Abstract: Gas-liquid separation comprising a) feeding a product stream comprising a mixture of liquid and gaseous hydrocarbon products and water vapour; b) collecting the first liquid at a liquid outlet of the first vapour-liquid separator; c) discharging the first gas stream from a gas outlet of the first vapour-liquid separator; d) feeding the first cooled mixture from the first cooler into a second vapour-liquid separator; e) collecting the second liquid at a liquid outlet of the second vapour-liquid separator; f) discharging the second gas stream from a gas outlet of the second vapour-liquid separator; g) feeding the second gas stream from the gas outlet of the second vapour-liquid separator through a second cooler, h) feeding the second cooled mixture from the second cooler into a third vapour-liquid separator; i) collecting the third liquid at a liquid outlet; and j) discharging the third gas stream from a gas outlet.

Abstract: Some embodiments are directed toward a method of removing a catalyst carrier engaged in a reactor tube of a tubular reactor. The method can include inserting a retrieval tool through an open end of the reactor tube and extending the retrieval tool along the reactor tube to contact and engage the catalyst carrier; and subsequently applying a force to the retrieval tool to attempt to dislodge the catalyst carrier and displace the catalyst carrier towards the open end of the reactor tube. The retrieval tool can include a head portion including a plurality of sprung-mounted arms, a handle portion, and an elongate body extending between the head portion and the handle portion. Engaging the retrieval tool with the catalyst carrier can include engaging the sprung-mounted arms of the head portion with one or more features formed in the catalyst carrier.

Abstract: A conveyor, a system and a method for controlled discharge of a stack of components from a tube, the conveyor comprising: i) a frame configured to be located in proximity to an outlet of the tube; and ii) a plurality of feed elements mounted to the frame. The feed elements being distributed around and along a feed path that extends through the frame so as to contact, in use, components passing through the frame along the feed path. One or more of the feed elements comprise a tensioning mechanism for adjusting a level of friction between said one or more of the feed elements and the components passing through the frame along the feed path.

Abstract: A method of installing a thermocouple in a reactor tube of a tubular reactor, comprising lowering a weighted tow line through a stack of catalyst carriers and using a tow line to pull the thermocouple down the reactor tube through inner channels of the stack of catalyst carriers into a desired installation position.

Abstract: A method of passivating a Fischer-Tropsch catalyst in a catalyst carrier disposed within a Fischer-Tropsch reactor, the method comprising: providing a Fischer-Tropsch catalyst in a catalyst carrier disposed within a Fischer-Tropsch reactor, the Fischer-Tropsch reactor having an inlet and an outlet, the Fischer-Tropsch catalyst having hydrocarbons on its surface; contacting the Fischer-Tropsch catalyst with a gas, the gas passed into the inlet having a first oxygen content; and while maintaining the flow of gas: adjusting the temperature of the Fischer-Tropsch catalyst to strip hydrocarbons from the surface of the Fischer-Tropsch catalyst; removing stripped hydrocarbons from the catalyst carrier and the Fischer-Tropsch reactor; adjusting the temperature of the Fischer-Tropsch catalyst; increasing the oxygen content of the gas; cooling the catalyst; and increasing the oxygen content of the gas passed to the inlet, wherein: the gas passed into the inlet having the first oxygen content is an inert.

Abstract: A catalyst carrier for insertion into a reactor tube of a tubular reactor comprises a container for holding catalyst and a seal for sealing between the container and the reactor tube. The seal comprises at least a first seal layer and a second seal layer each comprising a plurality of deflectable tongues separated by notches. The second seal layer is rotationally offset relative to the first seal layer such that the notches of the second seal layer are aligned with the deflectable tongues of the first seal layer.

Abstract: A catalyst carrier for insertion into a reactor tube of a tubular reactor that comprises a container containing particles of catalyst. The container further contains a compacting element for reducing fluidisation of the particles of catalyst.

Abstract: A chemical reactor system comprising: a) a main reactor comprising: i) a reaction chamber containing catalyst, ii) an inlet for feeding feedstock gas from a feedstock source into the reaction chamber to contact the catalyst, and iii) an output for reaction products produced in the reaction chamber from reaction of the feedstock gas in the presence of the catalyst; and b) a reaction testing module comprising: i) an inlet configured to receive feedstock gas from the same feedstock source supplying feedstock gas to the main reactor, and ii) at least one test reactor in fluid communication with the inlet and each comprising a reaction chamber containing catalyst, wherein the main reactor is a Fischer Tropsch reactor containing a Fischer Tropsch catalyst.

Abstract: A method is described for shutting down a Fischer-Tropsch reactor fed with a reactant gas mixture comprising a synthesis gas and a recycle gas recovered from the Fischer-Tropsch reactor in a synthesis loop, said Fischer-Tropsch reactor containing a Fischer-Tropsch catalyst cooled indirectly by a coolant under pressure, comprising the steps of: (a) depressurising the coolant to cool the reactant gas mixture to quench Fischer-Tropsch reactions taking place in the Fischer-Tropsch reactor, (b) stopping the synthesis gas feed to the Fischer-Tropsch reactor, and (c) maintaining circulation of the recycle gas through the Fischer-Tropsch reactor during steps (a) and (b) to remove heat from the Fischer-Tropsch reactor. The method safely facilitates a more rapid return to operating conditions than a full shut-down.

Abstract: A method of tracking use of catalyst carriers within a tubular reactor, the tubular reactor comprising a plurality of reactor tubes, each reactor tube being configured to receive a plurality of catalyst carriers, the method comprising for each of at least some of the catalyst carriers, the steps of: —marking the catalyst carrier with a carrier identifier; —reading the carrier identifier when installing the catalyst carrier into a reactor tube; and —accessing a database to retrieve and/or record installation data associated with the identified catalyst carrier.

