Abstract: A plant for treating fluid products obtained from an oil well, to produce a hydrocarbon product, comprises a series of separators at progressively lower pressures, to which the fluid products are supplied in succession. A high pressure gas phase is obtained from the separator and is supplied to a flow restrictor so as to undergo cooling through the Joule Thomson effect, and then passed to a NGL separator to produce a natural gas liquid stream and a gaseous natural gas stream. The natural gas stream is then processed chemically, using a synthesis gas production unit, and a Fischer-Tropsch synthesis unit to produce a synthetic crude oil. The synthetic crude oil is supplied to one of the separators, and the natural gas liquid stream is supplied to another of the separators; the pressure in the one separator is greater than the pressure in the other separator.

Abstract: Gas-to-liquids processes for treating natural gas, including the steps of subjecting the natural gas to expansion through a flow restrictor so as to undergo cooling through the Joule Thomson effect. The processes then separate the resulting liquids from the remaining natural gas and processing the natural gas to form a synthesis gas. The synthesis gas is subjected to Fischer-Tropsch synthesis and the output from the Fischer-Tropsch synthesis is separated into a hydrocarbon product and an aqueous phase and the aqueous phase is steam stripped to extract the oxygenates which are then injected into the natural gas stream upstream of the flow restrictor.

Abstract: A plant for treating fluid products obtained from an oil well, to produce a hydrocarbon product, comprises a series of separators at progressively lower pressures, to which the fluid products are supplied in succession. A high pressure gas phase is obtained from the separator and is supplied to a flow restrictor so as to undergo cooling through the Joule Thomson effect, and then passed to a NGL separator to produce a natural gas liquid stream and a gaseous natural gas stream. The natural gas stream is then processed chemically, using a synthesis gas production unit, and a Fischer-Tropsch synthesis unit to produce a synthetic crude oil. The synthetic crude oil is supplied to one of the separators, and the natural gas liquid stream is supplied to another of the separators; the pressure in the one separator is greater than the pressure in the other separator.

Abstract: Gas-to-liquids processes for treating natural gas, including the steps of subjecting the natural gas to expansion through a flow restrictor so as to undergo cooling through the Joule Thomson effect. The processes then separate the resulting liquids from the remaining natural gas and processing the natural gas to form a synthesis gas. The synthesis gas is subjected to Fischer-Tropsch synthesis and the output from the Fischer-Tropsch synthesis is separated into a hydrocarbon product and an aqueous phase and the aqueous phase is steam stripped to extract the oxygenates which are then injected into the natural gas stream upstream of the flow restrictor.

Abstract: A gas-to-liquids process and plant for treating natural gas, in which the natural gas is subjected to expansion through a flow restrictor so as to undergo cooling through the Joule Thomson effect, enables liquids to be separated from the gas stream. The natural gas may be cooled before it reaches the flow restrictor by heat exchange with fluid that has passed through the flow restrictor. This decreases the proportion of longer-chain hydrocarbons in the natural gas, which may simplify subsequent processing, and may enable the size of the plant to be decreased.

Abstract: Apparatuses for use in plants for processing methane, the apparatuses comprising a plurality of reaction modules each including a plurality of Fischer-Tropsch reactors operable to convert a gaseous mixture including carbon monoxide and hydrogen to a liquid hydrocarbon. Each module may be disconnected and taken away for servicing while allowing the plant to continue to operate. In some of the apparatuses, each Fischer-Tropsch reactor comprises a plurality of metal sheets arranged as a stack to define first and second flow channels for flow of respective fluids, the channels being arranged alternately to ensure good thermal contact between the fluids in the channels.

