Patents by Inventor Tom N. Kalnes

Tom N. Kalnes 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).

  • Patent number: 10369556
    Abstract: An integrated process for gasoline production is described. The process includes introducing a feed comprising n-C5 hydrocarbons into a disproportionation reaction zone in the presence of a disproportionation catalyst to form a disproportionation mixture comprising iso-C4 and C6+ disproportionation products and unreacted n-C5 hydrocarbons. An iso-C4 hydrocarbon stream and an olefin feed are introduced into an alkylation reaction zone in the presence of an alkylation catalyst to produce an alkylation mixture comprising alkylate and unreacted iso-C4 paraffins. The disproportionation mixture and the alkylation mixture are combined, and the combined mixture is separated into at least a stream comprising the alkylate product, an iso-C4 stream, and an unreacted n-C5 hydrocarbon stream. The iso-C4 stream is recycled to the alkylation reaction zone, and the unreacted n-C5 hydrocarbon stream is recycled to the disproportionation reaction zone. The stream comprising the alkylate product is recovered.
    Type: Grant
    Filed: December 11, 2014
    Date of Patent: August 6, 2019
    Assignee: UOP LLC
    Inventors: Tom N. Kalnes, Stuart Smith, Douglas A. Nafis, Alakananda Bhattacharyya, Bryan K. Glover, Susie C. Martins
  • Patent number: 9567534
    Abstract: A flexible process for gasoline refineries is described. The process can vary depending on the available feedstock and the desired products. At one time, the process can involve disproportionating pentanes to a product mixture including isobutane and isohexane. At other times, by switching the feedstock and operating conditions, the process can convert a mixture of C4 and C7 paraffins to a low aromatic blendstock with suitable octane and a vapor pressure lower than butanes. The process can be performed in separate stand-alone units operated at different times, or a single unit can be operated according to one process at one time and according to the other process at another time.
    Type: Grant
    Filed: April 21, 2014
    Date of Patent: February 14, 2017
    Assignee: UOP LLC
    Inventors: Tom N. Kalnes, Stuart Smith, Mary Wier, Alakananda Bhattacharyya, Hayim Abrevaya
  • Publication number: 20160168054
    Abstract: An integrated process for gasoline production is described. The process includes introducing a feed comprising n-C5 hydrocarbons into a disproportionation reaction zone in the presence of a disproportionation catalyst to form a disproportionation mixture comprising iso-C4 and C6+ disproportionation products and unreacted n-C5 hydrocarbons. An iso-C4 hydrocarbon stream and an olefin feed are introduced into an alkylation reaction zone in the presence of an alkylation catalyst to produce an alkylation mixture comprising alkylate and unreacted iso-C4 paraffins. The disproportionation mixture and the alkylation mixture are combined, and the combined mixture is separated into at least a stream comprising the alkylate product, an iso-C4 stream, and an unreacted n-C5 hydrocarbon stream. The iso-C4 stream is recycled to the alkylation reaction zone, and the unreacted n-C5 hydrocarbon stream is recycled to the disproportionation reaction zone. The stream comprising the alkylate product is recovered.
    Type: Application
    Filed: December 11, 2014
    Publication date: June 16, 2016
    Inventors: Tom N. Kalnes, Stuart Smith, Douglas A. Nafis, Alakananda Bhattacharyya, Bryan K. Glover, Susie C. Martins
  • Publication number: 20160168053
    Abstract: An integrated alkylation and disproportionation process and apparatus are described. n-C4 and n-C5 are routed to a disproportionation reaction zone for conversion to iso-C4 and C6+ isoparaffin-rich product. The iso-C4 is routed to an alkylation reaction zone and reacted with refinery propylene and butenes to produce alkylate product. The C6+ isoparaffin-rich product and alkylate product are recovered. Unconverted iso-C4 and/or olefins are recycled to the alkylation reaction zone, and unconverted n-C4 and n-C5 are recycled to the disproportionation reaction zone.