Abstract: A method of operating a tubular reactor, the method comprising, for at least some of the reactor tubes, the steps of: a) connecting together two or more catalyst carriers to form a linked set; b) installing into the reactor tube the linked set and an additional plurality of catalyst carriers that are unconnected to the linked set so that the linked set and the additional plurality of catalyst carriers extend at least partway between an inlet end of the reactor tube and an outlet end of the reactor tube, with the linked set being proximate the inlet end; c) operating the tubular reactor to pass one or more reactants through the reactor tube from the inlet end to the outlet end; and d) subsequently, withdrawing the linked set from the inlet end of the reactor tube while retaining the additional plurality of catalyst carriers within the reactor tube.

Abstract: Gas-liquid separation comprising a) feeding a product stream comprising a mixture of liquid and gaseous hydrocarbon products and water vapour; b) collecting the first liquid at a liquid outlet of the first vapour-liquid separator; c) discharging the first gas stream from a gas outlet of the first vapour-liquid separator; d) feeding the first cooled mixture from the first cooler into a second vapour-liquid separator; e) collecting the second liquid at a liquid outlet of the second vapour-liquid separator; f) discharging the second gas stream from a gas outlet of the second vapour-liquid separator; g) feeding the second gas stream from the gas outlet of the second vapour-liquid separator through a second cooler; h) feeding the second cooled mixture from the second cooler into a third vapour-liquid separator; i) collecting the third liquid at a liquid outlet; and j) discharging the third gas stream from a gas outlet.

Abstract: The present disclosure relates generally to processes for initiating Fischer-Tropsch synthesis. In particular, the application concerns a process for the initiation of Fischer-Tropsch synthesis, the process comprising: (i) providing the reaction zone with a temperature of no more than 140° C.; then (ii) purging the reaction zone with a purge gas comprising N2 at a pressure in the range of 2 barg to 10 barg; then (iii) contacting the catalyst in the reaction zone with a gaseous reaction mixture comprising H2 and CO in a ratio of between 1:1 and 3:1 at a pressure of no more than 20 barg and at a temperature of no more than 140° C.; then (iv) heating the reaction zone to a temperature of at least 200° C.; and (v) pressurizing the reaction zone to a pressure in the range of 30 barg and 45 barg.

Abstract: The present disclosure relates generally to processes for activating Fischer-Tropsch synthesis catalysts. In particular, the application concerns a process for the activation of a Fischer-Tropsch synthesis catalyst, the process comprising: (i) contacting the catalyst with a first gaseous composition comprising at least 80% N2 at a pressure in the range of 2 barg to 20 barg at a temperature of no more than 150° C.; (ii) contacting the catalyst with a second gaseous composition comprising at least 80% H2 to form a H2/N2 gaseous composition with a H2:N2 molar ratio in the range of 0.2:1 to 2:1, resulting in a pressure in the range of 10 barg to 30 barg; (iii) increasing the temperature to a range of 220° C. to 260° C.; (iv) maintaining the catalyst at the conditions of step (iii) for a hold period in the range of 2 hr to 96 hr.

Abstract: A method is described for shutting down a Fischer-Tropsch reactor fed with a reactant gas mixture comprising a synthesis gas and a recycle gas recovered from the Fischer-Tropsch reactor in a synthesis loop, said Fischer-Tropsch reactor containing a Fischer-Tropsch catalyst cooled indirectly by a coolant under pressure, comprising the steps of: (a) depressurising the coolant to cool the reactant gas mixture to quench Fischer-Tropsch reactions taking place in the Fischer-Tropsch reactor, (b) stopping the synthesis gas feed to the Fischer-Tropsch reactor, and (c) maintaining circulation of the recycle gas through the Fischer-Tropsch reactor during steps (a) and (b) to remove heat from the Fischer-Tropsch reactor. The method safely facilitates a more rapid return to operating conditions than a full shut-down.

Abstract: A catalyst carrier for insertion into a reactor tube of a tubular reactor comprises a container for holding catalyst and a seal for sealing between the container and the reactor tube. The seal comprises at least a first seal layer and a second seal layer each comprising a plurality of deflectable tongues separated by notches. The second seal layer is rotationally offset relative to the first seal layer such that the notches of the second seal layer are aligned with the deflectable tongues of the first seal layer.

Abstract: A catalyst carrier for insertion into a reactor tube of a tubular reactor that comprises a container containing particles of catalyst. The container further contains a compacting element for reducing fluidisation of the particles of catalyst.

Abstract: A method of installing a thermocouple in a reactor tube of a tubular reactor, comprising lowering a weighted tow line through a stack of catalyst carriers and using a tow line to pull the thermocouple down the reactor tube through inner channels of the stack of catalyst carriers into a desired installation position.

Abstract: Process for converting synthesis gas to hydrocarbons in a slurry reactor in the presence of a Fischer-Tropsch catalyst comprising cobalt and zinc oxide. The process is carried out by a) activating the Fischer-Tropsch catalyst with a reducing gas consisting of hydrogen and an inert gas at a temperature between 330 and 400° C., and b) contacting the activated Fischer-Tropsch catalyst from step a) with synthesis gas in the slurry reactor in order to convert the synthesis gas into hydrocarbons.

Abstract: The present invention relates to a process for converting synthesis gas to hydrocarbons, in particular to hydrocarbons in the C5-C60 range particularly suitable for use as liquid motor fuels, in a slurry reactor in the presence of a Fischer-Tropsch catalyst comprising cobalt and zinc oxide wherein the Fischer-Tropsch catalyst is activated with a reducing gas consisting of hydrogen and an inert gas at 330 to 400° C. prior to contact with synthesis gas in the slurry reactor.