Abstract: Methane reacts with steam generating carbon monoxide and hydrogen in a first catalytic reactor; the resulting gas mixture undergoes Fischer-Tropsch synthesis in a second catalytic reactor. In the steam/methane reforming, the gas mixture passes through a narrow channel having mean and exit temperatures both in the range of 750° C. to 900° C., residence time less than 0.5 second, and the channel containing a catalyst, so that only reactions having comparatively rapid kinetics will occur. Heat is provided by combustion of methane in adjacent channels. The ratio of steam to methane may be about 1.5. Almost all methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After Fischer-Tropsch synthesis, the remaining hydrogen may be fed back to the combustion channels. The steam for the reforming step may be generated from water generated by the chemical reactions, by condensing products from Fischer-Tropsch synthesis and by condensing water vapor generated in combustion.

Abstract: A reactor module for Fischer-Tropsch synthesis having a generally rectangular reactor block with a stack of plates defining flow channels for coolant and flow channels for the synthesis reaction arranged alternately in the block. The synthesis flow channels extend in a generally vertical direction between upper and lower faces of the reactor block and are defined by plates in combination with either bars or sheets such that each channel is of width no more than 200 mm. The coolant flow channels are oriented in the same direction, and communicate through distributor chambers with inlet and outlet ports at side faces of the reactor block. A plant may contain a multiplicity of such reactor modules operating in parallel, the modules being interchangeable and replaceable. The temperature control is enhanced by allowing the coolant flow to be parallel to the synthesis gas flow.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, for an endothermic reaction and for an exothermic reaction respectively, and each containing a removable fluid-permeable catalytic insert to catalyze the reaction. The flow channels have a straight portion extending from one end face of the reactor and a linking portion that communicates between the end of the straight portion and at least one side face of the reactor, wherein the straight portion and the linking portion are defined at least in part by fin structures. The fm structures of the linking portion may be perforated, so that there are perforations aligned with each straight portion, but at the end of the reactor each line of perforations is obstructed. Removal of the obstructions enables the catalytic inserts to be pushed out of the flow channels when they are spent.

Abstract: A gas-to-liquids process and plant for treating natural gas, in which the natural gas is subjected to expansion through a flow restrictor so as to undergo cooling through the Joule Thomson effect, enables liquids to be separated from the gas stream. The natural gas may be cooled before it reaches the flow restrictor by heat exchange with fluid that has passed through the flow restrictor. This decreases the proportion of longer-chain hydrocarbons in the natural gas, which may simplify subsequent processing, and may enable the size of the plant to be decreased.

Abstract: A compact catalytic reactor (20) comprises a channel for a rapid reaction having an inlet (26) for a gas mixture to undergo the reaction. The channel is provided with two different catalyst structures (32, 34), a first catalyst structure (32) in the vicinity of the inlet (26) and a second catalyst structure (34) further from the inlet, such that a gas mixture supplied to the inlet flows past them both. The first catalyst structure (32) has little catalytic activity for the rapid reaction, whereas the second catalyst structure (34) has catalytic activity for the rapid reaction. This is applicable to combustion of gas mixtures containing hydrogen, for which the first catalyst structure (32) may comprise uncoated oxidized aluminum-containing ferritic steel, while the second catalyst structure (34) may incorporate Pt and/or Pd in an alumina support. Exhaust gases may also be recycled to the inlet (26) to inhibit combustion.

Abstract: A compact catalytic reactor defining a multiplicity of alternately arranged first and second flow channels, for carrying first and second fluids, respectively. At least the first fluids undergo a chemical reaction. Each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal foil substrate, said catalyst structure defining flow paths therethrough. The substrate comprises a stack of spaced-apart foils wherein the catalyst structure incorporates a multiplicity of resilient strips which are bent out from the foil substrate so as to project from the substrate and to support said catalyst structure resiliently spaced away from at least one adjacent wall of said channel. Each strip being connected to said catalyst structure only at an end or ends of said strip, and being integral with said foil.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least the first fluids undergo a chemical reaction. Each first flow channel containing a removable gas-permeable catalyst structure (20) incorporating a metal substrate, the catalyst structure defining flow paths therethrough, with catalytic material on at least some surfaces of each such path. The catalyst structure also incorporates a multiplicity of projecting resilient lugs (22) which support the catalyst structure (20) spaced away from at least one adjacent wall of the channel (17).

