Abstract: Methods and apparatus for coating particulate material are provided. The apparatus includes a vessel having a top and a bottom, a vertically extending conduit having an inlet in the vessel and an outlet outside of the vessel, a first fluid inlet in the bottom of the vessel for introducing a transfer fluid, a second fluid inlet in the bottom of the vessel for introducing a coating fluid, and a fluid outlet from the vessel. The method includes steps of agitating a material, contacting the material with a coating material, and drying the coating material to produce a coated material. The invention may be adapted to coat aerogel beads, among other materials. A coated aerogel bead and an aerogel-based insulation material are also disclosed.

Abstract: In one exemplary embodiment, a unit for regenerating a hydrocarbon conversion catalyst for a hydrocarbon conversion zone can generally include passing the hydrocarbon conversion catalyst through, sequentially, a catalyst-disengaging zone having a first atmosphere, an adsorption zone having a second atmosphere, and a regeneration zone including a combustion zone; introducing an inert gas between the first atmosphere and the second atmosphere; and passing a flue gas from the combustion zone to the adsorption zone.

Abstract: Production of polycrystalline silicon in substantially closed-loop processes and systems is disclosed. The processes and systems generally involve disproportionation of trichlorosilane to produce silane or dichlorosilane and thermal decomposition of silane or dichlorosilane to produce polycrystalline silicon.

Abstract: A system for treating an exhaust stream issued by a power plant processes the exhaust stream in a methanol reactor. The exhaust stream contains CO and/or CO2, and can be a full stack or a partial stack exhaust stream. The methanol reactor is a pellet style of methanol reactor, and can be a foam or an alpha alumina oxide foam reactor. A plasma chamber generates H2 for reacting in the methanol reactor. A portion of the exhaust stream issued by the power plant is consumed in the plasma chamber. An algae reactor converts sequestered CO2 to O2. The algae is exposed to the exhaust stream to extract nutrients therefrom and thereby augment growth of the algae. The plasma chamber receives at a high temperature region thereof CO that is reduced to its elemental state. Cooling of the exhaust stream and precipitates the methanol to be re-burned as a fuel.

Abstract: A reaction apparatus for producing trichlorosilane in which metal silicon powder M is reacted with hydrogen chloride gas, thus generating trichlorosilane, includes: an apparatus body into which the metal silicon powder is supplied; and an ejection port for ejecting the hydrogen chloride gas into the apparatus body from the bottom part of the apparatus body, wherein a plurality of holed pieces having a through hole penetrating in the thickness direction and a plurality of pellets interposed between these holed pieces are stacked in a mixed state on the upper side of the ejection port.

Abstract: Provided are an apparatus for manufacturing carbon nanotubes and a method of manufacturing carbon nanotubes with the apparatus. A plurality of carbon-nanotube-synthesizing units are disposed in series to continuously perform a carbon-nanotube-synthesizing process. Thus, carbon nanotubes having a uniform quality can be synthesized.

Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.

Abstract: The invention concerns an apparatus and a method for manufacturing polycrystalline silicon having a reduced amount of boron compounds. The invention provides an apparatus and a method which mix an unpurified trichlorosilane with purified hydrogen gas from an activated carbon tower. The mixture is sent to a distillation apparatus for purifying trichlorosilane.

Abstract: The invention concern an apparatus and a method for manufacturing polycrystalline silicon having a reduced amount of boron compounds. The invention feeds Ar gas in a trichlorosilane line, which connects a trichlorosilane (TCS) tank and a series of distillation units. The distillation units have a pressure transducer and a pressure independent control valve (PIC-V) positioned on a vent gas line for discharging vent gas from the distillation units. Ar gas is fed to the TCS line with higher pressure than the pressure set for opening the PIC-V. The TCS is distilled by the distillation units with continuously discharging vent gas from the distillation units.

