Patents by Inventor Marco Badano
Marco Badano has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10464818Abstract: A process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then together with air in a secondary reformer (2) is characterized in that the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of more than 35 bar in the catalytic tubes, in that air is added to said secondary reformer in excess over the nitrogen amount required for ammonia synthesis and in that the excess of nitrogen is removed downstream the secondary reformer preferably by cryogenic separation or by molecular sieves of the TAS or PSA type. This process allows to obtain high synthesis gas production capacities and lower investment and energy costs.Type: GrantFiled: June 29, 2017Date of Patent: November 5, 2019Assignee: Casale SAInventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20180072580Abstract: A process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then together with air in a secondary reformer (2) is characterized in that the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of more than 35 bar in the catalytic tubes, in that air is added to said secondary reformer in excess over the nitrogen amount required for ammonia synthesis and in that the excess of nitrogen is removed downstream the secondary reformer preferably by cryogenic separation or by molecular sieves of the TAS or PSA type. This process allows to obtain high synthesis gas production capacities and lower investment and energy costs.Type: ApplicationFiled: June 29, 2017Publication date: March 15, 2018Applicant: Casale SAInventors: Ermanno FILIPPI, Marco BADANO, Geoffrey Frederick SKINNER
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Patent number: 9708250Abstract: A process for ammonia-urea production where: liquid ammonia produced in an ammonia section is fed to a urea section directly at the ammonia synthesis pressure, and where the liquid ammonia is purified at high pressure with the steps of: cooling the liquid ammonia (20) obtaining a cooled liquid ammonia stream (21), separating a gaseous fraction (22) comprising hydrogen and nitrogen from said cooled liquid ammonia, obtaining purified liquid ammonia (23) at a high pressure, and reheating said purified liquid ammonia (23) after separation of said gaseous fraction, obtaining a reheated purified ammonia (24) having a temperature suitable for feeding to the urea synthesis process. The application also deals with an ammonia-urea plant comprising an ammonia cooler, a liquid-gas separator and an ammonia re-heater and with a method for revamping existing ammonia-urea plants.Type: GrantFiled: February 10, 2012Date of Patent: July 18, 2017Assignee: Casale SAInventors: Ermanno Filippi, Marco Badano, Federico Zardi, Andrea Scotto
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Patent number: 9376326Abstract: Method for modifying a hot wall ammonia reactor con vessel (2) having partial opening, comprising: assembly directly inside the vessel (2) of a catalytic cartridge (7) with modular elements, said modular elements being of a size compatible with introduction into the vessel through a pre-existing partial opening (6) of the vessel, and each comprising at least one panel (11); the panels (11) of said modular elements forming a substantially cylindrical outer wall (7a) of said cartridge (7), and an annular flux space (8) between said outer wall of the cartridge and an inner wall of the vessel; said panels (11) being provided with a respective heat insulation layer (13) before introduction into the vessel (2).Type: GrantFiled: March 11, 2011Date of Patent: June 28, 2016Assignee: Casale SAInventors: Marco Badano, Mirco Tarozzo, Federico Maffietti
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Patent number: 9040011Abstract: The present invention concerns a process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then in a secondary reformer (2) together with an oxidant gas. In this process, the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of at least 45 bar in the catalytic tubes and a flow of essentially pure oxygen or oxygen-enriched air is added to said secondary reformer as oxidant gas for substantially reforming together with said all the hydrocarbons content of said product gas exiting the primary reformer (1). In the case essentially pure oxygen is used as oxidant gas, a flow of nitrogen is added downstream the secondary reformer (2) to reach a N2/H2 molar ratio corresponding to or close to the stoichiometric ratio for ammonia synthesis.Type: GrantFiled: November 6, 2008Date of Patent: May 26, 2015Assignee: Casale SAInventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20150086465Abstract: A process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then together with air in a secondary reformer (2) is characterized in that the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of more than 35 bar in the catalytic tubes, in that air is added to said secondary reformer in excess over the nitrogen amount required for ammonia synthesis and in that the excess of nitrogen is removed downstream the secondary reformer preferably by cryogenic separation or by molecular sieves of the TAS or PSA type. This process allows to obtain high synthesis gas production capacities and lower investment and energy costs.Type: ApplicationFiled: December 5, 2014Publication date: March 26, 2015Applicant: Casale SAInventors: Ermanno FILIPPI, Marco BADANO, Geoffrey Frederick SKINNER
