Abstract: A method for generating syngas having a H2:CO ratio of less than 2:1 including selecting a predetermined desired syngas H2:CO molar ratio, selecting a hydrocarbon with a natural H2:CO molar ratio less than the desired ratio, selecting a hydrocarbon with a natural H2:CO molar ratio greater than the desired ratio, mixing the two hydrocarbons such that the natural H2:CO molar ratio of the mixture is the desired ratio, and catalytically partially oxidizing the mixture to produce syngas with the desired ratio.

Abstract: A process and catalyst are disclosed for reducing coking in hydrocarbon processing reactions. The preferred embodiments employ a sulfur-containing material such as hydrogen sulfide to reduce catalyst susceptibility to deactivation from carbon deposits formed during processing.

Abstract: A method for the recovery of rhodium from spent supported catalysts. In one embodiment, a method for recovering rhodium from a host material includes roasting the host material in air at a temperature sufficient to convert at least a portion of rhodium to Rh2O3, leaching the host material in a solution with a leaching constituent which is reactive with Rh2O3 to form a first intermediate species, reacting the first intermediate species in a solution with an acidifying constituent or complexing agent to form a second intermediate species, and purifying the second intermediate species. Preferably, the roasting temperature is approximately from 600° C. to 800° C. for 0.5 to 10 hours. In some embodiments, the host material is ground to particles in the range of 0.1 to 10 mm.

Abstract: A process is presented for separating and removing acid gases or base gases from an acid feed gas or a base feed gas, respectively, by use of a gas permeable membrane and caustic or acidic solution. In particular, the process utilizes a caustic or an acidic solution, separated from the base feed gas or acid feed gas by a gas permeable membrane, to react with the base gases, such as, for example, ammonia (NH3), or acid gases, such as, for example, hydrogen cyanide (HCN), hydrogen sulfide (H2S), carbon dioxide (CO2), carbon oxysulfide (COS) and oxides of nitrogen (NOx), to form salts, thereby facilitating the removal of said base gas or said acid gas from the base feed gas or acid feed gas, respectively. In another aspect of the present invention is presented an apparatus for treating a feed gas containing an acid or a base gas wherein the apparatus comprises a feed gas passage; a treatment solution container containing a treatment solution; and a gas permeable membrane.

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 system in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream, preferably comprising hydrocarbons. In accordance with this invention the catalyst system used in the process includes at least one catalytic material for Fischer-Tropsch reactions (e.g., iron, cobalt, nickel and/or ruthenium), preferably comprising cobalt, and a support comprising aluminum borate. The catalyst system can be prepared by impregnating alumina with a boron-containing composition to form an aluminum borate support and applying a Fischer-Tropsch catalytically active material to the aluminum borate to form a supported catalyst 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: A catalyst useful for the production of olefins from alkanes via oxidative dehydrogenation (ODH) is disclosed. In accordance with a preferred embodiment of the present invention, a catalyst for use in ODH processes includes a MCrAlY support. M is preferably a base metal, or combination of base metals. A base metal is herein defined as a non-Group VIII metal, with the exception of iron, cobalt and nickel. Suitable base metals include Group IB-VIIB metals, Group IIIA-VA metals, Lanthanide metals, iron, cobalt and nickel. In a preferred embodiment, M is iron. Additionally, the catalyst may optionally include a Group VIII promoter. Suitable Group VIII promoters include Ru, Rh, Pd, Os, Ir, and Pt. In another preferred embodiment, M is a combination of a Lanthanide metal and iron with a front-loaded Group VIII promoter.

Abstract: Catalysts and methods useful for the production of olefins from alkanes via oxidative dehydrogenation (ODH) are disclosed. The ODH catalysts include a base metal selected from the group consisting of lanthanide metals, their oxides, and combinations thereof. The base metal is more preferably selected from the group consisting of samarium, cerium, praseodymium, terbium, their corresponding oxides and combinations thereof. The base metal loading is preferably between about 0.5 and about 20 weight percent and more preferably between about 2 and about 10 weight percent. Optionally, the ODH catalysts are further comprised of a Group VIII promoter metal present at trace levels. The Group VIII promoter metal is preferably platinum, palladium or a combination thereof and is preferably present at a promoter metal loading of between about 0.005 and about 0.1 weight percent. Optionally, the ODH catalyst is supported on a refractory support.

Abstract: Catalysts and methods useful for the production of olefins from alkanes via oxidative dehydrogenation (ODH) are disclosed. The ODH catalysts are comprised of a Group VIII promoter metal present at trace levels. The Group VIII promoter metal is preferably platinum, palladium or a combination thereof and is preferably present at a promoter metal loading of between about 0.005 and about 0.1 weight percent. Optionally, the ODH catalysts include a base metal, metal oxide, or combination thereof. The optional base metal is selected from the group consisting of Group IB-IIB metals, Group IVB-VIIB metals, Group IIA-VA metals, scandium, yttrium, actinium, iron, cobalt, nickel, their oxides, and combinations thereof. The base metal is more preferably selected from the group consisting copper, tin, chromium, gold, manganese and their respective oxides and any combinations thereof. The base metal loading is preferably between about 0.5 and about 10 weight percent.

