Patents by Inventor Raffaele Ostuni

Raffaele Ostuni 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).

  • Publication number: 20210163286
    Abstract: Process including the production of a hydrogen-containing synthesis gas by conversion of a hydrocarbon feedstock, wherein said process has a heat input provided by combustion of a plurality of process fuel streams and said plurality of process fuel streams comprises at least one fuel stream of ammonia. Combustion of said at least one fuel stream of ammonia is performed non-catalytically in at least one fired equipment.
    Type: Application
    Filed: December 5, 2018
    Publication date: June 3, 2021
    Inventors: Raffaele Ostuni, Ermanno Filippi
  • Publication number: 20210156560
    Abstract: A method for the control of nitrogen oxides content in the combustion fumes of a thermal power plant is disclosed; the method comprises the on-site production of ammonia by the steps of: electrolysis of water as a source of hydrogen; separation of air as a source of nitrogen, formation of a make-up gas and synthesis of ammonia in a suitable synthesis loop; said on-site produced ammonia, or a solution thereof, is used for a process of reduction of nitrogen oxides in the combustion fumes.
    Type: Application
    Filed: February 4, 2021
    Publication date: May 27, 2021
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Federico ZARDI
  • Publication number: 20210130272
    Abstract: Process for the synthesis of methanol comprising: reforming a hydrocarbon feedstock into a synthesis gas containing carbon oxides and hydrogen in a molar ratio (H2—CO2)/(CO+CO2) lower than 1.7; elevating said molar ratio to a value of at least 1.9; compressing said synthesis gas and converting the same into crude methanol; separating said crude methanol into a liquid stream of methanol and a gaseous stream containing unreacted synthesis gas; subjecting at least 50% (vol) of said gaseous stream to hydrogen recovery and mixing the recovered hydrogen with said synthesis gas in order to elevate its molar ratio to a value of at least 1.9.
    Type: Application
    Filed: January 31, 2018
    Publication date: May 6, 2021
    Inventors: Maddalena Lepri, Pietro Moreo, Raffaele Ostuni
  • Patent number: 10954187
    Abstract: A process for producing ammonia and a derivative of ammonia from a natural gas feed comprising conversion of natural gas into a make-up synthesis gas; synthesis of ammonia; use of said ammonia to produce said derivative of ammonia, wherein a portion of the natural gas feed is used to fuel a gas engine; power produced by said gas engine; is transferred to at least one power user of the process, such as a compressor; heat is re-covered from exhaust gas of said gas engine; and at least part of said heat may be recovered as low-grade heat available at a temperature not greater than 200° C., to provide process heating to at least one thermal user of the process, such as CO2 removal unit or absorption chiller; a corresponding plant and method of modernization are also disclosed.
    Type: Grant
    Filed: August 5, 2015
    Date of Patent: March 23, 2021
    Assignee: Casale SA
    Inventors: Geoffrey Frederick Skinner, Raffaele Ostuni
  • Patent number: 10954124
    Abstract: A process for producing ammonia make-up synthesis gas and a procedure for revamping a front-end of an ammonia plant for producing ammonia make-up synthesis gas are disclosed, wherein the make-up synthesis gas is produced by means of steam reforming of a hydrocarbon gaseous feedstock; said front-end includes a primary reformer, a secondary reformer, a shift conversion section, a CO2 removal section and optionally a methanation section; a shell-and-tube gas-heated reformer is installed after said secondary reformer, and a portion of the available feedstock is reformed in the tubes of said gas-heated reformer, and heat is provided to the shell side of said gas-heated reformer by at least a portion of product gas leaving the secondary reformer, possibly mixed with product gas leaving the tubes of said gas-heated reformer.
    Type: Grant
    Filed: October 13, 2014
    Date of Patent: March 23, 2021
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20210069643
    Abstract: Process for reducing the content of NOx and N2O from an input tail gas (10) of a nitric acid process, said input tail gas having a temperature lower than 400° C., the process comprising an abatement stage at least including a deN2O stage and deNOx stage and providing a conditioned tail gas (12) having a temperature greater than the input tail gas (10), wherein, prior to submission to said abatement stage, said input tail gas (10) is pre-heated to a temperature of at least 400° C. by indirect heat exchange with at least a portion of said conditioned gas (12).
    Type: Application
    Filed: February 19, 2019
    Publication date: March 11, 2021
    Inventors: Fabio Laurenzi, Raffaele Ostuni, Jean Francois Granger
  • Patent number: 10858313
    Abstract: A process for producing ammonia and a derivative of ammonia from a natural gas feed comprising conversion of natural gas into a make-up synthesis gas; synthesis of ammonia; use of said ammonia to produce said derivative of ammonia, wherein a portion of the natural gas feed is used to fuel a gas turbine; power produced by said gas turbine is transferred to at least one power user of the process, such as a compressor; heat is recovered from exhaust gas of said gas turbine, and at least part of said heat is recovered as low-grade heat available at a temperature not greater than 200° C., to provide process heating to at least one thermal user of the process, such as CO2 removal unit or absorption chiller; a corresponding plant and method of modernization are also disclosed.
