Abstract: A method for converting synthesis gas into liquid hydrocarbons by introducing a synthesis gas feed into a Fischer-Tropsch system that includes a catalytic reactor fluidly connected with at least two slurry loops, the reactor comprising at least as many reactor product outlets and slurry return inlets as slurry loops; each slurry loop comprising a separation system comprising at least one separator, an inlet of each separator fluidly connected to a reactor product outlet via a slurry offtake, and an outlet of each separator fluidly connected to a slurry return inlet via a slurry return; separating concentrated catalyst slurry from the reaction product via the slurry loops; removing liquid hydrocarbon product from each separator; and returning concentrated catalyst slurry to the catalytic reactor via the slurry returns and slurry return inlets. A system for converting synthesis gas into liquid hydrocarbons via the method is also disclosed.

Abstract: A method including introducing a carbonaceous feedstock and a heated heat transfer material into a gasifier, whereby at least a portion of the carbonaceous material is pyrolyzed; removing a gasification product gas comprising, entrained therein, char, particulate heat transfer material, and optionally unreacted carbonaceous feedstock; separating a solids product comprising char, heat transfer material and optionally unreacted carbonaceous material from the gasification product gas; heating at least a portion of the solids product via a combustor, thus producing a heated portion of the solids product and a combustor flue gas, wherein a portion of the heat for heating is obtained via combustion of the char; separating the heated portion from the flue gas, and introducing the separated heated portion into the gasifier, providing heat for pyrolysis; and utilizing at least a portion of the gasification product gas for Fischer-Tropsch synthesis and/or power production.

Abstract: A method for converting synthesis gas into liquid hydrocarbons by introducing a synthesis gas feed into a Fischer-Tropsch system that includes a catalytic reactor fluidly connected with at least two slurry loops, the reactor comprising at least as many reactor product outlets and slurry return inlets as slurry loops; each slurry loop comprising a separation system comprising at least one separator, an inlet of each separator fluidly connected to a reactor product outlet via a slurry offtake, and an outlet of each separator fluidly connected to a slurry return inlet via a slurry return; separating concentrated catalyst slurry from the reaction product via the slurry loops; removing liquid hydrocarbon product from each separator; and returning concentrated catalyst slurry to the catalytic reactor via the slurry returns and slurry return inlets. A system for converting synthesis gas into liquid hydrocarbons via the method is also disclosed.

Abstract: A catalytic reaction system comprising: a catalytic reactor fluidly connected with at least two slurry loops, wherein the reactor comprises at least as many reactor product outlets and at least as many slurry return inlets as slurry loops; wherein each slurry loop comprises a separation system comprising a separation system inlet, a separation system product outlet, and a concentrated catalyst slurry outlet; a slurry offtake fluidly connecting the separation system inlet with one of the reactor product outlets; and a slurry return fluidly connecting the separation system outlet with one of the slurry return inlets. The system may comprise at least three slurry loops. The system may comprise at least four slurry loops. A method for converting synthesis gas into liquid hydrocarbons via the catalytic reaction system in also disclosed.

Abstract: A method including introducing a carbonaceous feedstock and a heated heat transfer material into a gasifier, whereby at least a portion of the carbonaceous material is pyrolyzed; removing a gasification product gas comprising, entrained therein, char, particulate heat transfer material, and optionally unreacted carbonaceous feedstock; separating a solids product comprising char, heat transfer material and optionally unreacted carbonaceous material from the gasification product gas; heating at least a portion of the solids product via a combustor, thus producing a heated portion of the solids product and a combustor flue gas, wherein a portion of the heat for heating is obtained via combustion of the char; separating the heated portion from the flue gas, and introducing the separated heated portion into the gasifier, providing heat for pyrolysis; and utilizing at least a portion of the gasification product gas for Fischer-Tropsch synthesis and/or power production.

Abstract: A system including at least one hydrogen extraction unit comprising an inlet for a synthesis feedgas from a synthesis feedgas line and adapted to remove at least one hydrogen-rich gas and at least one hydrogen-lean gas from the synthesis feedgas to yield a refined synthesis gas; and at least one hydrocarbon synthesis reactor, at least one dedicated activation reactor, or both, wherein the at least one hydrocarbon synthesis reactor is fluidly connected with the at least one hydrogen extraction unit and configured to provide liquid hydrocarbons and a first byproduct gas from a synthesis reactor feedstream comprising at least a portion of the refined synthesis gas; and wherein the at least one dedicated activation reactor is fluidly connected with the at least one hydrogen extraction unit, the at least one hydrocarbon synthesis reactor, or both, and configured for activation of hydrocarbon synthesis catalyst via an activation gas.

