Abstract: The invention relates to methods for improving the octane number of a synthetic naphtha stream and optionally for producing olefins and/or solvents. In one embodiment, the method comprises aromatizing at least a portion of a synthetic naphtha stream to produce an aromatized hydrocarbon stream; and isomerizing at least a portion of the aromatized hydrocarbon stream to produce an isomerized aromatized hydrocarbon stream having a higher octane rating than the synthetic naphtha stream. Alternatively, the method comprises providing at least three synthetic naphtha cuts comprising a C4-C5 stream; a C6-C8 stream and a C9-C11 stream; aromatizing some of the C6-C8 stream to form an aromatized hydrocarbon stream with a higher octane number; steam cracking some of the C6-C8 stream and optionally the C9-C11 stream to form olefins; and selling some portions of C9-C11 stream as solvents. In preferred embodiments, the synthetic naphtha is derived from Fischer-Tropsch synthesis.

Abstract: The present invention is generally related towards enhancing the yield and/or cold-flow properties of certain hydrocarbon products, increasing the degree of isomerization in a diesel product and/or increasing the production rate of a diesel product. The embodiments generally include reducing the residence time of lighter hydrocarbon fractions during hydrocracking, thereby decreasing secondary cracking, by various configurations of introducing at least two hydrocarbon feedstreams of different boiling ranges at different entry points in a hydrocracking unit. A method further includes forming a hydrocarbons stream comprising primarily C5+ Fischer-Tropsch hydrocarbon products; fractionating hydrocarbons stream to form at least a wax fraction and an intermediate fraction which serve as separate feedstreams to a hydrocracking unit comprising at least two hydroconversion zones.

Abstract: The present invention provides a process for natural gas in the form, e.g., of stranded gas or associated gas to transportable liquids. More particularly, the present invention provides a process in which the gas is non-oxidatively converted to aromatic liquid, preferably in proximity to the welihead, which may be onshore or offshore. In one aspect, the present invention provides integration of separation of wellhead fluids into associated gas and crude with blending of the aromatic liquid derived from the gas with the crude. Alternatively, or in combination, in another aspect, the present invention provides integration of conversion of byproduct hydrogen to power with non-oxidative conversion of gas to aromatic liquid.

Abstract: In a system and method for recovering a catalyst, a slurry comprising said catalyst and residual hydrocarbons is heated so as to vaporize hydrocarbons. The vaporized hydrocarbons are separated from the catalyst. The separated catalyst is preferably further contacted with a stripping medium so as to further remove remaining hydrocarbons. In an embodiment, the catalyst is a Fischer-Tropsch catalyst contained in a reactor, preferably a slurry bubble reactor. In some embodiments, the slurry is diluted with additional hydrocarbons, and the residual hydrocarbons comprise waxy hydrocarbons. In an embodiment, substantially all of the hydrocarbons in the slurry are vaporized. In an embodiment, the catalyst is separated from the vaporized hydrocarbons via centrifugation. In an embodiment, substantially all of the hydrocarbons are removed from the catalyst.

Abstract: Methods and apparatus for removing wax products from a slurry used in a Fischer-Tropsch reactor. The preferred embodiments of the present invention are characterized by a solid/liquid separation system that removes liquid products from a slurry by drawing the fluid across a filter medium composed of a filter cake disposed on a substrate. In the preferred embodiments, the filter cake is desirable and performs the majority of the filtration. In certain embodiments, the filter medium is disposed in a filter housing where slurry flows parallel to the longitudinal axis of the filter medium from and inlet to an outlet. The characteristics or properties of the cake, which will effect the performance of the solid/liquid separation system, can be controlled by regulating the velocity of the slurry flowing across the cake, where the velocity may be regulated by adjusting the slurry flow through the filter housing or may be self-regulated by changing slurry velocities influenced by the design of the filter housing.

Abstract: 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.

Abstract: Methods for producing clean liquid/wax products from a slurry used in a Fischer-Tropsch reactor are disclosed. In general, one embodiment of the present invention comprises a solid/liquid filtration system having a filter medium comprising a substrate and a filter cake deposited on the substrate, wherein the filter cake is generated by deposition of solids from the slurry. The thickness of the filter cake can be maintained within a desired range by controlling the slurry velocity and/or the pressure differential across the filter medium. This invention relates to a method of operation of such filtration system which increases filtration cycle time and improved filtrate quality resulting in very low solid content in filtrate.

Abstract: The invention relates to methods for improving the octane number of a synthetic naphtha stream and optionally for producing olefins and/or solvents. In one embodiment, the method comprises aromatizing at least a portion of a synthetic naphtha stream to produce an aromatized hydrocarbon stream; and isomerizing at least a portion of the aromatized hydrocarbon stream to produce an isomerized aromatized hydrocarbon stream having a higher octane rating than the synthetic naphtha stream. Alternatively, the method comprises providing at least three synthetic naphtha cuts comprising a C4-C5 stream; a C6-C8 stream and a C9-C11 stream; aromatizing some of the C6-C8 stream to form an aromatized hydrocarbon stream with a higher octane number; steam cracking some of the C6-C8 stream and optionally the C9-C11 stream to form olefins; and selling some portions of C9-C11 stream as solvents. In preferred embodiments, the synthetic naphtha is derived from Fischer-Tropsch synthesis.

