Patents by Inventor Sara L. Rolfe
Sara L. Rolfe 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: 10086365Abstract: A method of strengthening a precipitated unsupported iron catalyst by: preparing a precipitated unsupported iron catalyst containing copper and potassium; adding a solution comprising a structural promoter to the previously prepared catalyst; drying the mixture; and calcining the dried catalyst. A method for preparing an iron catalyst, the method comprising: precipitating a catalyst precursor comprising iron phases selected from hydroxides, oxides, and carbonates; adding a promoter to the catalyst precursor to yield a promoted precursor; drying the promoted precursor to yield dried catalyst; and calcining the dried catalyst, wherein the catalyst further comprises copper and potassium. A method of preparing a strengthened precipitated iron catalyst comprising: co-precipitating iron, copper, magnesium, and aluminum; washing the precipitate; alkalizing the precipitate; and drying the precipitate to yield a dried catalyst precursor.Type: GrantFiled: August 26, 2008Date of Patent: October 2, 2018Assignee: RES USA, LLCInventors: Belma Demirel, Charles B. Benham, Dan Fraenkel, Richard A. Bley, Jesse W. Taylor, Sara L. Rolfe, Harold A. Wright
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Patent number: 9649610Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: GrantFiled: August 25, 2014Date of Patent: May 16, 2017Assignee: RES USA, LLCInventors: Harold A. Wright, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray J. Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Patent number: 9522372Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: GrantFiled: July 2, 2013Date of Patent: December 20, 2016Assignee: RES USA, LLCInventors: Harold A. Wright, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray J. Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Patent number: 8946114Abstract: A method of producing stable ferrous nitrate solution by dissolving iron in nitric acid to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2% over a second time period. A method of producing stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, including obtaining a stable ferrous nitrate solution; dissolving iron in nitric acid to form a ferric nitrate solution; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. A method of preparing an iron catalyst is also described.Type: GrantFiled: May 29, 2009Date of Patent: February 3, 2015Assignee: Res USA, LLC.Inventors: Pandurang V. Nikrad, Jesse W. Taylor, Richard A. Bley, Danny M. Dubuisson, Sara L. Rolfe, Belma Demirel, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20150023842Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: ApplicationFiled: August 25, 2014Publication date: January 22, 2015Inventors: Harold A. WRIGHT, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray J. Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Publication number: 20130296448Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: ApplicationFiled: July 2, 2013Publication date: November 7, 2013Inventors: Harold A. Wright, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray J. Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Patent number: 8530366Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: GrantFiled: January 5, 2011Date of Patent: September 10, 2013Assignee: Rentech, Inc.Inventors: Harold A. Wright, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Patent number: 8435920Abstract: Processes are disclosure which comprise alternately contacting an oxygen-carrying catalyst with a reducing substance, or a lower partial pressure of an oxidizing gas, and then with the oxidizing gas or a higher partial pressure of the oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxygenated state. In certain embodiments, the oxygen-carrying catalyst comprises at least one metal oxide-containing material containing a composition having the following formulas: (a) CexByB?zB?O?, wherein B=Ba, Sr, Ca, or Zr; B?=Mn, Co, and/or Fe; B?=Cu; 0.01<x<0.99; 0<y<0.6; 0<z<0.5; (b) Ce1-x-yNixByO2-*, wherein B=Zr, Ba, Ca, La, or K; 0.02<x<0.1; 0<y<0.1; and 0.02<*<0.15; and 1<?<2.2 and (c) coal ash either as a catalyst material itself or as a support for said unary or binary metal oxides.Type: GrantFiled: October 11, 2010Date of Patent: May 7, 2013Assignee: Eltron Research & Development, Inc.Inventors: James H. White, Erick J. Schutte, Sara L. Rolfe
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Patent number: 8138115Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: GrantFiled: February 26, 2010Date of Patent: March 20, 2012Assignee: Rentech, Inc.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20110313061Abstract: A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.Type: ApplicationFiled: January 5, 2011Publication date: December 22, 2011Applicant: RENTECH, INC.Inventors: Harold A. Wright, Belma Demirel, Sergio Mohedas, Bahman Rejai, Ray Huang, Deena Ferdous, Jesse W. Taylor, Dawid J. Duvenhage, Sara L. Rolfe
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Patent number: 7968611Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%: 99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: GrantFiled: February 26, 2010Date of Patent: June 28, 2011Assignee: Rentech, Inc.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20110024687Abstract: Processes are disclosure which comprise alternately contacting an oxygen-carrying catalyst with a reducing substance, or a lower partial pressure of an oxidizing gas, and then with the oxidizing gas or a higher partial pressure of the oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxygenated state. In certain embodiments, the oxygen-carrying catalyst comprises at least one metal oxide-containing material containing a composition having the following formulas: (a) CexByB?zB?O?, wherein B?Ba, Sr, Ca, or Zr; B??Mn, Co, and/or Fe; B??Cu; 0.01<x<0.99; 0<y<0.6; 0<z<0.5; (b) Ce1-x-yNixByO2-*, wherein B?Zr, Ba, Ca, La, or K; 0.02<x<0.1; 0<y<0.1; and 0.02<*<0.15; and 1<?<2.2 and (c) coal ash either as a catalyst material itself or as a support for said unary or binary metal oxides.Type: ApplicationFiled: October 11, 2010Publication date: February 3, 2011Applicant: ELTRON RESEARCH & DEVELOPMENT, INC.Inventors: James H. White, Erick J. Schutte, Sara L. Rolfe