Abstract: Methane reacts with steam generating carbon monoxide and hydrogen in a first catalytic reactor; the resulting gas mixture undergoes Fischer-Tropsch synthesis in a second catalytic reactor. In the steam/methane reforming, the gas mixture passes through a narrow channel having mean and exit temperatures both in the range of 750° C. to 900° C., residence time less than 0.5 second, and the channel containing a catalyst, so that only reactions having comparatively rapid kinetics will occur. Heat is provided by combustion of methane in adjacent channels. The ratio of steam to methane may be about 1.5. Almost all methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After Fischer-Tropsch synthesis, the remaining hydrogen may be fed back to the combustion channels. The steam for the reforming step may be generated from water generated by the chemical reactions, by condensing products from Fischer-Tropsch synthesis and by condensing water vapor generated in combustion.

Abstract: A catalytic reactor (40) comprises a plurality of sheets (42) defining flow channels (44) between them. Within each flow channel (44) is a foil (46) of corrugated material whose surfaces are coated with catalytic material apart from where they contact the sheets (44). At each end of the reactor (40) are headers to supply gas mixtures to the flow channels (44), the headers communicating with adjacent channels being separate. The reactor (40) enables different gas mixtures to be supplied to adjacent channels (44), which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the sheets (42) separating the adjacent channels (44), from the exothermic reaction to the endothermic reaction.

Abstract: Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor (14); the resulting gas mixture can then be used to perform Fisher-Tropsch synthesis in a second catalytic reactor (26). In performing the steam/methane reforming, the gas mixture is passed through a narrow channel in which the mean temperature and exit temperature are both in the range 750° C. to 900° C. the residence time being less than 0.5 second, and the channel containing a catalyst, so that only those reactions that have comparatively rapid kinetics will occur. The heat is provided by combustion of methane in adjacent channels (17). The ratio of steam to methane should preferably be 1.4 to 1.6, for example about 1.5. Almost all the methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After performing Fischer-Tropsch synthesis, the remaining hydrogen is preferably fed back (34) to the combustion channels (17).

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, for an endothermic reaction and for an exothermic reaction respectively, and each containing a removable fluid-permeable catalytic insert to catalyze the reaction. The flow channels have a straight portion extending from one end face of the reactor and a linking portion that communicates between the end of the straight portion and at least one side face of the reactor, wherein the straight portion and the linking portion are defined at least in part by fin structures. The fm structures of the linking portion may be perforated, so that there are perforations aligned with each straight portion, but at the end of the reactor each line of perforations is obstructed. Removal of the obstructions enables the catalytic inserts to be pushed out of the flow channels when they are spent.

Abstract: A catalyst support is made by coating a metal substrate with a solution containing a precursor for a ceramic and an amphiphilic compound, and treating the coating such that it forms a micelle structure. The coating is then treated to form a mesoporous ceramic coating on the metal substrate. The micelle structure acts as a template, so that the pores are of regular size. The active catalytic material can then be deposited in the pores. The metal substrate may for example be a corrugated foil, which can enable reaction heat to be dissipated from hot spots.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, the first flow channels being no more than 10 mm deep and providing flow paths for combustible reactants, and containing a catalyst structure (20) to catalyze combustion of the reactants, and having at least one inlet for at least one of the reactants. The first flow channel also includes an insert (40 or 60) adjacent to each inlet, this insert not being catalytic to the combustion reaction; the insert may define gaps which are narrower than the maximum gap size for preventing flame propagation.

Abstract: A catalytic reaction module (10) for performing an endothermic reaction such as steam methane reforming, includes separate reactor blocks (12), each reactor block defining a multiplicity of first and second flow channels (15, 16) arranged alternately within the block to ensure thermal contact between the first and second flow channels. The reactor blocks (12a, 12b) may be arranged and connected for series flow of a combustible gas mixture in the first flow channels (15) and also of a gas mixture to undergo the endothermic reaction in the second flow channels (16). This enables the combustion process to be carried out in stages, with the option of cooling the combustion gases between stages, and introducing additional fuel and additional air.