    Type: Application
    Filed: December 11, 2014
    Publication date: June 16, 2016
    Inventors: Tom N. Kalnes, Stuart Smith, Alakananda Bhattacharyya, Mary Wier
  • Publication number: 20160168061
    Abstract: Methods and apparatuses for catalytically generating a polyol from biomass are provided. An exemplary method includes the steps of: contacting a feed stream comprising biomass to acid conditions in a first reaction zone, wherein the acid conditions in the first reaction zone are sufficient to hydrolyze a saccharide from the biomass to generate glucose; directing at least a first portion of a first effluent from the first reaction zone to a second reaction zone; and contacting the at least first portion of the first effluent with a first saccharide-to-polyol catalyst system under conditions suitable for catalytic conversion of saccharide to polyol.
    Type: Application
    Filed: December 10, 2014
    Publication date: June 16, 2016
    Inventors: Tom N. Kalnes, John Qianjun Chen, Joseph Anthony Kocal
  • Publication number: 20160159710
    Abstract: A hydrocarbon disproportionation process is described. The process includes contacting a hydrocarbon feed in a disproportionation reaction zone with a disproportionation catalyst in the presence of hydrogen and an added chloride promoter under disproportionation conditions including to obtain disproportionation products, wherein the disproportionation catalyst comprises a solid catalyst comprising a refractory inorganic oxide having a metal halide dispersed thereon.
    Type: Application
    Filed: December 5, 2014
    Publication date: June 9, 2016
    Inventors: Stuart Smith, Alakananda Bhattacharyya, Tom N. Kalnes, Mary Wier, Paul T. Barger
  • Publication number: 20160159711
    Abstract: A flexible hydrocarbon conversion process utilizing the same reaction zone for isomerization and disproportionation is described. The feed and type of products are selected. The hydrocarbon feed is contacted with a catalyst and in the presence of hydrogen and an added chloride promoter. The catalyst comprises a solid catalyst comprising a refractory inorganic oxide having a metal halide dispersed thereon. The operating conditions are varied depending on whether isomerization or disproportionation is desired.
    Type: Application
    Filed: December 5, 2014
    Publication date: June 9, 2016
    Inventors: Stuart Smith, Tom N. Kalnes, Alakananda Bhattacharyya, Mary Wier
  • Publication number: 20160145178
    Abstract: Methods and apparatuses for catalytically generating a polyol from whole biomass are provided. An exemplary method includes the steps of: depolymerizing at least a portion of lignin present in a stream that includes whole biomass; generating an effluent that includes depolymerized lignin and a saccharide; separating the effluent to generate a depolymerized lignin stream and a saccharide process stream, wherein the saccharide process stream includes a saccharide and an amount of lignin that is reduced relative to an amount of lignin present the effluent; and contacting the saccharide process stream with a saccharide-to-polyol catalyst system under conditions suitable for the catalytic conversion of saccharide to polyol.
    Type: Application
    Filed: November 20, 2014
    Publication date: May 26, 2016
    Inventors: Tom N Kalnes, John Qianjun Chen, Joseph Anthony Kocal
  • Patent number: 9284494
    Abstract: The recovery of solids, and particularly solid particulates used as catalysts in slurry hydroprocessing, from asphaltene containing hydrocarbons is improved by controlling asphaltene precipitation. The formation of agglomerates of the solid particulates, having an increased diameter, results in the presence of precipitated asphaltenes, possibly due to flocculation. Asphaltene precipitation is controlled by varying process parameters or introducing additional diluent or flush streams that change the polarity of an asphaltene containing liquid product recovered from an effluent of a slurry hydroprocessing reaction zone.
    Type: Grant
    Filed: November 15, 2008
    Date of Patent: March 15, 2016
    Assignee: UOP LLC
    Inventors: Lorenz J. Bauer, Tom N. Kalnes, James F. McGehee
  • Patent number: 9222037
    Abstract: Apparatuses and methods for deoxygenating a biomass-derived pyrolysis oil are provided herein. In one example, the method comprises of dividing a feedstock stream into first and second feedstock portions. The feedstock stream comprises the biomass-derived pyrolysis oil and has a temperature of about 60° C. or less. The first feedstock portion is combined with a heated organic liquid stream to form a first heated diluted pyoil feed stream. The first heated diluted pyoil feed stream is contacted with a first deoxygenating catalyst in the presence of hydrogen to form an intermediate low-oxygen pyoil effluent. The second feedstock portion is combined with the intermediate low-oxygen pyoil effluent to form a second heated diluted pyoil feed stream. The second heated diluted pyoil feed stream is contacted with a second deoxygenating catalyst in the presence of hydrogen to form additional low-oxygen pyoil effluent.
