Abstract: A method of providing sulfidation corrosion resistance and corrosion induced fouling resistance to a heat transfer component surface includes providing a silicon containing steel composition including an alloy and a Si-partitioned non-metallic film formed on a surface of the alloy. The alloy is formed from the composition ?, ?, and t, in which ? is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof, ? is Si, and t is at least one alloying element selected from the group consisting of Cr, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, La, Y, Ce, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, Ga, Ge, As, In, Sn, Sb, Pb, B, C, N, P, O, S and mixtures thereof. The Si-partitioned non-metallic film comprises at least one of sulfide, oxysulfide and mixtures thereof.

Abstract: A heat transfer component that is resistant to both corrosion and fouling is disclosed having a heat exchange surface formed from a silicon containing steel composition including an alloy and a non-metallic film formed on a surface of the alloy. The alloy is formed from the composition ?, ?, and ?, in which ? is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof, ? is Si, and ? is at least one alloying element selected from the group consisting of Cr, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, La, Y, Ce, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, Ga, Ge, As, In, Sn, Sb, Pb, B, C, N, P, O, S and mixtures thereof. The non-metallic film comprises sulfide, oxide, carbide, nitride, oxysulfide, oxycarbide, oxynitride and mixtures thereof. The surface roughness of the heat transfer component is less than 40 micro inches.

Abstract: A novel injector/reactor apparatus and an efficient process for the partial oxidation of light hydrocarbon gases, such as methane, to convert such gases to useful synthesis gas for recovery and/or subsequent hydrocarbon synthesis. Sources of a light hydrocarbon gas, such as methane, and oxygen or an oxygen-containing gas are preheated and pressurized and injected through an injector means at high velocity into admixture with each other in the desired relative proportions, at a plurality of mixing nozzles which are open to the catalytic partial oxidation reaction zone and are uniformly-spaced over the face of the injector means, to form a reactant gaseous premix having a pressure drop equal to at least about 3% of the lowest upstream pressure of either of said gases.

Abstract: A novel injector/reactor apparatus and an efficient process for the partial oxidation of light hydrocarbon gases, such as methane, to convert such gases to useful synthesis gas for recovery and/or subsequent hydrocarbon synthesis. Sources of a light hydrocarbon gas, such as methane, and oxygen or an oxygen-containing gas are preheated and pressurized and injected through an injector means at high velocity into admixture with each other in the desired proportions, at a plurality of mixing nozzles which are open to the catalytic partial oxidation reaction zone of a reactor and are uniformly-spaced over the face of the injector, to form a reactant gaseous premix having a pressure drop through the injector.

Abstract: High surface purity heat transfer solids are formed, suitably by washing and treating particulate refractory inorganic solids, notably alumina, which contains as impurities up to about 0.5 wt. % silicon and/or up to about 500 wppm boron, with an acid, or dilute acid solution sufficient to reduce the concentration of silicon and boron in the outer peripheral surface layer of the particles, e.g., as measured inwardly toward the center of a particle to a depth of about 50 .ANG. using X-ray photoelectron spectroscopy, to no greater than about 5 atom percent silicon and boron, preferably about 2 atom percent silicon and boron, based on the total number of cations within said outer peripheral surface layer, thereby reducing the tendency of said particles to sinter and agglomerate in the conversion of said hydrocarbon to hydrogen and carbon monoxide in a fluidized bed synthesis gas operation vis-a-vis particles otherwise similar except that the particles are not treated with the acid.

Abstract: A particulate, precalcined low silica content zirconia, especially one stabilizer with yttria, is useful as a catalyst support or as a heat transfer solids component for conducting chemical reactions at high temperature, in oxidizing, reducing or hydrothermal conditions, especially in syn gas operations. An admixture of precalcined particulate low silica content zirconia, particularly a low silica content yttria-stabilized zirconia, is employed in a preferred embodiment as a heat transfer solid, in concentrations ranging generally from about 10 wt. % to about 99.9 wt. % with a particulate catalyst notably a nickel-on-alumina catalyst, in concentration ranging generally from about 0. 1 wt. % to about 90 wt. %. Such an admixture provides a particularly useful catalytic contact mass in high temperature oxidizing, reducing and hydrothermal environments, notably in conducting synthesis gas generation operations.