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Patent number: 7879756Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: GrantFiled: August 11, 2008Date of Patent: February 1, 2011Assignee: Rentech, Inc.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Patent number: 7824574Abstract: Processes are disclosure which comprise alternately contacting an oxygen-carrying catalyst with a reducing substance, or a lower partial pressure of an oxidizing gas, and then with the oxidizing gas or a higher partial pressure of the oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxygenated state. In certain embodiments, the oxygen-carrying catalyst comprises at least one metal oxide-containing material containing a composition having one of the following formulas: (a) CexByB?zB?O?, wherein B=Ba, Sr, Ca, or Zr; B?=Mn, Co, or Fe; B?=Cu; 0.01<x<0.99; 0<y<0.6; 0<z<0.5; and 1<?<2.2; (b) SrvLawBxB?yB?zO?, wherein B=Co or Fe; B?=Al or Ga; B?=Cu; 0.01<v<1.4; 0.1<w<1.6; 0.1<x<1.9; 0.1<y<0.9; 0<z<2.2; and 3<?<5.5).Type: GrantFiled: September 20, 2007Date of Patent: November 2, 2010Assignee: Eltron Research & DevelopmentInventors: James H. White, Erick J. Schutte, Sara L. Rolfe
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Publication number: 20100152307Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: ApplicationFiled: February 26, 2010Publication date: June 17, 2010Applicant: RENTECH, INC.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20100152036Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: ApplicationFiled: February 26, 2010Publication date: June 17, 2010Applicant: RENTECH, INC.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20090298681Abstract: A method of producing stable ferrous nitrate solution by dissolving iron in nitric acid to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2% over a second time period. A method of producing stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, including obtaining a stable ferrous nitrate solution; dissolving iron in nitric acid to form a ferric nitrate solution; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. A method of preparing an iron catalyst is also described.Type: ApplicationFiled: May 29, 2009Publication date: December 3, 2009Applicant: RENTECH, INC.Inventors: Pandurang V. Nikrad, Jesse W. Taylor, Richard A. Bley, Danny M. Dubuisson, Sara L. Rolfe, Belma Demirel, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20090298678Abstract: A method of producing a catalyst precursor comprising iron phases by co-feeding a ferrous nitrate solution and a precipitation agent into a ferric nitrate solution to produce a precipitation solution having a desired ferrous:ferric nitrate ratio and from which catalyst precursor precipitates; co-feeding a ferric nitrate solution and a precipitation agent into a ferrous nitrate solution to produce a precipitation solution having a desired ferrous:ferric nitrate ratio and from which catalyst precursor precipitates; or precipitating a ferrous precipitate from a ferrous nitrate solution by contacting the ferrous nitrate solution with a first precipitation agent; precipitating a ferric precipitate from ferric nitrate solution by contacting the ferric nitrate solution with a second precipitation agent and combining the ferrous and ferric precipitates to form the catalyst precursor, wherein the ratio of ferrous:ferric precipitates is a desired ratio.Type: ApplicationFiled: May 29, 2009Publication date: December 3, 2009Applicant: RENTECH, INC.Inventors: Belma DEMIREL, Jesse W. TAYLOR, Pandurang V. NIKRAD, Sara L. ROLFE, Dawid J. DUVENHAGE, Harold A. WRIGHT
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Publication number: 20090069451Abstract: A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.Type: ApplicationFiled: August 11, 2008Publication date: March 12, 2009Applicant: RENTECH, INC.Inventors: Belma Demirel, Charles B. Benham, Jesse W. Taylor, Pandurang V. Nikrad, Sara L. Rolfe, Olga P. Ionkina, Dawid J. Duvenhage, Harold A. Wright
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Publication number: 20090062108Abstract: A method of strengthening a precipitated unsupported iron catalyst by: preparing a precipitated unsupported iron catalyst containing copper and potassium; adding a solution comprising a structural promoter to the previously prepared catalyst; drying the mixture; and calcining the dried catalyst. A method for preparing an iron catalyst, the method comprising: precipitating a catalyst precursor comprising iron phases selected from hydroxides, oxides, and carbonates; adding a promoter to the catalyst precursor to yield a promoted precursor; drying the promoted precursor to yield dried catalyst; and calcining the dried catalyst, wherein the catalyst further comprises copper and potassium. A method of preparing a strengthened precipitated iron catalyst comprising: co-precipitating iron, copper, magnesium, and aluminum; washing the precipitate; alkalizing the precipitate; and drying the precipitate to yield a dried catalyst precursor.Type: ApplicationFiled: August 26, 2008Publication date: March 5, 2009Applicant: RENTECH, INC.Inventors: Belma Demirel, Charles B. Benham, Dan Fraenkel, Richard A. Bley, Jesse W. Taylor, Sara L. Rolfe, Harold A. Wright