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Publication number: 20140018575Abstract: A process for ammonia -urea production where: liquid ammonia produced in an ammonia section is fed to a urea section directly at the ammonia synthesis pressure, and where the liquid ammonia is purified at high pressure with the steps of: cooling the liquid ammonia (20) obtaining a cooled liquid ammonia stream (21), separating a gaseous fraction (22) comprising hydrogen and nitrogen from said cooled liquid ammonia, obtaining purified liquid ammonia (23) at a high pressure, and reheating said purified liquid ammonia (23) after separation of said gaseous fraction, obtaining a reheated purified ammonia (24) having a temperature suitable for feeding to the urea synthesis process. The application also deals with an ammonia -urea plant comprising an ammonia cooler, a liquid-gas separator and an ammonia re-heater and with a method for revamping existing ammonia -urea plants.Type: ApplicationFiled: February 10, 2012Publication date: January 16, 2014Applicant: Urea Casale SAInventors: Ermanno Filippi, Marco Badano, Frederico Zardi, Andrea Scotto
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Patent number: 8545727Abstract: A process for producing ammonia synthesis gas, where a natural gas feedstock (10) is reformed in a primary steam reformer (12) and in a secondary reformer (14) at a pressure of at least 35 bar; the product syngas (16) at the output of the secondary reformer is cooled and subject to catalytic medium-temperature shift, converting the CO into CO2 and H2; downstream said medium-temperature shift, the carbon dioxide is removed from the syngas by physical absorption.Type: GrantFiled: August 26, 2009Date of Patent: October 1, 2013Assignee: Ammonia Casale SAInventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20130014365Abstract: Method for modifying a hot wall ammonia reactor con vessel (2) having partial opening, comprising: assembly directly inside the vessel (2) of a catalytic cartridge (7) with modular elements, said modular elements being of a size compatible with introduction into the vessel through a pre-existing partial opening (6) of the vessel, and each comprising at least one panel (11); the panels (11) of said modular elements forming a substantially cylindrical outer wall (7a) of said cartridge (7), and an annular flux space (8) between said outer wall of the cartridge and an inner wall of the vessel; said panels (11) being provided with a respective heat insulation layer (13) before introduction into the vessel (2).Type: ApplicationFiled: March 11, 2011Publication date: January 17, 2013Applicant: Ammonia Casale SAInventors: Marco Badano, Mirco Tarozzo, Federico Maffietti
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Publication number: 20120308466Abstract: A process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then together with air in a secondary reformer (2) is characterized in that the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of more than 35 bar in the catalytic tubes, in that air is added to said secondary reformer in excess over the nitrogen amount required for ammonia synthesis and in that the excess of nitrogen is removed downstream the secondary reformer preferably by cryogenic separation or by molecular sieves of the TAS or PSA type. This process allows to obtain high synthesis gas production capacities and lower investment and energy costs.Type: ApplicationFiled: August 16, 2012Publication date: December 6, 2012Applicant: Ammonia Casale S.A.Inventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20110223090Abstract: A process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then together with air in a secondary reformer (2) is characterized in that the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of more than 35 bar in the catalytic tubes, in that air is added to said secondary reformer in excess over the nitrogen amount required for ammonia synthesis and in that the excess of nitrogen is removed downstream the secondary reformer preferably by cryogenic separation or by molecular sieves of the TAS or PSA type. This process allows to obtain high synthesis gas production capacities and lower investment and energy costs.Type: ApplicationFiled: July 18, 2008Publication date: September 15, 2011Applicant: Ammonia Casale S.A.Inventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20110168948Abstract: A process for producing ammonia synthesis gas, where a natural gas feedstock (10) is reformed in a primary steam reformer (12) and in