Abstract: A method of producing synthesis gas via gasification in a Fischer-Tropsch plant, the method including providing a number of gasifiers, the number of gasifiers provided being at least one more than the base number required to provide 100% plant capacity of synthesis gas when each gasifier is operated at 100% gasifier capacity. A method of continually producing synthesis gas via gasification of a carbonaceous feed in a Fischer-Tropsch plant by providing a number of gasifiers, the number of gasifiers provided being at least one more than the base number required to provide 100% plant capacity of synthesis gas when each gasifier is operated at 100% gasifier capacity; and adjusting the amount of synthesis gas produced by adjusting the number of online gasifiers, the flow rate of carbonaceous feed to each gasifier, or a combination thereof. A system for carrying out the method is also provided.

Abstract: A method for meeting both base-load and peak-load demand in a power production facility. By integrating a Fischer-Tropsch (FT) hydrocarbon production facility with an electrical power generating facility, peak-load power demand can be met by reducing the temperature of the FT reactor thereby increasing the quantity of tail gases and using FT tail gases to fuel a gas turbine generator set. The method enables rapid power response and allows the synthesis gas generating units and the FT units to operate with constant flow rates.

Abstract: A system for separating liquids from solids comprising an immobilization unit comprising an immobilization vessel containing a bed of magnetizable material and a magnet configured to produce a magnetic field within the immobilization vessel, wherein the immobilization vessel further comprises an immobilization vessel outlet and an immobilization vessel inlet for a fluid comprising liquid and metal-containing particles.

Abstract: A method for transforming at least a part of the catalyst precursor hematite into x-carbide (Fe5C2) and ??-carbide (FeC2.2) without a large amount of fines generation. This method slows the transformation of the hematite to iron carbides by reducing the partial pressure of the synthesis gas by inert gas dilution. The activation time is about three to about five hours.

Abstract: A method for meeting both base-load and peak-load demand in a power production facility. By integrating a Fischer-Tropsch (FT) hydrocarbon production facility with an electrical power generating facility, peak-load power demand can be met by reducing the temperature of the FT reactor thereby increasing the quantity of tail gases and using FT tail gases to fuel a gas turbine generator set. The method enables rapid power response and allows the synthesis gas generating units and the FT units to operate with constant flow rates.

Abstract: A method of producing a catalyst precursor comprising iron phases by co-feeding a ferrous nitrate solution and a precipitation agent into a ferric nitrate solution to produce a precipitation solution having a desired ferrous:ferric nitrate ratio and from which catalyst precursor precipitates; co-feeding a ferric nitrate solution and a precipitation agent into a ferrous nitrate solution to produce a precipitation solution having a desired ferrous:ferric nitrate ratio and from which catalyst precursor precipitates; or precipitating a ferrous precipitate from a ferrous nitrate solution by contacting the ferrous nitrate solution with a first precipitation agent; precipitating a ferric precipitate from ferric nitrate solution by contacting the ferric nitrate solution with a second precipitation agent and combining the ferrous and ferric precipitates to form the catalyst precursor, wherein the ratio of ferrous:ferric precipitates is a desired ratio.

Abstract: A method of producing stable ferrous nitrate solution by dissolving iron in nitric acid to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2% over a second time period. A method of producing stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, including obtaining a stable ferrous nitrate solution; dissolving iron in nitric acid to form a ferric nitrate solution; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. A method of preparing an iron catalyst is also described.

Abstract: A pesticide or herbicide formulation comprising an effective amount of a pesticide or herbicide in a carrier or solvent fluid, wherein the carrier or solvent fluid comprises a Fischer-Tropsch hydrocarbon produced via Fischer-Tropsch conversion of synthesis gas. A method of producing a pesticide or herbicide formulation by combining an amount of an herbicide or pesticide and a biodegradable solvent to form a pesticide or herbicide solution. A method of producing a pesticide or herbicide formulation by converting synthesis gas into Fischer-Tropsch products in the presence of a Fischer-Tropsch catalyst and combining at least one Fischer-Tropsch product with a pesticide or herbicide to create the formulation.

Abstract: A method for transforming at least a part of the catalyst precursor hematite into x-carbide (Fe5C2) and ??-carbide (FeC2.2) without a large amount of fines generation. This method slows the transformation of the hematite to iron carbides by reducing the partial pressure of the synthesis gas by inert gas dilution. The activation time is about three to about five hours.

Abstract: A method of producing fuel by converting an alcohol stream comprising at least one alcohol into synthesis gas; providing a first synthesis gas stream, wherein at least a portion of the first synthesis gas stream comprises synthesis gas obtained from the alcohol conversion; converting a feed comprising synthesis gas via Fischer-Tropsch into a Fischer-Tropsch product comprising hydrocarbons, wherein at least a portion of the feed comprises synthesis gas from the first synthesis gas stream; and converting at least a portion of the Fischer-Tropsch product into fuel. A diesel fuel comprising hydrocarbons formed by Fischer-Tropsch conversion of synthesis gas derived from an alcohol stream comprising at least one alcohol.