Abstract: A hydrogen permselective membrane, a method of forming a permselective membrane and an apparatus comprising a permselective membrane, a porous substrate and an optional intermediate layer are described. Using chemical vapor deposition (CVD) at low reactant gas concentration, high permselectivities are achieved with minimal reduction in hydrogen permeance.

Abstract: The invention relates to methods for improving the octane number of a synthetic naphtha stream and optionally for producing olefins and/or solvents. In one embodiment, the method comprises aromatizing at least a portion of a synthetic naphtha stream to produce an aromatized hydrocarbon stream; and isomerizing at least a portion of the aromatized hydrocarbon stream to produce an isomerized aromatized hydrocarbon stream having a higher octane rating than the synthetic naphtha stream. Alternatively, the method comprises providing at least three synthetic naphtha cuts comprising a C4-C5 stream; a C6-C8 stream and a C9-C11 stream; aromatizing some of the C6-C8 stream to form an aromatized hydrocarbon stream with a higher octane number; steam cracking some of the C6-C8 stream and optionally the C9-C11 stream to form olefins; and selling some portions of C9-C11 stream as solvents. In preferred embodiments, the synthetic naphtha is derived from Fischer-Tropsch synthesis.

Abstract: The invention relates to methods and apparatus for mixing a plurality of gases. The preferred embodiments of the invention comprise forming bubbles of at least two gases injected separately into a liquid, and passing said bubbles through a gas-induced turbulent liquid region to enhance gas transfer between bubbles and to thereby mix the at least two gases. Creating the gas-induced turbulent liquid region preferably includes using a high gas superficial velocity, and may further include using powered mechanical devices, static internal structures, fluid recirculation, or combinations thereof. The gas mixture is preferably supplied to a reaction zone. In one embodiment a bubble tank mixer supplies a gas mixture comprising oxygen and a hydrocarbon gas to an oxidation reaction zone disposed above said mixer. In alternative embodiments the reaction zone and mixer may be integrated into the same vessel.

Abstract: 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.

Abstract: An apparatus and method is disclosed for producing alcohols, particularly methanol, according to an alcohol synthesis process. The apparatus comprises a catalytic distillation reactor where reactants are fed into the catalytic distillation reactor to undergo catalytic reaction to form methanol. Methanol production beyond the thermodynamic limit is achieved in the apparatus through use of multiple distillation stages, preferably at least three.

Abstract: Methods for producing clean liquid/wax products from a slurry used in a Fischer-Tropsch reactor are disclosed. In general, one embodiment of the present invention comprises a solid/liquid filtration system having a filter medium comprising a substrate and a filter cake deposited on the substrate, wherein the filter cake is generated by deposition of solids from the slurry. The thickness of the filter cake can be maintained within a desired range by controlling the slurry velocity and/or the pressure differential across the filter medium. This invention relates to a method of operation of such filtration system which increases filtration cycle time and improved filtrate quality resulting in very low solid content in filtrate.

Abstract: A hydrogen permselective membrane, a method of forming a permselective membrane and an apparatus comprising a permselective membrane, a porous substrate and an optional intermediate layer are described. Using chemical vapor deposition (CVD) at low reactant gas concentration, high permselectivities are achieved with minimal reduction in hydrogen permeance.

Abstract: he present invention provides a process for natural gas in the form, e.g., of stranded gas or associated gas to transportable liquids. More particularly, the present invention provides a process in which the gas is non-oxidatively converted to aromatic liquid, preferably in proximity to the wellhead, which may be onshore or offshore. In one aspect, the present invention provides integration of separation of wellhead fluids into associated gas and crude with blending of the aromatic liquid derived from the gas with the crude. Alternatively, or in combination, in another aspect, the present invention provides integration of conversion of byproduct hydrogen to power with non-oxidative conversion of gas to aromatic liquid.

Abstract: The present invention features a system and method for circulating catalyst between a reactor system and a regenerator system. A circulating catalyst system includes a reactor system, a regenerator system, and a distribution unit. The reactor system and regenerator system are adapted to exchange catalyst. The regeneration system preferably includes a regeneration zone adapted for the contact of catalyst with a regeneration gas. The system and method are adapted so that more than one regeneration gas may contact catalyst. The distribution unit is adapted to control the percentage of catalyst contacting each regeneration gas. Thus, the distribution unit is adapted to select the percentages so as to maintain the reactor system and regeneration system under a heat balance regime. Heat is preferably transferred from the regenerator system to the reactor system by an exchange of catalyst.

Abstract: An apparatus and method is disclosed for producing alcohols, particularly methanol, according to an alcohol synthesis process. The apparatus comprises a catalytic distillation reactor where reactants are fed into the catalytic distillation reactor to undergo catalytic reaction to form methanol. Methanol production beyond the thermodynamic limit is achieved in the apparatus through use of multiple distillation stages, preferably at least three.