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 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: 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 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: The present invention includes an integrated process for the production of carbon filaments, comprising converting a portion of hydrocarbons to alkenes via oxidative dehydrogenation and further converting a portion of the alkenes to carbon filaments via contact with a metal catalyst. A portion of unconverted hydrocarbons remaining after oxidative dehydrogenation may also be further converted to carbon filaments via contact with the metal catalyst. The conversion of hydrocarbons to alkenes via oxidative dehydrogenation and further conversion of the alkenes and unconverted hydrocarbons to carbon filaments via contact with a metal catalyst may be carried out in the same or separate reactor vessels. A plurality of reactor vessels arranged in parallel may be used for the conversion of the alkenes and unconverted hydrocarbons to carbon filaments.

Abstract: An apparatus and method is disclosed for producing hydrocarbons according to the Fischer-Tropsch process. The apparatus comprises a catalytic distillation reactor where reactants are fed into the catalytic distillation reactor to undergo catalytic reaction to form hydrocarbons. Physical separation of the unreacted materials and products occurs simultaneously in the catalytic distillation reactor. The catalytic distillation reactor is divided into reaction chambers so as to optimize control of the reaction and the distribution of hydrocarbon products. A monolith, such as a foam monolith or a honeycomb monolith, preferably a honeycomb monolith, is disposed with said reaction chamber serves both as catalyst support and as distillation packing material. A honeycomb monolith preferably includes channels having an axis disposed at a nonzero angle with respect to the axis of a reaction chamber containing the honeycomb monolith.