Abstract: A method and apparatus for converting a hydrocarbon and oxygen containing gas feed stream to a product stream, such as syngas, including catalytically partially oxidizing the hydrocarbon feed stream over a catalyst bed. The catalyst bed has a downstream zone which is less resistant to flow than the upstream zone.

Abstract: A method of partially oxidizing a feed gas comprises providing a reactor containing a catalyst, providing a gas distributor comprising a body having a plurality of channels therethrough and a plurality of outlets from said channels for distributing gas across the catalyst, feeding the feed gas and the oxygen-containing gas into the gas distributor and allowing the feed gas and the oxygen-containing gas to flow through the gas distributor and out through the outlets into contact with the catalyst. The gas distributor preferably comprises a micro-channel gas distributor, which can be assembled by providing a plurality of etched plates defining flow channels, and stacking and fusing the plates. The reactant gases can be mixed within the gas distributor or maintained separately until they have exited the gas distributor.

Abstract: Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and H2 and, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500° C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Abstract: Disclosed herein are methods and apparatuses for cogenerating organic compounds (e.g., benzene, toluene, xylene, formate, acetate, propionate, butyrate, C1-C4 acids, C1-C4 alcohols, methanol, naphthalene, acenaphthylene, fluorene, phenanthrene, anthracene, fluoranthene, and pyrene) along with synthesis gas in a synthesis gas reactor, preferably a catalytic partial oxidation reactor.

Abstract: A pretreatment method for increasing the average pore size of a catalyst support is disclosed which increases the diffusivity and effectiveness factor ?. The pretreatment method includes calcining the support in moisturized air at an elevated temperature sufficient to increase the average pore size. In some embodiments, the support may be treated with an acidic/basic solution prior to the calcination step. Alternatively, the calcination step may occur in a gas mixture including water/air/acidic (or basic) gases.

Abstract: Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and O2 is passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.

Abstract: Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Abstract: A method and apparatus for converting a hydrocarbon and oxygen containing gas feed stream to a product stream, such as syngas, including catalytically partially oxidizing the hydrocarbon feed stream over a catalyst bed. The catalyst bed has a downstream section which is less resistant to flow than the upstream section.

Abstract: Disclosed herein are methods and apparatuses for cogenerating organic compounds (e.g., benzene, toluene, xylene, formate, acetate, propionate, butyrate, C1-C4 acids, C1-C4 alcohols, methanol, naphthalene, acenaphthylene, fluorene, phenanthrene, anthracene, fluoranthene, and pyrene) along with synthesis gas in a synthesis gas reactor, preferably a catalytic partial oxidation reactor.

Abstract: A submicron-particle-enhanced catalyst and method for its making are disclosed. The catalyst comprises <1 micron diameter particles distributed over the surface of a monolith or divided carrier to provide a high surface area catalyst having highly dispersed catalytic active sites available for catalyzing fast chemical reactions at short contact time and high space time yield. A syngas production method carried out in a short contact time reactor is disclosed in which a gaseous stream of light hydrocarbon and O2 is passed over a submicron-particle-enhanced catalyst to produce a mixture of carbon monoxide and hydrogen.

Abstract: The present invention includes methods and apparatus for start-up a chemical reactor wherein at least a portion of the igniter is downstream from the reaction zone which needs to be ignited. Particularly, embodiments of the present invention include a partial oxidation reactor with an igniter downstream of the partial oxidation zone.

Abstract: A method of partially oxidizing a feed gas comprises providing a reactor containing a catalyst, providing a gas distributor comprising a body having a plurality of channels therethrough and a plurality of outlets from said channels for distributing gas across the catalyst, feeding the feed gas and the oxygen-containing gas into the gas distributor and allowing the feed gas and the oxygen-containing gas to flow through the gas distributor and out through the outlets into contact with the catalyst. The gas distributor preferably comprises a micro-channel gas distributor, which can be assembled by providing a plurality of etched plates defining flow channels, and stacking and fusing the plates. The reactant gases can be mixed within the gas distributor or maintained separately until they have exited the gas distributor.

Abstract: Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Abstract: Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and H2 and, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500° C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Abstract: A method and apparatus for converting a hydrocarbon and oxygen containing gas feed stream to a product stream, such as syngas, including catalytically partially oxidizing the hydrocarbon feed stream over a catalyst bed. The catalyst bed has a downstream section which is less resistant to flow than the upstream section.

Abstract: A process is disclosed for the hydrogenation of carbon monoxide. The process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream, preferably comprising hydrocarbons. The catalyst used in the process is in the form of a sponge. The process is preferably adapted to produce hydrocarbons suitable for the production of diesel fuel. The catalyst used in the process includes at least one catalytic metal for Fischer-Tropsch reactions, preferably cobalt. Preferably the catalyst further includes at least one promoter suitable for the Fischer-Tropsch reaction, such as at least one element selected from among Groups 2-15 of the Periodic Table, preferably at lease one of chromium, iron, molybdenum, nickel, palladium, platinum, rhenium, rhodium, ruthenium, and combinations thereof.

Abstract: Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and O2 is passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.