Abstract: A process for the production of syn gas (hydrogen and carbon monoxide) by reaction at high temperature between low molecular weight hydrocarbons, steam and oxygen in an impurities-containing refractory lined reaction zone. The lined reaction zone is pretreated with steam, or with steam and a reducing gas, e.g. a mixture of steam and hydrogen to leach out, react with, and transport the impurities, i.e., the reaction products of silica, or silica plus phosphorus or sulfur, or silica plus phosphorus and sulfur, from the reaction zone. Steam alone may be used to leach out, convert the silica to gaseous silicic acid, and remove same from the reaction zone; and then the hydrocarbons, steam and oxygen feeds are introduced into the reaction zone to produce syn gas.

Abstract: A process for the in situ attrition and break up of an agglomerating, or agglomerated catalyst to maintain and control the fluidization characteristics of a bed wherein low molecular weight hydrocarbons, oxygen and steam are contacted with the bed to produce hydrogen and carbon monoxide via both partial oxidation and steam reforming reactions. The feeds are injected into the reaction zone with mechanical energy input sufficient to balance the intrinsic rate of agglomeration by fracturing and breaking apart in situ the agglomerated catalyst to maintain the fluidization characteristics of the bed throughout the cycle of operation.

Abstract: A particulate, precalcined low silica content zirconia, especially one stabilized with yttria, is useful as a catalyst support or as a heat transfer solids component for conducting chemical reactions at high temperature, in oxidizing, reducing or hydrothermal conditions, especially in syn gas operations. An admixture of precalcined particulate low silica content zirconia, particularly a low silica content yttria-stabilized zirconia, is employed in a preferred embodiment as a heat transfer solid, in concentrations ranging generally from about 10 wt. % to about 99.9 wt. %, with a particulate catalyst, notably a nickel-on-alumina catalyst, in concentration ranging generally from about 0.1 wt. % to about 90 wt. %. Such an admixture provides a particularly useful catalytic contact mass in high temperature oxidizing, reducing and hydrothermal environments, notably in conducting synthesis gas generation operations.

Abstract: A structurally modified alumina useful as a catalyst support, or heat transfer solid for fluidized bed synthesis gas processing. A Group IIA metal, or metals, particularly magnesium and barium, is composited with a particulate alumina to provide a catalyst support, or alumina heat transfer solid, having increased resistance to sintering and agglomeration; properties which promote defluidization of the bed in conducting fluidized bed reactions at high temperatures. The particles of preference are represented by formulas (1) and (2), a composite particle being represented by formula (1), as follows:M.sub.x Al.sub.2 O.sub.3+x (1)with the core of the particle being represented by formula (2), as follows:M.sub.y Al.sub.2 O.sub.3+y (2)where in formulas (1) and (2) M is a Group IIA metal, x is a number ranging from about 0.01 to about 0.4 and is representative of the number of moles of the metal M per mole of Al.sub.2 O.sub.3 y is a number equal to or greater than zero, and x is greater than y.

Abstract: High surface purity heat transfer solids are formed, suitably by washing and treating particulate refractory inorganic solids, notably alumina, which contains as impurities up to about 0.5 wt. % silicon and/or up to about 500 wppm boron, with an acid, or dilute acid solution sufficient to reduce the concentration of silicon and boron in the outer peripheral surface layer of the particles, e.g., as measured inwardly toward the center of a particle to a depth of about 50 .ANG. using X-ray photoelectron spectroscopy, to no greater than about 5 atom percent silicon and boron, preferably about 2 atom percent silicon and boron, based on the total number of cations within said outer peripheral surface layer, thereby reducing the tendency of said particles to sinter and agglomerate in the conversion of said hydrocarbon to hydrogen and carbon monoxide in a fluidized bed synthesis gas operation vis-a-vis particles otherwise similar except that the particles are not treated with the acid.

Abstract: Alumina heat transfer solids are admixed with a catalyst, or catalysts, and used in conducting high temperature fluidized bed reactions, particularly in a process for the production of hydrogen and carbon monoxide from a low molecular weight hydrocarbon by contact with a fluidized bed of catalyst and said heat transfer solids at high temperature in the presence of oxygen, or steam, or both oxygen and steam. The particulate heat transfer solids are characterized as having a performance index, PI, greater than 20, preferably greater than 40, as characterized by the formula PI=[(i).times.(ii).times.(iii).times.(iv)].sup.-1 where (i) the peripheral outer surface of the particle contains <5 atom % (Si+B) as impurities, and (ii) <20 atom % Na, Fe, Ca and Ti as impurities, where the bulk concentrations of the (Si+B) is sufficient to migrate into and contaminate the outer surface layer of the particles at process conditions. Moreover the (iii) tapped bulk density of the particles range from about 1.

Abstract: A process for the reactivation, or rejuvenation of a nickel-alumina catalyst employed in the production of a gas comprised of an admixture of hydrogen and carbon monoxide, or synthesis gas, by the conversion, in a reactor, or reaction zone, of light hydrocarbons in a fluidized bed of the catalyst at elevated temperature, in the presence of steam and oxygen. Catalyst reactivation is accomplished by withdrawing a portion of the catalyst from the fluidized bed of the reactor and treating the catalyst in an oxidation zone at temperature sufficient to oxidize and convert the nickel component of the catalyst to nickel aluminate and disperse said nickel aluminate within the alumina support, and then recycling the treated catalyst to the reactor, or reaction zone, to reactivate and increase the activity of the catalyst.

Abstract: A process utilizing a particulate catalyst, or particulate catalyst admixed with particulate heat transfer solids for conducting high temperature fluidized bed syn gas operations. Hydrogen and carbon monoxide are produced from a low molecular weight hydrocarbon by contact thereof, at high temperature in the presence of oxygen, or steam and oxygen, with a fluidized bed comprising said particulate solids. In one of its forms, barium hexaluminate is employed as a heat transfer solid, in concentrations ranging generally from about 10 wt. % to about 99.9 wt. %, in admixture with a particulate catalyst containing a metal, or metals, component catalytic for the production of hydrogen and carbon monoxide from low molecular weight hydrocarbons contacted with a fluidized bed of the catalyst at high temperature hydrothermal conditions. The catalyst, suitably one having a barium hexaluminate carrier component, is employed in concentration ranging generally from about 0.1 wt. % to about 90 wt. %.

Abstract: Cement is produced by feeding residue solids containing carbonaceous material and ash constituents obtained from converting a carbonaceous feed material into liquids and/or gases into a cement-making zone and burning the carbon in the residue solids to supply at least a portion of the energy required to convert the solids into cement.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced in the gasifier or similar reaction zone, alkali metal constitutents are recovered from the particles by withdrawing and passing the particles from the reaction zone to an alkali metal recovery zone in the substantial absence of molecular oxygen and treating the particles in the recovery zone with water or an aqueous solution in the substantial absence of molecular oxygen. The solution formed by treating the particles in the recovery zone will contain water-soluble alkali metal constituents and is recycled to the conversion process where the alkali metal constituents serve as at least a portion of the alkali metal constituents which comprise the alkali metal-containing catalyst.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered from the particles by treating them with a calcium or magnesium-containing compound in the presence of water. The treating process is carried out under conditions such that the calcium or magnesium-containing compound reacts with water insoluble constituents of the alkali metal residues such as alkali metal aluminosilicates to produce an aqueous solution containing water soluble alkali metal constituents. The aqueous solution is recycled to the gasification process where the alkali metal constituents serve as at least a portion of the alkali metal constituents which comprise the alkali metal-containing catalyst.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered from the particles primarily in the form of water soluble alkali metal formates by treating the particles with a calcium or magnesium-containing compound in the presence of water at a temperature between about 250.degree. F. and about 700.degree. F. and in the presence of added carbon monoxide. During the treating process the water insoluble alkali metal compounds comprising the insoluble alkali metal residues are converted into water soluble alkali metal formates.

Abstract: A process for the preparation of high surface area mixed metal oxides by decomposition of solid solutions of carbonates possessing the calcite structure. Oxide compounds comprising mixtures of Ca, Mn, Fe, Co, Ni, Zn, Cd and Mg can be prepared by this method. For example, CaMnO.sub.3 with a surface area of 11 m.sup.2 /g useful as a battery cathode, has been prepared by the instant method, that is, by decomposition of a CaMn(CO.sub.3).sub.2 precursor.The mixed metal carbonate solid solutions which are used as precursors for the preparation of the mixed metal oxides are themselves prepared by the precipitation from solution of the appropriate metal ions by the addition of an excess of a carbonate ion source (such as (NH.sub.4).sub.2 CO.sub.3). The metal-ion ratio in this solution is adjusted so that the resulting precipitate has the same stoichiometry as the desired oxide.

Abstract: A novel battery is disclosed in which the cathode active material is an oxide having a perovskite or perovskite related structure and the general formula ABO.sub.3, wherein A is an element selected from Group IIA of the Periodic Table of the Elements and B is a non-noble transition metal selected from Group VIIB and VIII of the periodic Table of the Elements. The anode is a metal selected from cadmium, zinc, lead, lithium, sodium and potassium.