    Type: Grant
    Filed: January 18, 2019
    Date of Patent: December 8, 2020
    Assignee: Casale SA
    Inventors: Raffaele Ostuni, Geoffrey Frederick Skinner
  • Patent number: 10816264
    Abstract: A process for purification of a current of hydrogen synthesis gas (100), particularly in the front-end of an ammonia plant, wherein said gas contains hydrogen and minor amounts of carbon monoxide, carbon dioxide, water and impurities, said process including steps of methanation (13) of said current (100), converting residual amounts of carbon monoxide and carbon dioxide to methane and water, dehydration (14) of the gas to remove water, and then a cryogenic purification (15) such as liquid nitrogen wash, to remove methane and Argon; a corresponding plant and method for revamping an ammonia plant are also disclosed.
    Type: Grant
    Filed: June 25, 2014
    Date of Patent: October 27, 2020
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni, Damiano Marzari Chiesa
  • Publication number: 20200317534
    Abstract: A process for the synthesis of ammonia from a make-up gas containing hydrogen and nitrogen, comprising at least two steps for the synthesis of ammonia, wherein: said reactive steps are performed in series and each of said reactive steps provides an ammonia-containing product gas; the second and any subsequent reactive step receives, as a feed stream, at least a portion of the product gas of the previous reactive step; an intermediate adsorptive step of ammonia is performed between consecutive reactive steps, so that the product gas of each step is depleted of ammonia prior to the subsequent reactive step of said series.
    Type: Application
    Filed: April 20, 2017
    Publication date: October 8, 2020
    Inventors: Raffaele OSTUNI, Cristina FERRINI, Javier GOICOCHEA
  • Publication number: 20200290870
    Abstract: Process for manufacturing a hydrogen-containing synthesis gas from a natural gas feedstock, comprising the conversion of said natural gas into a raw product gas and purification of said product gas, the process having a heat input provided by combustion of a fuel; said process comprises a step of conversion of a carbonaceous feedstock, and at least a portion of said fuel is a gaseous fuel obtained by said step of conversion of said carbonaceous feedstock.
    Type: Application
    Filed: June 1, 2020
    Publication date: September 17, 2020
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Geoffrey Frederick SKINNER, Ermanno FILIPPI
  • Publication number: 20200290885
    Abstract: Process for the synthesis of ammonia comprising the steps of reforming of a hydrocarbon feedstock into a raw product gas, purification of said raw product gas obtaining a make-up synthesis gas, conversion of said synthesis gas into ammonia; said purification includes shift conversion of carbon monoxide into carbon dioxide and the reforming process requires a heat input which is at least partially recovered from at least one of said step of shift conversion, which is carried out with a peak temperature of at least 450° C., and said step of conversion into ammonia.
    Type: Application
    Filed: June 4, 2020
    Publication date: September 17, 2020
    Applicant: Casale SA
    Inventors: Raffaele Ostuni, Ermanno Filippi, Umberto Rossi
  • Publication number: 20200289982
    Abstract: A nitric acid production process, comprising tertiary abatement of N2O and NOx on a tail gas withdrawn from an absorption stage, said abatement including passing the tail gas over a sequence of a deN2O stage comprising a Fe-z catalyst and a deNOx stage comprising a V2O5-TiO2 catalyst in the presence of gaseous ammonia, wherein the tail gas at the inlet of deN2O stage and the tail gas at the inlet of deNOx stage have a temperature greater than 400° C.
    Type: Application
    Filed: October 3, 2018
    Publication date: September 17, 2020
    Applicant: Casale SA
    Inventors: Iacopo Cerea, Giada Franceschin, Raffaele Ostuni
  • Publication number: 20200290869
    Abstract: Process for manufacturing a hydrogen-containing synthesis gas from a natural gas feedstock, comprising the conversion of said natural gas into a raw product gas and purification of said product gas, the process having a heat input provided by combustion of a fuel; said process comprises a step of conversion of a carbonaceous feedstock, and at least a portion of said fuel is a gaseous fuel obtained by said step of conversion of said carbonaceous feedstock.
