Abstract: A cobalt containing catalyst supported on a metal oxide suitable for performing a Fischer-Tropsch reaction. A pore volume of a metal oxide support, before loading of cobalt thereon, is within the range of 0.35 to 0.6 cc/g. The support has an average pore diameter before the cobalt loading and reduction such that the effective average pore diameter after cobalt loading and reduction is 14 nanometers or higher. A cobalt loading of 11 weight % or higher is also provided. An alpha value higher than 0.89 in a diesel to wax weight ratio below 1.07 is provided.

Abstract: A process for converting carbonaceous materials or light hydrocarbon gases into products comprising predominately C5+ hydrocarbons. The process converts the feedstock into synthesis gas comprising hydrogen and carbon monoxide and then uses the Fischer-Tropsch reaction to produce heavy hydrocarbons. A small excess of hydrogen is produced in the syngas generator or by water gas shift for use in product upgrading and for blending with Fischer-Tropsch tail gas for recycle back to syngas generation. A portion of the Fischer-Tropsch tail gas is used as fuel, thus purging combustible light gases and CO2 from the tail gas. Hydrogen rich purge gas is blended into the remaining tail gas resulting in a recycle stream that is returned to the syngas generator. The tail gas components are therefore efficiently used to produce more products.

Abstract: A process to convert light hydrocarbons such as natural gas to a liquid or liquids. Vacuum pressure swing adsorption (VPSA) is used to produce a stream of relatively high purity oxygen. The relatively high purity oxygen is reacted with light hydrocarbons and steam in an autothermal reformer in order to produce synthesis gas. The synthesis gas is thereafter converted to a hydrocarbon liquid or liquids via a Fischer Tropsch or related reaction.

Abstract: A reactor for carrying out a chemical reaction in a three phase slurry system providing a horizontal reaction vessel with a cross sectional area which is dependent on the vessel length, vessel diameter, and axial position. The vessel has a gas inlet at or near the bottom of the reaction vessel and a gas distributor. The gas product exits the vessel by conduit means at or near the top of the reaction vessel. The vessel includes a plurality of horizontal cooling coils to provide a cooling medium to the slurry. In the reaction vessel, the synthesis gas has an average linear velocity which is a function of the vessel cross sectional area.

Abstract: A reactor for carrying out a chemical reaction in a three phase slurry system providing a horizontal reaction vessel with a cross sectional area which is dependent on the vessel length, vessel diameter, and axial position. The vessel has a gas inlet at or near the bottom of the reaction vessel and a gas distributor. The gas product exits the vessel by conduit means at or near the top of the reaction vessel. The vessel includes a plurality of horizontal cooling coils to provide a cooling medium to the slurry. In the reaction vessel, the synthesis gas has an average linear velocity which is a function of the vessel cross sectional area.

Abstract: A process for regenerating a slurry Fischer-Tropsch catalyst, which needs regeneration, involves de-waxing and drying the catalyst sufficiently to produce a free-flowing catalyst powder that is fluidizable; fluidizing the catalyst powder; treating the catalyst powder with an oxygen treatment; reducing the catalyst powder with a reducing gas to form a reduced catalyst powder; and mixing the reduced catalyst powder with hydrocarbons to form a regenerated, slurry catalyst. The oxidation and reduction steps may be repeated. An oxygen treatment includes using a fixed O2 level with ramped temperatures, fixed temperatures with increased O2 levels, or a combination.

Abstract: A Fischer-Tropsch catalyst for the conversion of synthesis gas into Fischer-Tropsch products includes a stationary Fischer-Tropsch catalyst having a voidage ratio greater than approximately 0.45 or 0.6 and may further have a catalyst concentration for a given reactor volume of at least 10 percent. A Fischer-Tropsch catalyst has a structured shape promoting non-Taylor flow and/or producing a productivity in the range of 200-4000 vol CO/vol. Catalyst/hour or greater over at least a 600 hour run of a Fischer-Tropsch reactor with the catalyst therein. A system for converting synthesis gas into longer-chain hydrocarbon products through the Fisher-Tropsch reaction has a reactor for receiving synthesis gas directly or as a saturated hydrocarbon liquid or a combination, and a stationary, structured Fischer-Tropsch catalyst disposed within the reactor for converting at least a portion of the synthesis gas into longer-chain hydrocarbons through Fischer-Tropsch reaction.