Abstract: The present invention includes a process for producing carbon filaments and synthesis gas from a mixture of alkanes, preferably natural gas, comprising converting a first portion of the alkanes, preferably C2+ hydrocarbons, directly to carbon filaments and converting a second portion of the alkanes, preferably methane, to syngas. The natural gas may be separated into a first feed stream comprising ethane, propane, and butane and a second feed stream comprising methane. The first feed stream is fed to a carbon filament CF reactor to produce carbon filaments and hydrogen. The second feed stream is fed to a syngas production reactor to produce syngas. Alternatively, the natural gas is fed to at least one carbon filament reactor that is maintained at an effective temperature to convert C2+ hydrocarbons in the natural gas to carbon filaments and hydrogen, thereby filtering methane from the natural gas.

Abstract: A method for generating syngas having a H2:CO ratio of less than 2:1 including selecting a predetermined desired syngas H2:CO molar ratio, selecting a hydrocarbon with a natural H2:CO molar ratio less than the desired ratio, selecting a hydrocarbon with a natural H2:CO molar ratio greater than the desired ratio, mixing the two hydrocarbons such that the natural H2:CO molar ratio of the mixture is the desired ratio, and catalytically partially oxidizing the mixture to produce syngas with the desired ratio.

Abstract: A catalyst system and process for use in ODH that allows high conversion of hydrocarbon feedstock at high gas velocities, while maintaining high selectivity of the process to the desired products. In accordance with a preferred embodiment, a catalyst for use in ODH processes includes a dehydrogenative catalytically active component and an oxidative catalytically active component. The catalyst preferably has the general formula &agr;AOx-&bgr;BOy-&ggr;COz, wherein A is a precious metal and/or transition metal, B is a rare earth metal, C is an element chosen from Groups IIA, IIIA, and IVA, and O is oxygen. In accordance with another preferred embodiment, a method for converting gaseous hydrocarbons to olefins includes reacting an alkane feed stream with an oxidized bifunctional catalyst in a riser reactor to produce product vapors containing olefins and paraffins and a reduced catalyst.

Abstract: A method for the recovery of rhodium from spent supported catalysts. In one embodiment, a method for recovering rhodium from a host material includes roasting the host material in air at a temperature sufficient to convert at least a portion of rhodium to Rh2O3, leaching the host material in a solution with a leaching constituent which is reactive with Rh2O3 to form a first intermediate species, reacting the first intermediate species in a solution with an acidifying constituent or complexing agent to form a second intermediate species, and purifying the second intermediate species. Preferably, the roasting temperature is approximately from 600° C. to 800° C. for 0.5 to 10 hours. In some embodiments, the host material is ground to particles in the range of 0.1 to 10 mm.

Abstract: A catalyst useful for the production of olefins from alkanes via oxidative dehydrogenation (ODH) is disclosed. In accordance with a preferred embodiment of the present invention, a catalyst for use in ODH processes includes a base metal, a promoter metal, and a support comprising a plurality of discrete structures. A base metal is herein defined as a non-Group VIII metal, with the exception of iron, cobalt and nickel. Suitable base metals include Group IB-VIIB metals, Group IIIA-VA metals, Lanthanide metals, iron, cobalt and nickel. Suitable promoter metals include Group VIII metals (i.e. platinum, palladium, ruthenium, rhodium, osmium, and iridium). In some embodiments the support is fabricated from a refractory material. Suitable refractory support materials include alumina, stabilized aluminas, zirconia, stabilized zirconias (PSZ), titania, yttria, silica, niobia, and vanadia.

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: Catalysts with silica-encapsulated magnetic supports are disclosed, along with their manner of making and process for separating them from a product stream in a reactor. A preferred catalyst comprises a catalytically active metal, preferably cobalt, and appropriate promoters, a magnetic support, preferably comprising magnetite, and an encapsulating material, preferably silica, encapsulating the magnetic support.

Abstract: A process and catalyst are disclosed for the catalytic partial oxidation of light hydrocarbons to produce synthesis gas at superatmospheric pressures. A preferred catalyst used in the process includes a nickel-magnesium oxide solid solution and at least one promoter chosen from Cr, Mn, Mo, W, Sn, Re, Rh, Ru, Ir, Pt, La, Ce, Sm, Yb, Lu, Bi, Sb, In and P, and oxides thereof, carried on a refractory support.

Abstract: A method for producing small spherical particles that are especially useful as catalysts and catalyst supports employed in chemical processes is disclosed. According to some embodiments, the method includes impregnating a porous support with a metal or metal oxide and dissolving the support to release spherical particles. In certain embodiments the support that is employed in the method comprises a number of spherical voids which determine the size of the spherical particles, and preferably have micrometer range diameters. One embodiment of an attrition resistant Fischer-Tropsch catalyst comprises a plurality of micrometer size spherical metal and/or metal oxide particles that are prepared according to the above-described method.

Abstract: A method for water removal in hydrocarbon product reactors operating at Fischer-Tropsch conditions. The water removal decreases the concentration of water in the reactor. In one embodiment, a method of reducing the concentration of water in a Fischer-Tropsch reactor containing a water-rich hydrocarbon product includes removing water from the water-rich hydrocarbon product of the reactor by a water removal means so as to form a water-reduced hydrocarbon product and returning that product to the reactor.

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.