    Type: Grant
    Filed: November 14, 2012
    Date of Patent: December 29, 2015
    Assignee: UOP LLC
    Inventor: Tom N. Kalnes
  • Publication number: 20150344382
    Abstract: Methods and systems for hydrogen self-sufficient production of hydrocarbons from a renewable feedstock are provided. An exemplary method includes providing a renewable feedstock; contacting the renewable feedstock and hydrogen from a hydrogen stream with one or more catalysts to generate an effluent comprising n-paraffins and by-product hydrocarbons having 9 or fewer carbon atoms; separating the by-product hydrocarbons from the effluent to generate a hydrocarbon by-product stream; and feeding the hydrocarbon by-product stream to a hydrogen plant to generate the hydrogen stream. In this exemplary embodiment, the by-product hydrocarbons constitute the entire feed and fuel of the hydrogen plant, and wherein no hydrogen is added from an external source.
    Type: Application
    Filed: May 30, 2014
    Publication date: December 3, 2015
    Applicant: UOP LLC
    Inventors: Donald A. Eizenga, Daniel L. Ellig, Tom N. Kalnes
  • Patent number: 9193926
    Abstract: Fuel compositions exhibiting reduced greenhouse gas (GHG) emissions, based on a lifecycle assessment from the time of cultivation of feedstocks (in the case of plant materials) or extraction of feedstocks (in the case of fossil fuels) required for the compositions (up to and including the ultimate combustion of the fuel composition by the end user) are disclosed. The reduced level of emissions (“carbon footprint”) is achieved by incorporating a pyrolysis derived component having a higher heating value than ethanol and meeting other applicable standards for fossil fuel (e.g., petroleum) derived components conventionally used for the same purpose, such as transportation fuels. Advantageously, fuel compositions comprising pyrolysis derived gasoline can exhibit lower GHG emissions than gasoline derived solely from petroleum, or even conventional blends of petroleum derived gasoline and ethanol.
    Type: Grant
    Filed: December 15, 2010
    Date of Patent: November 24, 2015
    Assignee: UOP LLC
    Inventor: Tom N. Kalnes
  • Publication number: 20150299584
    Abstract: A flexible process for gasoline refineries is described. The process can vary depending on the available feedstock and the desired products. At one time, the process can involve disproportionating pentanes to a product mixture including isobutane and isohexane. At other times, by switching the feedstock and operating conditions, the process can convert a mixture of C4 and C7 paraffins to a low aromatic blendstock with suitable octane and a vapor pressure lower than butanes. The process can be performed in separate stand-alone units operated at different times, or a single unit can be operated according to one process at one time and according to the other process at another time.
    Type: Application
    Filed: April 21, 2014
    Publication date: October 22, 2015
    Applicant: UOP LLC
    Inventors: Tom N. Kalnes, Stuart Smith, Mary Wier, Alakananda Bhattacharyya, Hayim Abrevaya
  • Publication number: 20150299593
    Abstract: A process for refining naphtha and upgrading butanes is described. The process involves separating a hydrotreated heavy naphtha feed into a C7-rich fraction and a C8+-rich fraction in a separation zone and then reacting the C7-rich fraction with C4 paraffins to form to a low aromatic gasoline blendstock. The C8+-rich fraction is sent to a reforming zone to form a reformed product with higher octane and lower RVP than a reformed product derived from heavy naphtha.
    Type: Application
    Filed: April 21, 2014
    Publication date: October 22, 2015
    Applicant: UOP LLC
    Inventors: Tom N. Kalnes, Stuart Smith, Hayim Abrevaya, Mary Wier, Alakananda Bhattacharyya
  • Patent number: 9039790
    Abstract: Methods for making a fuel composition comprising contacting one or more components of a hydroprocessing feedstock, for example both a fatty acid- or triglyceride-containing component and a paraffin-rich component, with hydrogen under catalytic hydroprocessing conditions are disclosed. The methods are effective to upgrade the component(s) and provide a hydroprocessed biofuel. A representative method utilizes a single-stage process in which hydrogen-containing recycle gas is circulated through both a hydrodeoxygenation zone and a hydrocracking zone in series.