Abstract: A process for regenerating a slurry Fischer-Tropsch catalyst, which needs regeneration, involves de-waxing and drying the catalyst sufficiently to produce a free-flowing catalyst powder that is fluidizable; fluidizing the catalyst powder; treating the catalyst powder with an oxygen treatment; reducing the catalyst powder with a reducing gas to form a reduced catalyst powder; and mixing the reduced catalyst powder with hydrocarbons to form a regenerated, slurry catalyst. The oxidation and reduction steps may be repeated. An oxygen treatment includes using a fixed O2 level with ramped temperatures, fixed temperatures with increased O2 levels, or a combination.

Abstract: The invention is directed to reactor systems, apparatus, and processes which are useful for conducting chemical reactions that may be effected in a three phase slurry system. One particular application of the invention converts synthesis gas (syngas) into hydrocarbons. Syngas is comprised of carbon monoxide and hydrogen. In general, a low profile bed reactor is capable of conducting an exothermic catalytic conversion. The reactor may also include a catalyst contained in a moving fluid system which ascends in the reactor in one or more stages. A heat exchanger optionally may be used to remove heat, and water may be removed from the reaction as it proceeds from one stage to another. The reactor is designed in a relatively low profile horizontal design, and is usually more efficient and inexpensive to operate (or build) than taller vertically oriented reactors of the same type.

Abstract: A system and method for converting normally gaseous, light hydrocarbons into heavier, longer-chain hydrocarbons includes a turbine; a first synthesis gas subsystem; a second synthesis gas subsystem that receives thermal energy from the turbine and which preferably includes a steam reformer; and a synthesis subsystem for receiving synthesis gas from the first synthesis gas subsystem and the second synthesis gas subsystem and for producing the heavier hydrocarbons. A method includes using a plurality of synthesis gas subsystems to prepare synthesis gas for delivery to and conversion in a synthesis subsystem.

Abstract: A Fischer-Tropsch catalyst for the conversion of synthesis gas into Fischer-Tropsch products includes a stationary Fischer-Tropsch catalyst having a voidage ratio greater than approximately 0.45 or 0.6 and may further have a catalyst concentration for a given reactor volume of at least 10 percent. A Fischer-Tropsch catalyst has a structured shape promoting non-Taylor flow and/or producing a productivity in the range of 200-4000 vol CO/vol. Catalyst/hour or greater over at least a 600 hour run of a Fischer-Tropsch reactor with the catalyst therein. A system for converting synthesis gas into longer-chain hydrocarbon products through the Fisher-Tropsch reaction has a reactor for receiving synthesis gas directly or as a saturated hydrocarbon liquid or a combination, and a stationary, structured Fischer-Tropsch catalyst disposed within the reactor for converting at least a portion of the synthesis gas into longer-chain hydrocarbons through Fischer-Tropsch reaction.

Abstract: A system and method for converting normally gaseous, light hydrocarbons into heavier, longer-chain hydrocarbons includes a turbine; a first synthesis gas subsystem; a second synthesis gas subsystem that receives thermal energy from the turbine and which preferably includes a steam reformer; and a synthesis subsystem for receiving synthesis gas from the first synthesis gas subsystem and the second synthesis gas subsystem and for producing the heavier hydrocarbons. A method includes using a plurality of synthesis gas subsystems to prepare synthesis gas for delivery to and conversion in a synthesis subsystem.

