Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.

Abstract: A method of preparing a silicoaluminophosphate molecular sieve which comprises the steps of combining a source of silica, a source of phosphorous, a source of alumina and water to form a primary mixture; adding a structure directing agent to said mixture and optional seeds to form a synthesis mixture. The synthesis mixture is synthesized by heating the mixture to a crystallization temperature to form the sieve. The molar ratio of the structure directing agent relative to the source of alumina may vary between 1.3 and 1.9 and the ratio of water to the source of alumina may vary between 20 to 34.

Abstract: This invention relates to efficiently regenerating catalyst particles by minimizing the formation of localized “hot spots” and “cold spots” in a regeneration zone. Specifically this invention relates to a method for controlling regenerator temperature in an oxygenates-to-olefins system, comprising the steps of: contacting an oxygenate feed in a reactor with a catalytically effective amount of molecular sieve-containing catalyst under conditions effective for converting said oxygenate to a product containing light olefins and forming a coked catalyst; contacting a portion of the coked catalyst in a regenerator, having a catalyst bed height (Hc), an inlet height (Hi), and an outlet height (Ho), with an oxygen-containing regeneration medium under conditions effective to at least partially regenerate the coked catalyst; and conducting a portion of the catalyst from the regenerator to a catalyst cooler to form a cooled catalyst portion, wherein Ho is greater than Hi.

Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.

Abstract: Disclosed herein is a method of converting oxygenates to olefins comprising contacting an oxygenate stream with an acidic high silica chabazite catalyst in one or more oxygenate-to-olefins reactors; circulating greater than from 80% of the catalyst to one or more catalyst regenerators to form regenerated catalyst; circulating the regenerated catalyst, preferably the same amount of regenerated catalyst, back to the oxygenate-to-olefins reactor to contact an oxygenate stream; and isolating a stream of olefins from the one or more oxygenate-to-olefins reactors.

Abstract: Methods for producing alcohols from CO or CO2 and H2 utilizing a palladium-zinc on alumina catalyst are described. Methods of synthesizing alcohols over various catalysts in microchannels are also described. Ethanol, higher alcohols, and other C2+ oxygenates can produced utilizing Rh—Mn or a Fisher-Tropsch catalyst.

Abstract: The disclosed invention relates to a process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising: flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst; transferring heat from the process microchannels to a heat exchanger; and removing the product from the microchannel reactor; the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour; the selectivity to methane in the product being less than about 25%. The disclosed invention also relates to a supported catalyst comprising Co, and a microchannel reactor comprising at least one process microchannel and at least one adjacent heat exchange zone.

Abstract: A microchannel reactor is described which has at least one process microchannel and at least one heat exchange zone. The microchannel reactor may be used for conducting a Fischer-Tropsch synthesis reaction.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming alcohols over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described.

Abstract: This invention relates to efficiently regenerating catalyst particles by minimizing the formation of localized “hot spots” and “cold spots” in a regeneration zone. Specifically this invention relates to a method for controlling regenerator temperature in an oxygenates-to-olefins system, comprising the steps of: contacting an oxygenate feed in a reactor with a catalytically effective amount of molecular sieve-containing catalyst under conditions effective for converting said oxygenate to a product containing light olefins and forming a coked catalyst; contacting a portion of the coked catalyst in a regenerator, having a catalyst bed height (Hc), an inlet height (Hi), and an outlet height (Ho), with an oxygen-containing regeneration medium under conditions effective to at least partially regenerate the coked catalyst; and conducting a portion of the catalyst from the regenerator to a catalyst cooler to form a cooled catalyst portion, wherein Ho is greater than Hi.

Abstract: The invention provides methods of combusting a fuel in a reactor that includes at least 3 zones each of which contains a solid catalyst. A method of making a thermally-stable alumina support from fumed alumina is also described.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming alcohols over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described.

Abstract: Novel methods of Fischer-Tropsch synthesis are described. It has been discovered that conducting the Fischer-Tropsch synthesis over a catalyst with a catalytically active surface layer of 35 microns or less results in a liquid hydrocarbon product with a high ratio of C5-C20:C20+. Descriptions of novel Fischer-Tropsch catalysts and reactors are also provided. Novel hydrocarbon compositions with a high ratio of C5-C20:C20+ are also described.

Abstract: Methods for producing alcohols from CO or CO2 and H2 utilizing a palladium-zinc on alumina catalyst are described. Methods of synthesizing alcohols over various catalysts in microchannels are also described. Ethanol, higher alcohols, and other C2+ oxygenates can produced utilizing Rh—Mn or a Fisher-Tropsch catalyst.

Abstract: The disclosed invention relates to a novel cobalt catalyst and to a process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms in a reactor using the catalyst. The process can be conducted in any reactor and is particularly suitable for microchannel reactors.

Abstract: The disclosed invention relates to a process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising: flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst; transferring heat from the process microchannels to a heat exchanger; and removing the product from the microchannel reactor; the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour; the selectivity to methane in the product being less than about 25%. The disclosed invention also relates to a supported catalyst comprising Co, and a microchannel reactor comprising at least one process microchannel and at least one adjacent heat exchange zone.

Abstract: The disclosed invention relates to a process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising: flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst; transferring heat from the process microchannels to a heat exchanger; and removing the product from the microchannel reactor; the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour; the selectivity to methane in the product being less than about 25%. The disclosed invention also relates to a supported catalyst comprising Co, and a microchannel reactor comprising at least one process microchannel and at least one adjacent heat exchange zone.

Abstract: Catalysts containing 30 weight percent or more platinum have surprisingly been discovered to possess superior stability and activity for catalyzing combustion reactions. The addition of rhenium improves catalyst performance in fuel lean conditions but has undesirable effects in fuel rich conditions. The invention provides integrated combustion microreactors, chemical systems utilizing these integrated combustion microreactors, methods of combustion, and methods of providing heat to endothermic reactions in integrated combustion microreactors.

Abstract: The invention provides methods of combusting a fuel in a reactor that includes at least 3 zones each of which contains a solid catalyst. A method of making a thermally-stable alumina support from fumed alumina is also described.

Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.