    Type: Grant
    Filed: December 15, 2010
    Date of Patent: May 26, 2015
    Assignee: UOP LLC
    Inventor: Tom N. Kalnes
  • Publication number: 20140336427
    Abstract: Methods of and apparatuses for upgrading a hydrocarbon stream are provided. In an embodiment, a method of upgrading a hydrocarbon stream includes providing the hydrocarbon stream that includes a deoxygenated pyrolysis product. The hydrocarbon stream also includes a residual oxygen-containing compound content. The residual oxygen-containing compound content of the hydrocarbon stream is reduced to form an upgraded hydrocarbon stream.
    Type: Application
    Filed: May 9, 2013
    Publication date: November 13, 2014
    Inventors: Lance Awender Baird, Douglas B. Galloway, Tom N. Kalnes
  • Patent number: 8883108
    Abstract: This invention relates to a catalyst material, and its method of making and manufacture, useful for a diversity of chemical production processes as well as various emission control processes. More specifically, it relates to a catalyst composition, preferably comprising a metal oxide felt substrate, with one or more functional surface active constituents integrated on and/or in the substrate surface, which can be used in the removal of sulfur and sulfur compounds from hot gases as well as acting to trap solid particulates and trace metals within these hot gases.
    Type: Grant
    Filed: June 14, 2011
    Date of Patent: November 11, 2014
    Assignee: UOP LLC
    Inventors: Manuela Serban, Lisa M. King, Alakananda Bhattacharyya, Tom N. Kalnes, Kurt M. Vanden Bussche
  • Publication number: 20140318944
    Abstract: Disclosed in one embodiment is a method for the catalytic pyrolysis of a carbonaceous material that includes contacting the carbonaceous material with a plurality of catalyst particles to produce a gas phase product and a solid phase product and separating the gas phase product from the solid phase product and the plurality of catalyst particles. The method further includes partially regenerating the plurality of catalyst particles by exposing the solid phase product and the catalyst particles to a first oxidizing condition to produce an oxidized solid phase and a partially-regenerated catalyst and cooling the partially-regenerated catalyst and a non-oxidized portion of the solid phase product. Still further, the method includes further regenerating the partially-regenerated catalyst by exposing the non-oxidized portion of the solid phase product and the partially-regenerated catalyst to a second oxidizing condition.
    Type: Application
    Filed: April 25, 2013
    Publication date: October 30, 2014
    Applicant: UOP LLC
    Inventors: Lance A. Baird, Tom N. Kalnes, Douglas B. Galloway
  • Patent number: 8865954
    Abstract: A process has been developed for producing diesel boiling range fuel from renewable feedstocks such as fats and oils from plants and animals where the process provides for sulfur-component management. The process involves catalytically treating a renewable feedstock by hydrogenating and deoxygenating to provide a hydrocarbon fraction useful as a diesel boiling range fuel. A selective separation such as a hot high pressure hydrogen stripper may be used to remove at least the carbon oxides from the first zone effluent and provide a liquid recycle stream at pressure and temperature. A vapor stream is separated from the net process effluent and at least carbon dioxide is removed using at least one selective or flexible amine absorber. The resulting hydrogen-rich stream is recycled to the reaction zone.
    Type: Grant
    Filed: June 9, 2011
    Date of Patent: October 21, 2014
    Assignee: UOP LLC
    Inventors: Tom N. Kalnes, Terry L. Marker, John P. Brady
  • Patent number: 8865953
    Abstract: A process has been developed for producing diesel boiling range fuel from renewable feedstocks such as plant and animal fats and oils, the process providing for sulfur management. The process involves catalytically treating a renewable feedstock by hydrogenating and deoxygenating to provide a hydrocarbon fraction useful as a diesel boiling range fuel. The hydrocarbon fraction is isomerized to improve cold flow properties. A selective separation such as a hot high pressure hydrogen stripper is used to remove at least the carbon oxides from the first zone effluent before entering the isomerization zone, and to provide liquid recycle to the treating zone at pressure and temperature. A vapor stream is separated from the isomerization effluent and at least carbon dioxide is removed using at least one selective or flexible amine solution absorber. The resulting hydrogen-rich stream is recycled to the deoxygenation reaction zone.
    Type: Grant
    Filed: June 9, 2011
    Date of Patent: October 21, 2014
    Assignee: UOP LLC
    Inventors: John P. Brady, Tom N. Kalnes, Terry L. Marker