Abstract: Catalyst regeneration vessels including a chlorination zone that includes an outer mixing chamber, an inner mixing chamber, and a catalyst bed. The outer mixing chamber can include a lower portion and an upper portion, the lower portion of the outer mixing chamber including at least one air nozzle that injects a drying air stream into the outer mixing chamber, at least one chlorine input nozzle that injects a chlorine input stream into the outer mixing chamber, and at least a first baffle. The chlorination zone can also contain a second baffle that directs the mixed drying air stream and chlorine input stream from the outer mixing chamber to the inner mixing chamber.

Abstract: Methods and apparatus for the production of high purity silicon including a fluidized bed reactor with one or more protective layers deposited on an inside surface of the fluidized bed reactor. The protective layer may be resistant to corrosion by fluidizing gases and silicon-bearing gases.

Abstract: The present invention is an improved regenerated catalyst bend assembly for a fluid catalytic cracking unit. In a preferred embodiment, the reduced elevation (“RE-bend” or “REL-bend”) regenerated catalyst return line assembly of the present invention has an outlet elevation that is lower than the inlet elevation of the RE-bend or REL-bend regenerated catalyst return line assembly, and a process for utilizing the assembly in a fluid catalytic cracking unit. The present invention is especially useful in the modification of existing fluid catalytic cracking units to lower the elevation of the outlet of the regenerated catalyst return line assembly, thereby providing needed space to increase the fluid catalytic cracking reactor riser length.

Abstract: A method for preventing or reducing clogging of a fines ejector in a gas-phase olefin polymerization process is disclosed. The process involves injecting a liquid into the motive gas stream entering the fines ejector.

Abstract: A process for the gas-phase polymerization of ?-olefins carried out in two interconnected polymerization zones, wherein the growing polymer particles flow through the first of said polymerization zones (riser) under fast fluidization conditions, leave said riser and enter the second of said polymerization zones (downcomer) through which they flow downward in a densified form, the process being characterized in that: (a) the gas mixture present in the riser is totally or partially prevented from entering the downcomer by introducing into the upper part of said downcomer a liquid stream LB having a composition different from the gaseous mixture present in the riser; (b) the ratio R between the flow rate Fp of polymer circulated between said downcomer and said riser and the flow rate LB of said liquid being adjusted in a range from 10 to 50.

Abstract: A device for producing a product gas from a fuel, such as biomass, comprises a reactor which is delimited by a base and reactor walls. The reactor walls comprise a peripheral wall and an upper wall. The reactor comprises a supply opening for the supplying of biomass, as well as at least one riser for chemically converting the biomass supplied to a product gas and a solid. The riser is provided inside the peripheral wall and comprises an upper end and a tower end. The reactor furthermore has a discharge opening for discharging the product gas. The riser is attached to at least one reactor wall. The lower end of the riser is at a distance above at least one section of the base which is underneath it and is freely movable under the effect of thermal expansion.

Abstract: A fluidized bed reactor includes a bottom portion, a roof portion and side walls vertically extending between the bottom portion and the roof portion, forming a reaction chamber of the fluidized bed reactor. A solids separator is in connection with the reaction chamber. At least one side wall of the reaction chamber forms at least one indentation in the reaction chamber, which indentation is substantially vertical and extends from the plane of the side wall towards the reaction chamber.

Abstract: Techniques are provided for producing polymer particles of a size just slightly larger than the size of polymer fines. The technique may prevent or limit the occurrence of reactor fouls associated with large polymer particles. The technique also may provide a greater weight percentage of solids in the reactor. The desired polymer particle size may be achieved by employing a catalyst having particles of a size determined based on the expected catalyst productivity. In certain embodiments, the catalyst particle size may be determined based on the expected catalyst productivity, the polymer particle density, the catalyst particle density, and/or the polymer particle size.

Abstract: A reactor for hydrogenation of a silicon tetrahalide and metallurgical grade silicon to trihalosilane includes a bed of metallurgical silicon particles, one or more gas entry ports, one or more solids entry ports, one or more solids drains and one or more ports for removing the trihalosilane from the reactor. Fresh surfaces are generated on the bed particles by internal grinding and abrasion as a result of entraining feed silicon particles in a silicon tetrahalide/hydrogen feed stream entering the reactor and impinging that stream on the bed of silicon particles. This has the advantages of higher yield of the trihalosilane, higher burnup rate of the MGS, removal of spent MGS as a fine dust carryover in the trihalosilane effluent leaving the reactor and longer times between shutdowns for bed removal.

Abstract: Methods and apparatus for the production of high purity silicon including a fluidized bed reactor with one or more protective layers deposited on an inside surface of the fluidized bed reactor. The protective layer may be resistant to corrosion by fluidizing gases and silicon-bearing gases.

Abstract: Production of polycrystalline silicon in a substantially closed-loop process is disclosed. The processes generally include decomposition of trichlorosilane produced from metallurgical grade silicon.

Abstract: A process is disclosed for contacting feed with mixed catalyst in a secondary reactor that is incorporated into an FCC reactor. The mixed catalyst used in the secondary reactor is regenerated catalyst from a regenerator that regenerates spent catalyst from an FCC reactor that is mixed with spent catalyst from either the FCC reactor or the secondary reactor. The mixing of spent and regenerated catalyst reduces the catalyst temperature and tempers catalyst activity to inhibit both thermal and catalytic cracking reactions.

Abstract: The aim of the invention is to devise a flue gas purification system which allows the use of only one absorber even for large systems. The flue gas purification system according to the invention comprises a fluidized-bed reactor having a flue gas inlet unit and a flue gas outlet unit, a nozzle unit being mounted downstream of the flue gas inlet unit. Said nozzle unit is provided with nozzles, said nozzles having different cross-sections.

Abstract: The present invention relates to improved processes for the manufacture of acetic acid. A pump around reactor is used to produce additional heat for the production of steam. The pump around reactor receives a portion of the reaction solution produced by the carbonylation reactor and further reacts that portion with additional carbon monoxide and/or reactants.

Abstract: The apparatus converts FCC olefins to heavier compounds. The heavier compounds are more easily separated from the unconverted paraffins. The heavier compounds can be recycled to an FCC unit or delivered to a separate FCC unit. Suitable conversion zones are oligomerization and aromatic alkylation zones.

Abstract: A method for preparing polyolefin from alpha-olefin with high productivity using an internal circulating fluidized bed polymerization reactor is disclosed. The method for gas-phase polymerization of alpha-olefin comprising the steps of: supplying circulation gas including one or more alpha-olefins and inert gas into a polymerization reactor; polymerizing the alpha-olefin to polyolefin in two separated polymerization areas in the polymerization reactor; and discharging produced polyolefin from the polymerization reactor.

Abstract: A method for treating at least one interior surface (for example, a bed wall) of a fluidized bed polymerization reactor system, including by applying a solution catalyst (preferably at least substantially uniformly and in liquid form) to each surface, and optionally (where a catalyst component of the solution catalyst comprises at least one chromium containing compound) oxidizing at least some of the applied chromium containing compound in a controlled manner.

Abstract: Processing schemes and arrangements are provided for obtaining propylene and propane via the catalytic cracking of a heavy hydrocarbon feedstock and converting the propylene into cumene without separating the propane from the propane/propylene feed stream. The disclosed processing schemes and arrangements advantageously eliminate any separation of propylene from propane produced by a FCC process prior to using the combined propane/propane stream as a feed for a cumene alkylation process. A bottoms stream from the cumene column of the cumene alkylation process can be used and an absorption solvent in the FCC process thereby eliminating the need for a transalkylation reactor and a DIPB/TIPB column.

Abstract: A process for preventing or reducing polymer agglomeration and/or accumulation on or around the gas distribution grid in an olefin polymerization, fluidized-bed reactor. The process involves introducing one or more scouring balls into the reactor above the gas distribution grid, and carrying out olefin polymerization in the presence of the scouring balls. Also disclosed is a process for polymerizing olefins in a fluidized-bed reactor with reduced polymer agglomeration and/or accumulation on the gas distribution grid.

Abstract: A discharge system for removing a solid/gas mixture from a fluidized bed pressure vessel is provided. The discharge system includes a fluidized bed pressure vessel, a settling vessel, a transfer vessel, discharge line, primary discharge valve, and primary exit valve. Also in included is a method to operate the discharge system. The method includes transferring a solid/gas mixture from a fluidized bed pressure vessel to a settling vessel, transferring the solids to a transfer vessel, and then emptying the transfer vessel.

Abstract: A method for preventing or reducing agglomeration and/or accumulation on or around the gas distribution grid in a fluidized-bed vessel. The method involves introducing one or more scouring balls into the vessel above the gas distribution grid, and carrying out a fluidized-bed process in the presence of the scouring balls.

Abstract: A process and apparatus is described in which a sulfiding agent is added to a catalytic conversion reactor to prevent metal catalyzed coking. The catalytic reactor may be downstream from a first fluid catalytic cracking reactor that provides C10— hydrocarbons as feed to the downstream catalytic reactor.

Abstract: A process for producing silicon comprises the steps of a reduction step [1] of depositing silicon by reacting chlorosilanes and hydrogen in a reactor under heat and discharging an exhaust gas that contains hydrogen, oligomers of silanes, and a silicon powder; a carring step [2] of carrying the exhaust gas that has been exhausted in the step [1] while keeping a temperature of the exhaust gas at not less than 105° C.; a removal step [3] of supplying the exhaust gas that has been carried in the step [2] to a filter at a temperature of not less than 105° C. and discharging the exhaust gas from the filter at a temperature of not less than 105° C. to remove the silicon powder from the exhaust gas and give a mixed gas that contains the hydrogen and the oligomers of silanes; and a separation step [4] of cooling the mixed gas that has been obtained in the step [3] to separate the hydrogen as a gas phase from the mixed gas.

Abstract: Methods and systems for preparing catalyst, such as chromium catalysts, are provided. The valence of at least a portion of the catalyst sent to an activator is changed from Cr(III) to Cr(VI). The catalyst is prepared or activated continuously using a fluidization bed catalyst activator.

Abstract: The present invention relates to a high-pressure fluidized bed reactor for preparing granular polycrystalline silicon, comprising (a) a reactor tube, (b) a reactor shell encompassing the reactor tube, (c) an inner zone formed within the reactor tube, where a silicon particle bed is formed and silicon deposition occurs, and an outer zone formed in between the reactor shell and the reactor tube, which is maintained under the inert gas atmosphere, and (d) a controlling means to keep the difference between pressures in the inner zone and the outer zone being maintained within the range of 0 to 1 bar, thereby enabling to maintain physical stability of the reactor tube and efficiently prepare granular polycrystalline silicon even at relatively high reaction pressure.

Abstract: A reactor system includes a fluidized bed reactor with a fluidized zone having sorbent particles and catalyst particles. The sorbent particles are sized to become entrained in a product stream from the fluidized zone and the catalyst particles are sized to gravimetrically stay within the fluidized zone.

Abstract: A fluidized bed reactor device for sequestering flue gas CO2 from a flue gas source is provided. The fluidized bed reactor device comprises an operating portion having a first end and a second end. A flue gas inlet is formed at the first end of the operating portion with the flue gas inlet receiving flue gas from the flue gas source. A flue gas outlet formed at the second end of the operating portion. A distributor plate is mounted within the operating portion adjacent the first end of the operating portion. A volume of fly ash is encased within the operating portion between the second end and the distributor plate with the flue gas traveling through the distributor plate and the fly ash creating reacted flue gas wherein the reacted flue gas exits the operating portion through the flue gas outlet.

Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.