    Type: Application
    Filed: May 29, 2020
    Publication date: September 17, 2020
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Geoffrey Frederick SKINNER, Ermanno FILIPPI
  • Patent number: 10710893
    Abstract: Process for the synthesis of ammonia comprising the steps of reforming of a hydrocarbon feedstock into a raw product gas, purification of said raw product gas obtaining a make-up synthesis gas, conversion of said synthesis gas into ammonia; said purification includes shift conversion of carbon monoxide into carbon dioxide and the reforming process requires a heat input which is at least partially recovered from at least one of said step of shift conversion, which is carried out with a peak temperature of at least 450° C., and said step of conversion into ammonia.
    Type: Grant
    Filed: January 11, 2016
    Date of Patent: July 14, 2020
    Assignee: Casale SA
    Inventors: Raffaele Ostuni, Ermanno Filippi, Umberto Rossi
  • Patent number: 10669154
    Abstract: Process for manufacturing a hydrogen-containing synthesis gas from a natural gas feedstock, comprising the conversion of said natural gas into a raw product gas and purification of said product gas, the process having a heat input provided by combustion of a fuel; said process comprises a step of conversion of a carbonaceous feedstock, and at least a portion of said fuel is a gaseous fuel obtained by said step of conversion of said carbonaceous feedstock.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: June 2, 2020
    Assignee: Casale SA
    Inventors: Raffaele Ostuni, Geoffrey Frederick Skinner, Ermanno Filippi
  • Patent number: 10647587
    Abstract: Process and plant for the synthesis of ammonia from a hydrocarbon feedstock, comprising: primary reforming with steam and air-fired secondary reforming wherein primary reforming is performed at a temperature and pressure of at least 790° C. and 50 bar, and secondary reforming is carried out substantially in absence of excess air, the so obtained make-up synthesis gas having a H2 to N2 molar ratio in the range 2.5 to 3.
    Type: Grant
    Filed: January 27, 2016
    Date of Patent: May 12, 2020
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20200055738
    Abstract: Process for the synthesis of ammonia from natural gas comprising conversion of a charge of desulphurized natural gas and steam, with oxygen-enriched air or oxygen, into a synthesis gas, and treatment of the synthesis gas with shift reaction and decarbonation, wherein a part of the CO2-depleted synthesis gas, obtained after decarbonation, is separated and used as fuel fraction for one or more furnaces of the conversion section, and the remaining part of the gas is used to produce ammonia.
    Type: Application
    Filed: January 31, 2018
    Publication date: February 20, 2020
    Inventors: Francesco Baratto, Raffaele Ostuni
  • Patent number: 10562768
    Abstract: A process and plant for producing a makeup synthesis gas (20) for the synthesis of ammonia, comprising: reforming of a hydrocarbon feedstock (10) in a steam reformer (SMR), purification of said gas product obtaining a hydrogen synthesis gas, addition of a suitable amount of nitrogen (19) to said hydrogen synthesis gas, wherein said purification includes separation of hydrogen in a main separation unit (S1), which produces a hydrogen current (14) and a tail gas (15), and wherein further hydrogen is recovered from the said tail gas (15) in an additional separation unit (S2); some embodiments provides that an amount of gas product (24) is also fed to said additional separation unit; a corresponding method for the revamping of a front-end of an ammonia plant is also disclosed.
    Type: Grant
    Filed: September 2, 2014
    Date of Patent: February 18, 2020
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20200002273
    Abstract: A process for the production of ammonia and urea in an ammonia-urea integrated plant comprising an ammonia section and a tied-in urea section, wherein a hydrocarbon is reformed to produce ammonia make-up synthesis gas; said make-up gas is purified by shift conversion and removal of carbon dioxide; carbon dioxide is removed from the make-up gas by a first and a second CO2 removal sections;the first section removes CO2 by absorption with a suitable medium, and the second section removes CO2 by washing with a carbamate solution taken from the urea section; the make-up gas is reacted to produce ammonia; the CO2 removed from the make-up gas and at least part of the ammonia are used to produce urea.
    Type: Application
    Filed: February 1, 2018
    Publication date: January 2, 2020
    Applicant: Casale SA
    Inventors: Francesco Nettuno, Luca Rugnone, Raffaele Ostuni
  • Patent number: 10514203
    Abstract: Process for the synthesis of ammonia from a make-up gas containing hydrogen and nitrogen, said process comprising: generation of a synthesis gas (8) containing hydrogen and nitrogen in a molar ratio lower than 3, inside a front-end section (2); a first cryogenic purification, designed to remove nitrogen and raise said molar ratio; conversion of the synthesis gas into ammonia (13) inside a high-pressure synthesis loop (6), with extraction from said loop of a purge stream (14) containing hydrogen and inert gases; wherein at least a portion of said purge stream (14) undergoes a further purification in order to recover at least part of the hydrogen contained therein, obtaining at least one stream (15, 15a, 16, 18) containing recovered hydrogen which is recycled to the process.
    Type: Grant
    Filed: November 25, 2015
    Date of Patent: December 24, 2019
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni