering Co.Inventor: David C. Long
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Patent number: 5455281Abstract: Method of direct cooling synthesis gas in a catalytic reactor with one or more catalyst beds of a metal oxide catalyst being loaded on gas permeable partitions with distribution means, which method comprises admixing the synthesis gas during its passage through the reactor with a cooling gas being introduced into a mixing zone beneath each partition, wherein the mixing zones are obtained by passing a reducing gas through the catalyst bed, so that the catalyst volume shrinks during reduction of the catalyst particles, and, thereby, providing necessary cavities for the mixing zones beneath each partition.Type: GrantFiled: December 7, 1993Date of Patent: October 3, 1995Assignee: Haldor Topsoe A/SInventor: Haldor F. A. Topsoe
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Patent number: 5424335Abstract: The purge gas from a methanol synthesis loop is subjected to a further step of methanol synthesis, preferably while in indirect heat exchange with the purge gas undergoing heating to the synthesis inlet temperature so that the reacted purge gas, containing synthesized methanol, leaves the synthesis catalyst at a temperature below the maximum temperature achieved by the reacting purge gas during passage over the catalyst.The synthesis loop can be operated less efficiently, eg at a lower pressure or with added carbon dioxide, than is conventional since the additional methanol produced from the purge gas compensates for the loss of loop efficiency.The addition of the purge gas synthesis stage enables existing plants to be uprated by lowering the loop pressure, thus enabling a greater throughput through the synthesis gas compressor to be achieved.Type: GrantFiled: November 23, 1993Date of Patent: June 13, 1995Assignee: Imperial Chemical Industries PLCInventor: Peter E. J. Abbott
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Patent number: 5160456Abstract: Synthesis gas, hydrogen and carbon monixide, as produced in a fluid-bed or spouted-bed process by reacting methane or a lower alkane with steam and oxygen in the presence of essentially non-catalytic, heat carrying solids with periodic addition of a steam-reforming catalyst for maintaining a level of activity sufficient within 250.degree. F. of the approach to equilibrium.Type: GrantFiled: April 16, 1992Date of Patent: November 3, 1992Assignee: Exxon Research and Engineering CompanyInventors: Gerard C. Lahn, Frederick J. Kaiser, Jr., Rocco A. Fiato
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Patent number: 5143647Abstract: Start-up procedure for FBSG process involving starting up under oxidizing conditions with Al.sub.2 O.sub.3 (no Ni) particles in the bed and the switching to reducing conditions prior to adding Ni/Al.sub.2 O.sub.3 catalyst. This procedure will prevent catalyst particle agglomeration.Type: GrantFiled: June 7, 1991Date of Patent: September 1, 1992Assignee: Exxon Research and Engineering CompanyInventors: Geoffrey R. Say, James H. Taylor, David C. Long, Rocco A. Fiato
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Patent number: 5028634Abstract: Hydrocarbon synthesis is carried out in a two stage process wherein the pressure in the first stage is relatively higher and the pressure in the second stage is relatively lower and the second stage catalyst comprises cobalt on alumina.Type: GrantFiled: August 23, 1989Date of Patent: July 2, 1991Assignee: Exxon Research & Engineering CompanyInventor: Rocco A. Fiato
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Patent number: 4950821Abstract: An improved process is disclosed for the conversion of natural gas into middle distillates. In the process, natural gas is converted into synthesis gas or syngas consisting essentially of carbonmonoxide and hydrogen. The syngas is contacted with a series of three catalyst beds comprising of an admixture of oxides of copper, zinc and aluminium in the first bed, an oxide of aluminium in the second bed and silicate salt of a rare earth metal in the third bed. From the aqueous phase, the olefinic hydrocarbons are separated and then converted into oligomers boiling in the middle distillates range by contacting with solid oligomerization catalyst. The oligiomers in admixture with hydrogen are then converted into middle distillates by contacting the admixture with a hydrogenation catalyst. The middle distillates are well known for their varied applications as fuel and illuminators.Type: GrantFiled: August 11, 1989Date of Patent: August 21, 1990Assignee: Council of Scientific & Industrial ResearchInventors: Paul Ratnasamy, Subramanian Sivasanker
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Patent number: 4758600Abstract: Ethanol is prepared with high selectivity by the catalytic reaction of carbon monoxide and hydrogen.Type: GrantFiled: December 12, 1986Date of Patent: July 19, 1988Assignee: Agency of Industrial Science and TechnologyInventors: Satoshi Arimitsu, Katsumi Yanagi, Hitomi Hosono, Toshihiro Saito, Kazuaki Tanaka, Yuji Onda, Kazuo Takada, Keiji Mitarai, Nobuyuki Taniguchi, Yoshimitsu Ishii, Takakazu Fukushima
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Patent number: 4751248Abstract: A process for converting synthesis gas (CO+H.sub.2) to aliphatic alcohols containing at least 2 carbon atoms comprises the steps of passing the synthesis gas first through a catalyst zone comprising (a) Co metal and/or Co oxide and (b) MgO and/or ZnO (preferably MgO), and then through a catalyst zone comprising (c) Cu metal and/or Cu oxide and (d) ZnO.Type: GrantFiled: July 2, 1987Date of Patent: June 14, 1988Assignee: Phillips Petroleum CompanyInventors: Fan-Nan Lin, Filippo Pennella