Abstract: A Fischer-Tropsch catalyst for the conversion of synthesis gas into Fischer-Tropsch products includes a stationary Fischer-Tropsch catalyst having a voidage ratio greater than approximately 0.45 or 0.6 and may further have a catalyst concentration for a given reactor volume of at least 10 percent. A Fischer-Tropsch catalyst has a structured shape promoting non-Taylor flow and/or producing a productivity in the range of 200-4000 vol CO/vol. Catalyst/hour or greater over at least a 600 hour run of a Fischer-Tropsch reactor with the catalyst therein. A system for converting synthesis gas into longer-chain hydrocarbon products through the Fisher-Tropsch reaction has a reactor for receiving synthesis gas directly or as a saturated hydrocarbon liquid or a combination, and a stationary, structured Fischer-Tropsch catalyst disposed within the reactor for converting at least a portion of the synthesis gas into longer-chain hydrocarbons through Fischer-Tropsch reaction.

Abstract: A synthesis gas production system (302) incudes a gas turbine (310) having a compressor (312) with an autothermal reformer (308) between the compressor (312) and the turbine (314). The system (302) may include a separator (326) for removing a portion of the mass exiting the compressor (312) prior to its delivery to the autothermal reformer (308). Gaseous light hydrocarbons are delivered to the autothermal reformer (308) through conduit (330) and may be selectively controlled with a valve (331). Synthesis gas production system (302) may be used with a methanol process, ammonia process, a Fischer-Tropsch process (304), or other process involving synthesis gas.

Abstract: A synthesis gas production system (302) incudes a gas turbine (310) having a compressor (312) with an autothermal reformer (308) between the compressor (312) and the turbine (314). The system (302) may include a separator (326) for removing a portion of the mass exiting the compressor (312) prior to its delivery to the autothermal reformer (308). Gaseous light hydrocarbons are delivered to the autothermal reformer (308) through conduit (330) and may be selectively controlled with a valve (331). Synthesis gas production system (302) may be used with a methanol process, ammonia process, a Fischer-Tropsch process (304), or other process involving synthesis gas.

Abstract: A system for recovering liquid hydrocarbons from hydrates on an ocean floor includes a vessel, a positioning subsystem coupled to the vessel for holding the vessel in a desired location over a hydrate formation, a hydrate recovery subsystem coupled to the vessel for delivering hydrates from an ocean floor to the vessel and separating gas from hydrates removed from an ocean floor, a gas conversion subsystem coupled to the hydrate recovery subsystem for converting gas to liquids, and a storage and removal subsystem. Excess energy from the gas conversion subsystem is used elsewhere in the system. A method of recovering hydrates from an ocean floor is also provided.

Abstract: An apparatus for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons is provided. The process of using the apparatus comprises reacting the gaseous light hydrocarbons by autothermal reforming with air in the presence of recycled carbon dioxide and steam to produce a synthesis gas stream containing hydrogen and carbon monoxide. The synthesis gas stream is reacted in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from the hydrogen and carbon monoxide. The heavier hydrocarbons and water are separated, and the resulting residue gas stream is subjected to catalytic combustion with additional air to form a product stream comprising carbon dioxide and nitrogen. The carbon dioxide is separated from the nitrogen to produce a nitrogen product stream, and at least a portion of the separated carbon dioxide is recycled to the autothermal reforming step.

Abstract: A process and apparatus for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons is provided. The process comprises reacting the gaseous light hydrocarbons by autothermal reforming with air in the presence of recycled carbon dioxide and steam to produce a synthesis gas stream containing hydrogen and carbon monoxide. The synthesis gas stream is reacted in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from the hydrogen and carbon monoxide. The heavier hydrocarbons and water are separated, and the resulting residue gas stream is subjected to catalytic combustion with additional air to form a product stream comprising carbon dioxide and nitrogen. The carbon dioxide is separated from the nitrogen to produce a nitrogen product stream, and at least a portion of the separated carbon dioxide is recycled to the autothermal reforming step.