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: 20170283371
    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: Application
    Filed: August 5, 2015
    Publication date: October 5, 2017
    Applicant: Casale SA
    Inventors: Geoffrey Frederick Skinner, Raffaele OSTUNI
  • Publication number: 20170284667
    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: June 23, 2017
    Publication date: October 5, 2017
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Federico ZARDI
  • Publication number: 20170152218
    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: Application
    Filed: June 3, 2015
    Publication date: June 1, 2017
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Geoffrey Frederick SKINNER
  • Publication number: 20170029282
    Abstract: A method for revamping a front-end of an ammonia plant, said front-end comprising a reforming section (1, 2) with air-fired secondary reformer or autothermal reformer (2), a treatment section (3) of the effluent from said reforming section, and an air feed compressor (6), wherein an O2-containing stream (8) is directed to said reforming section (2) for use as oxidant, at least one nitrogen stream (9) is introduced at a suitable location of the front-end, to provide a desired molar ratio between hydrogen and nitrogen in the product gas, and at least part of said nitrogen stream (9) is compressed via said feed compressor (6).
    Type: Application
    Filed: April 3, 2015
    Publication date: February 2, 2017
    Applicant: Casale SA
    Inventors: Ermanno Filippi, Raffaele OSTUNI
  • Publication number: 20160311680
    Abstract: A process and a related equipment for producing ammonia synthesis gas from a hydrocarbon-containing feedstock (20), the process comprising the steps of: primary reforming with steam (21), secondary reforming with an oxidant stream (23), and purification of the effluent of said secondary reforming, said purification comprising a step of shift conversion (13) of carbon monoxide, wherein the synthesis gas (25) produced by said secondary reforming is subject to a medium-temperature shift over a copper-based catalyst, and the global steam to carbon ratio of the process is not greater than 2.
    Type: Application
    Filed: December 16, 2014
    Publication date: October 27, 2016
    Applicant: Casale SA
    Inventors: Ermanno FILIPPI, Raffaele OSTUNI
  • Patent number: 9463983
    Abstract: A method for regulation of an ammonia plant where a purge gas (10) containing inerts is extracted from ammonia synthesis loop (SL), and where the ammonia plant is operated at a partial load by keeping the ammonia synthesis loop at a nominal high pressure, and reducing the purge rate in order to increase concentration of inerts in the ammonia synthesis loop and avoid overheating of the ammonia reactor; preferably a water electrolysis section (WE) produces a hydrogen feed (3) and an air separator produces a nitrogen feed (4); hydrogen and nitrogen are mixed to form a make up gas (5) which is reacted at a high-pressure in said ammonia synthesis loop (SL).
    Type: Grant
    Filed: September 25, 2012
    Date of Patent: October 11, 2016
    Assignee: Casale SA
    Inventors: Raffaele Ostuni, Federico Zardi
  • Publication number: 20160264411
    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: Application
    Filed: October 13, 2014
    Publication date: September 15, 2016
    Applicant: Casale SA
    Inventors: Ermanno FILIPPI, Raffaele OSTUNI
  • Patent number: 9403146
    Abstract: A method of revamping of an ammonia plant fed with natural gas comprising a primary reformer (11) and a secondary reformer (12), the method comprising at least the following interventions: reducing the outlet temperature of the gas (17) flowing out from said primary reformer; adding a feeding line of substantially pure oxygen (30) directed to said secondary reformer (12) to at least partially replace the comburent process air; adding a nitrogen injection line (31) in an amount necessary to obtain a make-up gas suitable for ammonia synthesis.
    Type: Grant
    Filed: February 8, 2013
    Date of Patent: August 2, 2016
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20160207766
    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: Application
    Filed: September 2, 2014
    Publication date: July 21, 2016
    Applicant: Casale SA
    Inventors: Ermanno FILIPPI, Raffaele OSTUNI
  • Publication number: 20160146535
    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: Application
    Filed: June 25, 2014
    Publication date: May 26, 2016
    Inventors: Ermanno FILIPPI, Raffaele OSTUNI, Damiano CHIESA
  • Publication number: 20160115017
    Abstract: A process for producing ammonia synthesis gas from a hydrocarbon-containing feedstock in a front-end, comprising the steps of steam reforming of said feedstock, obtaining a synthesis gas comprising hydrogen, carbon monoxide and carbon dioxide; a treatment of said synthesis gas including shift of carbon monoxide and subsequent removal of carbon dioxide, wherein the shift of the synthesis gas includes high-temperature shift with an iron-based catalyst and at a temperature greater than 300° C. and the global steam-to-carbon ratio of the front end is 2.6 or less; a corresponding plant and a method for revamping a front-end of an ammonia plant are also disclosed.