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Patent number: 4628066Abstract: The present invention is a process for increasing the capacity of a gas phase synthesis loop for the production of methanol from a syngas feed. The syngas feed is initially passed to a liquid phase methanol reactor to convert a portion of the syngas to methanol or methanol and higher aliphatic alcohols. The mixture is subsequently cooled to condense and recover the methanol and/or higher alcohols. The unreacted syngas is passed to a gas phase synthesis loop for further conversion and recovery of methanol.Type: GrantFiled: February 12, 1986Date of Patent: December 9, 1986Assignee: Air Products and Chemicals, Inc.Inventors: Leo W. Bonnell, Joseph M. Pietrantonio
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Patent number: 4624968Abstract: A multi-stage catalyst system is disclosed for the production of waxes in a Fischer-Tropsch process while producing relatively low quantities of methane. A first catalyst converts CO and H.sub.2 into olefins, while a second catalyst converts the olefin, additional hydrogen and CO into higher molecular weight paraffin.Type: GrantFiled: December 30, 1985Date of Patent: November 25, 1986Assignee: Exxon Research and Engineering CompanyInventors: Chang J. Kim, Rocco A. Fiato
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Patent number: 4525482Abstract: This invention provides an improved, simple and energy saving process for producing a gas containing methane, which process utilizes a reactor having a catalyst bed of a structure wherein a synthesis gas is allowed to pass perpendicularly to the longitudinal directions of a plurality of cooling tubes installed vertically within the catalyst bed. Within the cooling tubes, a liquid coolant at its boiling temperature is flowed upwardly under pressure. A portion of the reaction product gas leaving the catalyst bed is mixed, without cooling, with fresh feed gas and is recirculated to the catalyst bed. The amount of the recycled gas is less than 5 times the amount of fresh feed gas. The foregoing process produces a product gas containing methane from a feed gas containing carbon monoxide and hydrogen.Type: GrantFiled: March 22, 1984Date of Patent: June 25, 1985Assignee: Toyo Engineering CorporationInventors: Kozo Ohsaki, Katsutoshi Kikuchi, Yoshitsugu Hirota
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Patent number: 4499209Abstract: A Fischer-Tropsch catalyst is prepared by impregnating a silica carrier with a solution of a zirconium or titanium compound, calcining the composition thus obtained, thereafter impregnating the carrier with a cobalt compound-containing solution and calcining and reducing the composition thus obtained. Catalysts so prepared and containing 5-40 pbw of cobalt and 2-150 pbw of zirconium or titanium per 100 pbw of silica, are used in the preparation of hydrocarbons from a H.sub.2 /CO mixture.Type: GrantFiled: October 28, 1983Date of Patent: February 12, 1985Assignee: Shell Oil CompanyInventors: Arend Hoek, Martin F. M. Post, Johannes K. Minderhoud, Peter W. Lednor
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Patent number: 4481305Abstract: Hydrocarbons and especially as gasoline are prepared by the catalytic conversion in two subsequent reactors of a synthesis gas containing hydrogen and carbon oxides and having a mole ratio CO/H.sub.2 above 1 and when the conversion commences a mole ratio CO/CO.sub.2 of 5 to 20. In the first reactor, which is preferably a cooled reactor, the synthesis gas is converted into a methane-containing first intermediate and this at least partly further into a second intermediate containing dimethyl ether, at 5-100 bar and 150.degree.-400.degree. C., in the presence of catalyst(s), the effluent from this reactor is combined with a recycle stream containing low boiling components of the effluent from the second reactor, and then passed to the second reactor, which is adiabatic, where the conversion of the second intermediate is carried out at substantially the same pressure as in the first reactor and 150.degree.-600.degree. C.Type: GrantFiled: September 6, 1983Date of Patent: November 6, 1984Assignee: Haldor Topsoe A/SInventors: Ernest Jorn, Jens R. Rostrup-Nielsen
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Patent number: 4443561Abstract: In a two-stage process for the conversion of H.sub.2 -poor syngas into hydrocarbons and oxygenates in which uncoverted syngas from the first stage product is converted in a second stage into paraffins over a Ni, Co or Ru catalyst, the H.sub.2 /CO molar ratio of the feed for the second stage is adjusted to the required value of 1.75-2.25 by blending this feed with an H.sub.2 -rich syngas with an H.sub.2 /CO molar ratio of at least above 1.75 which latter gas has been obtained by subjecting a small portion of the feed for the first stage to a high temperature (above 325.degree. C.) CO-shift.Type: GrantFiled: May 24, 1982Date of Patent: April 17, 1984Assignee: Shell Oil CompanyInventors: Sikko J. A. Boelema, Martin F. M. Post, Swan T. Sie
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Patent number: 4433066Abstract: A method for the production of high-caloric content gases is disclosed wherein feed gases containing CO and H.sub.2 are passed through at least two consecutive catalytic fluidized bed stages having cooling elements wherein, the feed gases being introduced to the first stage under pressure and to the subsequent stages under a pressure which is less than the pressure of the next preceding stage, and the gas produced from each preceding stage is fed to the next stage as a diluting gas. As a result of using the method of the present invention, one can avoid the necessity of compression of the feed gases in the subsequent reaction stages, thereby decreasing the cost as well as the technical difficulties encountered in the process.Type: GrantFiled: January 19, 1982Date of Patent: February 21, 1984Assignee: Didier Engineering GmbHInventors: Erich Hackler, Claus Flockenhaus, Werner Lommerzheim