Abstract: A system including at least one hydrogen extraction unit comprising an inlet for a synthesis feedgas from a synthesis feedgas line and adapted to remove at least one hydrogen-rich gas and at least one hydrogen-lean gas from the synthesis feedgas to yield a refined synthesis gas; and at least one hydrocarbon synthesis reactor, at least one dedicated activation reactor, or both, wherein the at least one hydrocarbon synthesis reactor is fluidly connected with the at least one hydrogen extraction unit and configured to provide liquid hydrocarbons and a first byproduct gas from a synthesis reactor feedstream comprising at least a portion of the refined synthesis gas; and wherein the at least one dedicated activation reactor is fluidly connected with the at least one hydrogen extraction unit, the at least one hydrocarbon synthesis reactor, or both, and configured for activation of hydrocarbon synthesis catalyst via an activation gas.

Abstract: A method of utilizing hydrogen in synthesis gas production by forming synthesis gas from one or more carbonaceous materials, the synthesis gas comprising hydrogen and carbon monoxide; separating a hydrogen-rich product and a hydrogen-lean product from the synthesis gas to yield an adjusted synthesis gas product; and activating a hydrocarbon synthesis catalyst with at least a portion of the hydrogen-lean product. A system for carrying out the method is also provided, the system including at least one hydrogen extraction unit and an activation reactor operable to activate hydrocarbon synthesis catalyst, wherein the activation reactor comprises an inlet fluidly connected with the at least one hydrogen extraction unit whereby at least a portion of a hydrogen-lean gas stream, at least a portion of a hydrogen-rich gas stream, or at least a portion of both may be introduced into the activation reactor.

Abstract: A system for activating Fischer-Tropsch catalyst comprising a reactor having a reactor outlet for overhead gas and operable under suitable conditions whereby a catalyst in a volume of liquid carrier comprising Fischer-Tropsch diesel, hydrocracking recycle oil, or a combination thereof may be activated in the presence of an activation gas; a condenser comprising an inlet fluidly connected to the reactor outlet for overhead gas and comprising a condenser outlet for condensed liquids; and a separation unit comprising an inlet fluidly connected to the condenser outlet and a separator outlet for a stream comprising primarily Fischer-Tropsch diesel; and a recycle line fluidly connecting the separator outlet, a hydrocracking unit, or both to the reactor, whereby Fischer-Tropsch diesel recovered from the reactor overhead gas, hydrocracking recycle oil, or a combination thereof may serve as liquid carrier for catalyst in the reactor. A method for activating Fischer-Tropsch catalyst is also provided.

Abstract: A method of producing synthesis gas via gasification in a Fischer-Tropsch plant, the method including providing a number of gasifiers, the number of gasifiers provided being at least one more than the base number required to provide 100% plant capacity of synthesis gas when each gasifier is operated at 100% gasifier capacity. A method of continually producing synthesis gas via gasification of a carbonaceous feed in a Fischer-Tropsch plant by providing a number of gasifiers, the number of gasifiers provided being at least one more than the base number required to provide 100% plant capacity of synthesis gas when each gasifier is operated at 100% gasifier capacity; and adjusting the amount of synthesis gas produced by adjusting the number of online gasifiers, the flow rate of carbonaceous feed to each gasifier, or a combination thereof. A system for carrying out the method is also provided.

Abstract: A catalytic reaction system comprising: a catalytic reactor fluidly connected with at least two slurry loops, wherein the reactor comprises at least as many reactor product outlets and at least as many slurry return inlets as slurry loops; wherein each slurry loop comprises a separation system comprising a separation system inlet, a separation system product outlet, and a concentrated catalyst slurry outlet; a slurry offtake fluidly connecting the separation system inlet with one of the reactor product outlets; and a slurry return fluidly connecting the separation system outlet with one of the slurry return inlets. The system may comprise at least three slurry loops. The system may comprise at least four slurry loops. A method for converting synthesis gas into liquid hydrocarbons via the catalytic reaction system in also disclosed.

Abstract: A method of utilizing hydrogen in synthesis gas production by forming synthesis gas from one or more carbonaceous materials, the synthesis gas comprising hydrogen and carbon monoxide; separating a hydrogen-rich product and a hydrogen-lean product from the synthesis gas to yield an adjusted synthesis gas product; and activating a hydrocarbon synthesis catalyst with at least a portion of the hydrogen-lean product. A system for carrying out the method is also provided, the system including at least one hydrogen extraction unit and an activation reactor operable to activate hydrocarbon synthesis catalyst, wherein the activation reactor comprises an inlet fluidly connected with the at least one hydrogen extraction unit whereby at least a portion of a hydrogen-lean gas stream, at least a portion of a hydrogen-rich gas stream, or at least a portion of both may be introduced into the activation reactor.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe203. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe2O3. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: An arrangement of cooling tubes within a Fischer-Tropsch slurry reactor simplifies removal and reinstallation of cooling tubes for reactor maintenance.