    Type: Application
    Filed: May 5, 2014
    Publication date: April 28, 2016
    Applicant: Casale SA
    Inventors: Raffaele Ostuni, Ermanno FILIPPI
  • Publication number: 20160060130
    Abstract: An ammonia plant is disclosed, where ammonia purge gas (20), is sent to a cryogenic recovery unit, said recovery unit comprising means of cooling (102, 202, 302, 402, 502) and a high-pressure phase separator (103, 203, 303, 403, 503) operating at loop pressure; inside said unit the purge gas (20) is cooled to a cryogenic temperature, and a partial liquefaction of methane and argon is achieved; the high-pressure phase separator separates the cooled stream into a gaseous stream and a bottom liquid; the gaseous stream is reheated in a passage of a heat exchanger; the unit is then capable to export a gaseous stream (123, 223, 323, 423, 523) containing nitrogen and hydrogen at loop pressure, that can be reintroduced at the suction side of the circulator (4) of the loop.
    Type: Application
    Filed: November 10, 2015
    Publication date: March 3, 2016
    Applicant: Casale SA
    Inventors: Raffaele Ostuni, Ermanno FILIPPI, Geoffrey Frederick SKINNER
  • Patent number: 9260303
    Abstract: A process for producing ammonia synthesis gas from a hydrocarbon source, comprising: conversion of the hydrocarbon source into a raw synthesis gas (14) in ATR or POX reactor (11) which is fired with oxygen (12) or oxygen-enriched air (28); a water-gas shift treatment of the raw synthesis gas (14), which consist of a medium-temperature shift (15) at a temperature of 200-300° C., thus obtaining a shifted synthesis gas (16); purification of said shifted synthesis gas (16) including at least a step of pressure-swing adsorption (17) to remove residual carbon oxides and methane from the synthesis gas, obtaining a purified synthesis gas (18), and optionally, addition of nitrogen (19) to said purified synthesis gas (18), thus obtaining ammonia synthesis gas with a desired hydrogen to nitrogen ratio.
    Type: Grant
    Filed: January 15, 2013
    Date of Patent: February 16, 2016
    Assignee: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20160023163
    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: October 8, 2015
    Publication date: January 28, 2016
    Applicant: Casale SA
    Inventors: Raffaele OSTUNI, Federico ZARDI
  • Publication number: 20150202546
    Abstract: Process and plant for refining a stream of crude methanol (103), comprising: pre-treatment of the crude methanol in a topping stage (100), for the separation of volatile components, at a defined topping pressure (p1); distillation of methanol with at least one final distillation step of methanol at a defined distillation pressure (p4), in which said distillation pressure (p4) is greater than the topping pressure (p1), and in which a gaseous stream of distilled methanol (440), which is produced in the final distillation step, is used to supply at least part of the heat for the pre- treatment topping step.
    Type: Application
    Filed: November 13, 2012
    Publication date: July 23, 2015
    Applicant: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20150151272
    Abstract: A method of revamping of an ammonia plant fed with natural gas comprising a primary reformer (11) and a secondary reformer (12), the method comprising at least the following interventions: reducing the outlet temperature of the gas (17) flowing out from said primary reformer; adding a feeding line of substantially pure oxygen (30) directed to said secondary reformer (12) to at least partially replace the comburent process air; adding a nitrogen injection line (31) in an amount necessary to obtain a make-up gas suitable for ammonia synthesis.
    Type: Application
    Filed: February 8, 2013
    Publication date: June 4, 2015
    Applicant: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20150139880
    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: January 20, 2015
    Publication date: May 21, 2015
    Applicant: Casale SA
    Inventors: Raffaele Ostuni, Federico Zardi
  • Publication number: 20150129806
    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: Application
    Filed: November 8, 2013
    Publication date: May 14, 2015
    Applicant: Ammonia Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20150014596
    Abstract: A process for producing ammonia synthesis gas from a hydrocarbon source, comprising: conversion of the hydrocarbon source into a raw synthesis gas (14) in ATR or POX reactor (11) which is fired with oxygen (12) or oxygen-enriched air (28); a water-gas shift treatment of the raw synthesis gas (14), which consist of a medium-temperature shift (15) at a temperature of 200-300° C., thus obtaining a shifted synthesis gas (16); purification of said shifted synthesis gas (16) including at least a step of pressure-swing adsorption (17) to remove residual carbon oxides and methane from the synthesis gas, obtaining a purified synthesis gas (18), and optionally, addition of nitrogen (19) to said purified synthesis gas (18), thus obtaining ammonia synthesis gas with a desired hydrogen to nitrogen ratio.
    Type: Application
    Filed: January 15, 2013
    Publication date: January 15, 2015
    Applicant: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni
  • Publication number: 20150008116
    Abstract: Process and plant for refining crude methanol, comprising at least three distillation stages operating in cascade at decreasing pressures, wherein a first stage (200) operates at a maximum distillation pressure (p2), a second stage (300) operates at a medium distillation pressure (p3), and a final distillation stage (400) operates at a minimum distillation pressure (p4), wherein the first stage and the distillation stage each produce a respective gaseous stream (204, 304) of distilled methanol, and a respective solution containing methanol that is fed to the next distillation stage, and wherein at least one first gaseous stream of distilled methanol (204), produced in the first distillation stage, and a second gaseous stream of distilled methanol (304), produced in the second distillation stage, are used as heat sources to heat the second distillation stage and the final distillation stage, respectively.
    Type: Application
    Filed: November 12, 2012
    Publication date: January 8, 2015
    Applicant: Casale SA
    Inventors: Ermanno Filippi, Raffaele Ostuni