a secondary reformer (14) at a pressure of at least 35 bar; the product syngas (16) at the output of the secondary reformer is cooled and subject to catalytic medium-temperature shift, converting the CO into CO2 and H2; downstream said medium-temperature shift, the carbon dioxide is removed from the syngas by physical absorption.Type: ApplicationFiled: August 26, 2009Publication date: July 14, 2011Applicant: Ammonia Casale S.A.Inventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20100303703Abstract: The present invention concerns a process for producing ammonia synthesis gas from the reforming of hydrocarbons with steam in a primary reformer (1) equipped with a plurality of externally heated catalytic tubes and then in a secondary reformer (2) together with an oxidant gas. In this process, the reaction of said hydrocarbons with said steam in said primary reformer (1) is performed at an operating pressure of at least 45 bar in the catalytic tubes and a flow of essentially pure oxygen or oxygen-enriched air is added to said secondary reformer as oxidant gas for substantially reforming together with said all the hydrocarbons content of said product gas exiting the primary reformer (1). In the case essentially pure oxygen is used as oxidant gas, a flow of nitrogen is added downstream the secondary reformer (2) to reach a N2/H2 molar ratio corresponding to or close to the stoichiometric ratio for ammonia synthesis.Type: ApplicationFiled: November 6, 2008Publication date: December 2, 2010Applicant: Ammonia Casale S.A.Inventors: Ermanno Filippi, Marco Badano, Geoffrey Frederick Skinner
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Publication number: 20080314563Abstract: A method for controlling the temperature of an exothermic reaction with simultaneous production of steam is based on the use of heat exchangers (5a) crossed by a recirculation liquid along an inner path extended between the inlet opening for the recirculation liquid and an outlet opening (5f), the recirculation liquid coming from a steam drum (10) for the separation of the produced steam and being fed to said inlet opening along a path external to the heat exchangers, the produced steam being integrated in the form of an additional liquid flow which is mixed at least in part with the recirculation liquid flowing along the external path.Type: ApplicationFiled: December 7, 2006Publication date: December 25, 2008Applicant: Methanol Casale S.A.Inventors: Ermanno Filippi, Enrico Rizzi, Mirco Tarozzo, Marco Badano
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Publication number: 20010006615Abstract: A process for the production of synthesis gas for obtaining compounds such as ammonia or methanol, in which hydrocarbons and steam are reacted first in a primary reforming section (11) and then—together with oxygen—in a secondary reforming section (12), thus obtaining CO, CO2, H2 and possibly N2 which are then fed to a carbon monoxide conversion section (13, 14), is distinguished by the fact of reacting hydrocarbons, steam and oxygen in an autothermal reforming section (20) provided in parallel with respect to other reforming sections (11, 12), and feeding the so produced CO, CO2, H2 and possibly N2 to the carbon monoxide conversion section (13, 14).Type: ApplicationFiled: February 20, 2001Publication date: July 5, 2001Inventor: Marco Badano
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Patent number: 6207078Abstract: A process for the production of synthesis gas for obtaining compounds such as ammonia or methanol, in which hydrocarbons and steam are reacted first in a primary reforming section (11) and then—together with oxygen—in a secondary reforming section (12), thus obtaining CO, CO2, H2 and possibly N2 which are then fed to a carbon monoxide conversion section (13, 14), is distinguished by the fact of reacting hydrocarbons, steam and oxygen in an autothermal reforming section (20) provided in parallel with respect to other reforming sections (11, 12), and feeding the so produced CO, CO2, H2 and possibly N2 to the carbon monoxide conversion section (13, 14).Type: GrantFiled: September 24, 1999Date of Patent: March 27, 2001Assignee: Ammonia Casale SAInventor: Marco Badano
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Patent number: 6106793Abstract: A process for ammonia and methanol co-production in a plant comprising a first primary reforming section (11) and a secondary reforming section (12) arranged in series, an ammonia synthesis section (13) and a methanol synthesis section (22), is distinguished by the fact that ammonia and methanol are produced in independent synthesis processes where the heat required for the reforming reaction in the methanol process is advantageously obtained by utilizing the high heat content present in the gas flow coming from the secondary reforming section (12) of the ammonia process.Type: GrantFiled: December 29, 1997Date of Patent: August 22, 2000Assignee: Methanol Casale S.A.Inventors: Marco Badano, Franco Fabbri, Ermanno Filippi