Abstract: A process and apparatus are described for converting a feed that is substantially comprised of halogenated materials, and especially byproduct and waste chlorinated hydrocarbons as are produced from a variety of chemical manufacturing processes, to one or more higher value products via a partial oxidation reforming reaction step. These products can be in the form of a useful or salable acid product and/or a product synthesis gas comprised of carbon monoxide and hydrogen, or the reaction product including the same hydrogen halide, carbon monoxide and hydrogen components can be employed as a feed in the synthesis of a different useful or salable product.

Abstract: A process for producing vinyl chloride monomer from ethylene and ethane having input of significant quantities of both ethane and ethylene in input streams to the affiliated reactor where hydrogen chloride in the reactor effluent is only partially recovered from the reactor effluent in the first unit operation after the ethane/ethylene-to-vinyl reaction step or stage. Steps are presented of oxydehydro-chlorination catalytic reaction of ethane, ethylene, hydrogen chloride, oxygen, and chlorine; cooling and condensing the reactor effluent stream; and separating the condensed raw product stream into vinyl chloride monomer and a reactor recycle stream.

Abstract: A process for producing vinyl chloride monomer where significant quantities of both ethane and ethylene in input streams to the affiliated reactor where hydrogen chloride in the reactor effluent is essentially fully recovered from the reactor effluent in the first unit operation after the ethane/ethylene-to-vinyl reaction step or stage. Steps are presented of oxydehydro-chlorination catalytic reaction of ethane, ethylene, hydrogen chloride, oxygen, and chlorine; quenching the reactor effluent stream to provide a raw product stream having essentially no hydrogen chloride; and separation of the raw product stream into a vinyl chloride monomer product stream and into a lights stream; and recycling the lights steam to the reactor.

Abstract: In one aspect, a process for producing vinyl chloride from ethane/ethylene involving: (a) combining ethane, ethylene, or mixtures thereof with an oxygen source and a chlorine source in a reactor containing a suitable catalyst under conditions sufficient to convert substantially all of the C2 hydrocarbon fed and to produce a product stream comprising vinyl chloride and hydrogen chloride; and (b) recycling unreacted hydrogen chloride back for use in Step (a). No C2 hydrocarbon recycle is required in this process. In another aspect, a process for producing vinyl chloride involving: (a) combining ethane, optionally ethylene, an oxygen source, and a chlorine source in a reactor containing a suitable catalyst under conditions sufficient to produce vinyl chloride and hydrogen chloride; (b) catalytically reacting said hydrogen chloride in a second reactor to provide a second reactor effluent essentially devoid of hydrogen chloride; and (c) recycling said second reactor effluent to step (a).

Abstract: Methods for improving a gasification process for halogenated materials and in particular for producing useful end products such as anhydrous or highly concentrated hydrogen halides and/or synthesis gas, the methods including recycling water/hydrogen halide vapors and/or carbon dioxide to a gasification reactor.

Abstract: A process and apparatus are described for converting a feed that is substantially comprised of halogenated materials, and especially byproduct and waste chlorinated hydrocarbons as are produced from a variety of chemical manufacturing processes, to one or more higher value products via a partial oxidation reforming reaction step. These products can be in the form of a useful or salable acid product and/or a product synthesis gas comprised of carbon monoxide and hydrogen, or the reaction product including the same hydrogen halide, carbon monoxide and hydrogen components can be employed as a feed in the synthesis of a different useful or salable product.

Abstract: A transition metal carbide (e.g., WC) is prepared by the following steps. A carbon-precursor mixture is formed by mixing a precursor comprised of (i) a transition metal oxide (e.g., WO.sub.x) and (ii) a material selected from the group consisting of: a transition metal (e.g., W); a transition metal carbide (e.g., WC) and a substoichiometric carbide (W.sub.2 C), in the presence of a source of carbon (e.g., carbon black) in an amount sufficient to form a reduced mixture comprised of the transition metal carbide and substoichiometric transition metal carbide, wherein the amount of the transition metal oxide and transition metal is essentially zero in said reduced mixture. The carbon-precursor mixture is heated in a reducing atmosphere (e.g., 5 percent hydrogen in argon) to a reducing temperature and for a time sufficient to produce the reduced mixture.

Abstract: Carbothermally reduce a metal oxide to its corresponding metal nitride or metal carbide powder in a vertical gravity flow reactor by adding precursor pellets containing the metal oxide, a thermally decomposed binder material and carbon or a source of carbon directly to a heated reaction zone within the reactor. The pellets form a pellet bed, the top of which must be maintained within the heated reaction zone. The binder material is a blend of wheat and corn starches, optionally in conjunction with another binder such as melamine. The binder material thermally decomposes to a carbonaceous residue which functions both as an additional source of carbon and as a binder for the precursor pellets. The reactor may be modified by adding an internal vent line to remove volatile materials from the heated reaction zone before they have an opportunity to condense on internal reactor surfaces.

Abstract: A method for making submicrometer metallic carbides and submicrometer solid solution metallic carbides from sources of at least one metallic oxide and carbon involves the rapid heating of a reactive particulate mixture of at least one metallic oxide and carbon in order to achieve a resulting particulate size of less than 1 micrometer. Submicrometer sized metallic carbides and solid solution metallic carbides have found great use in commercial ceramic applications. It has been found that the smaller sized particles produce a product having superior toughness and hardness. In addition, the submicrometer sized solid solution metallic carbide resulting from this method is also disclosed.

Abstract: Carbothermally reduce a metal oxide to its corresponding metal nitride or metal carbide powder in a vertical gravity flow reactor by adding precursor pellets containing the metal oxide, a thermally decomposed binder material and carbon or a source of carbon directly to a heated reaction zone within the reactor. The pellets form a pellet bed, the top of which must be maintained within the heated reaction zone. The binder material is a blend of wheat and corn starches, optionally in conjunction with another binder such as melamine. The binder material thermally decomposes to a carbonaceous residue which functions both as an additional source of carbon and as a binder for the precursor pellets. The reactor may be modified by adding an internal vent line to remove volatile materials from the heated reaction zone before they have an opportunity to condense on internal reactor surfaces.

Abstract: Rapidly heat powdered aluminum, an admixture of powdered aluminum and a compatible solid material, a powdered admixture of alumina and carbon, or aluminum nitride powder having a surface area lower than desired in the presence of a source of nitrogen at a temperature of 2473 to 3073K to produce aluminum nitride, then promptly quench the aluminum nitride product. The product has a surface area of greater than 10 m.sup.2 /g, preferably greater than 15 m.sup.2 /g.

Abstract: A process for preparing silicon carbide by carbothermal reduction which includes transporting, in a gaseous medium, a particulate reactive mixture of a silica source and a carbon source through a reaction zone. The heating rate of the atmosphere within the reaction zone is such that substantially all of the reactive mixture is heated at a heating rate of at least about 100.degree. C./second until an elevated temperature of at least 1800.degree. C. is reached. Either (1) carbon monoxide is added to the reaction zone or (2) a carbon monoxide level in the reaction is achieved in order to provide at least about 30 mole percent of the gases exiting the reaction zone to achieve a higher yield of silicon carbide.

Abstract: Rapidly heat powdered aluminum in the presence of a source of nitrogen at a temperature of 1873 to 2373 K. to produce aluminum nitride, then promptly quench the aluminum nitride product. The product has a surface area between 2 and 8 square meters per gram and an oxygen content of less than 1.2 weight percent.

Abstract: A two-stage upflow process for coal gasification and an apparatus useful therefor. An oxygen-containing gas and a first increment of a coal-in-water slurry are ignited in a horizontal fired slagging reactor by means of horizontal coaxial juxtaposed burner nozzles mounted in the reactor, thereby converting the oxygen, the coal, and the water into steam and gaseous combustion products. The discharge from the fired reactor is contacted overhead with a second increment of coal-water slurry in a vertical unfired heat-recovery unit connected to the upper end of the reactor. The heat evolved in the reactor is used in the heat recovery unit to convert the second increment of coal-water slurry into more steam, char and synthesis gas. The gas effluent is separated from the solid char, and synthesis gas is passed into a fire-tube boiler to recover heat and the cooled product gas is recovered as the desired fuel-rich product. The solid char is reslurried and recycled to the fired reactor 3 for further combustion.