Abstract: A method for transforming at least a part of the catalyst precursor hematite into ?-carbide (Fe5C2) and ??-carbide (FeC2.2) without a large amount of fines generation. This method slows the transformation of the hematite to iron carbides by reducing the partial pressure of the synthesis gas by inert gas dilution. The activation time is about three to about five hours.

Abstract: A method of activating an iron Fischer-Tropsch catalyst by introducing an inert gas into a reactor comprising a slurry of the catalyst at a first temperature, increasing the reactor temperature from the first temperature to a second temperature at a first ramp rate, wherein the second temperature is in the range of from about 150° C. to 250° C., introducing synthesis gas having a ratio of H2:CO to the reactor at a space velocity, and increasing the reactor temperature from the second temperature to a third temperature at a second ramp rate, wherein the third temperature is in the range of from about 270° C. to 300° C. The iron Fischer-Tropsch catalyst may be a precipitated unsupported iron catalyst, production of which is also provided.

Abstract: A novel method of combining the CTL fuel plant and IGCC electrical plant by sharing the systems of coal intake, coal preparation, gas separation, and water units is described herein. This configuration allows for the combined facility to offer advantages in efficiencies of production, operational flexibility, scalability, and reliability by a multi-path integration of the processing units.

Abstract: Methods of operating a business arrangement for an integrated CTL process and IGCC facility are disclosed herein. An embodiment of the method encompasses operating the integrated CTL and IGCC facility to optimize profitability, revenue and monitor inventory. Some advantages of the disclosed methods include reduced capital expenditures and increased availability of power or syngas during emergencies. Further advantages of the disclosed methods will be described in more detail herein.

Abstract: A catalyst support solution for improving the attrition resistance of a Fischer-Tropsch catalyst, the solution comprising: crystalline silica and at least one chemical promoter selected from alkali metal bases, wherein the support solution has a pH of greater than or equal to about 7. A structurally promoted catalyst comprising: crystalline silica; at least one basic chemical promoter; and iron; wherein the catalyst comprises SiO2:Fe in a ratio of from about 2:100 to about 24:100. A method of producing a structurally promoted precipitated iron catalyst, the method comprising: forming the structural support solution described above; stirring the support solution for a time to dissolve the silica in the solution; adding the support solution to a precipitated iron catalyst slurry to form an attrition resistant catalyst slurry; and drying the attrition resistant catalyst slurry to yield the structurally promoted precipitated iron catalyst.

Abstract: A catalyst loading system comprising: a vessel comprising at least one gas distribution nozzle at or near the bottom of the vessel, a top fluid distributor located at or near the top of the vessel, a catalyst inlet through which catalyst is introduced into the vessel, a first contact point at which catalyst introduced into the vessel first contacts the contents of the vessel, and a discharge outlet whereby catalyst exits the vessel. Methods of preparing catalyst slurry for introduction into a downstream reactor or in-situ activation within the vessel utilizing the catalyst loading system are also disclosed.

Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

Abstract: A method of utilizing hydrogen in synthesis gas production by forming synthesis gas from one or more carbonaceous materials, the synthesis gas comprising hydrogen and carbon monoxide; separating a hydrogen-rich product and a hydrogen-lean product from the synthesis gas to yield an adjusted synthesis gas product; and activating a hydrocarbon synthesis catalyst with at least a portion of the hydrogen-lean product. A system for carrying out the method is also provided, the system including at least one hydrogen extraction unit and an activation reactor operable to activate hydrocarbon synthesis catalyst, wherein the activation reactor comprises an inlet fluidly connected with the at least one hydrogen extraction unit whereby at least a portion of a hydrogen-lean gas stream, at least a portion of a hydrogen-rich gas stream, or at least a portion of both may be introduced into the activation reactor.

Abstract: A system for separating particulate from a fluid stream having an inlet solids content, the system comprising: a magnetic dynamic settling vessel comprising at least one magnetic field inside the vessel and/or one magnetized component; at least one inlet for introduction of the fluid stream having a starting solids content; at least one exit for a stream comprising a solids content not greater than the inlet solids content; at least one exit for a fluid stream comprising a solids content not less than the inlet solids content; and a vertical feed conduit extending at least 70% of the distance from the at least one fluid inlet to the at least one exit for a fluid stream comprising a solids content not less than the inlet solids content. A method for separating particulate from a fluid stream having an inlet solids content is also provided.

Abstract: A catalytic reaction system comprising: a catalytic reactor fluidly connected with at least two slurry loops, wherein the reactor comprises at least as many reactor product outlets and at least as many slurry return inlets as slurry loops; wherein each slurry loop comprises a separation system comprising a separation system inlet, a separation system product outlet, and a concentrated catalyst slurry outlet; a slurry offtake fluidly connecting the separation system inlet with one of the reactor product outlets; and a slurry return fluidly connecting the separation system outlet with one of the slurry return inlets. The system may comprise at least three slurry loops. The system may comprise at least four slurry loops. A method for converting synthesis gas into liquid hydrocarbons via the catalytic reaction system in also disclosed.