Abstract: A process and apparatus for fluidizing a population of catalyst particles having a low catalyst fines content includes a fluidized bed reactor which includes a plurality of catalyst particles in the reactor wherein the catalyst particles having a d2 value of greater than about 40 microns. The catalyst particles are contacted with a fluidizing medium under conditions to fluidize the particles, the reactor includes a continuous reaction zone and separation zone and the fluidized of the catalyst particles are situated within the reaction and both the reaction zone and the separation zone include obstructing members which obstruct the flow of particles such that the catalyst particles can be maintained at an axial gas Peclet number from about 10 to about 20.

Abstract: A method comprising providing a halogen stream; providing a first alkane stream; reacting at least a portion of the halogen stream with at least a portion of the first alkane stream to form a halogenated stream, wherein the halogenated stream comprises alkyl monohalides, alkyl polyhalides, and a hydrogen halide; providing a second alkane stream; and reacting at least a portion of the second alkane stream with at least a portion of the alkyl polyhalides to create at least some additional alkyl monohalides.

Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.

Abstract: Catalyst withdrawal apparatuses and methods for regulating catalyst inventory in one or more units are provided. In one embodiment, a catalyst withdrawal apparatus for removing catalyst from a FCC unit includes a vessel coupled to a flow control circuit. Another embodiment of a catalyst withdrawal apparatus includes a vessel, a delivery line, and control valve. The control valve is configured to control the amount of gas to the delivery line and entrained with the catalyst. Another embodiment of catalyst withdrawal apparatus includes a vessel coupled to a heat exchanger. The heat exchanger includes a first conduit; a housing confining a coolant volume around a portion of the first conduit; and a sliding seal sealing the housing to the first conduit in manner that allows longitudinal expansion. A fluid catalyst cracking system coupled to a catalyst withdrawal apparatus and method for withdrawing catalyst from a unit are also disclosed.

Abstract: Modular reactor for exothermic/endothermic chemical reactions which take place in three-phase systems, comprising a series of modules, superimposed with respect to each other, fixed to each other by means of coupling flanges, each module consisting of an external cylindrical body and a series of tube bundles, for the circulation of a thermal-exchange fluid, positioned inside said body.

Abstract: Injection nozzles for use in a gas distribution device are disclosed. In one aspect, the injection nozzle may include: a tube having a fluid inlet and a fluid outlet; wherein the inlet comprises a plurality of flow restriction orifices. In another aspect, embodiments disclosed herein relate to an injection nozzle for use in a gas distribution device, the injection nozzle including: a tube having a fluid inlet and a fluid outlet; wherein the fluid inlet comprises an annular orifice surrounding a flow restriction device. Injection nozzles according to embodiments disclosed herein may be disposed in a gas distribution manifold used in a vessel, for example, for conducting polymerization reactions, spent catalyst regeneration, and coal gasification, among others.

Abstract: An installation for increasing the intrinsic viscosity of a polyester material by solid phase polycondensation (SSP) comprises a heatable reaction container (2, 2?) in which the polyester material (P) can be left to reside at a predetermined thermal treatment temperature for a predetermined residence time until it has reached a desired intrinsic viscosity, and a cooling container (6, 6?) arranged downstream of the reaction container, the cooling container (6, 6?) being designed for cooling the polyester material discharged from the reaction container to a first cooling temperature which is lower than the reaction temperature. Downstream of the cooling container (6, 6?), a polyester material separator (7) is arranged which is designed for diverting the polyester material flow to a polyester material processing machine (8) and/or to an intermediate storage container (10).

Abstract: There are disclosed polymerization processes and associated apparatuses. The polymerization processes involve both making a polymeric material in a fluidized bed reactor having a feed distributor and catching a spitwad with a spitwad catcher, and the apparatuses are those corresponding to such processes.

Abstract: A method for treating at least one interior surface (for example, a bed wall) of a fluidized bed polymerization reactor system, including by applying a solution catalyst (preferably at least substantially uniformly and in liquid form) to each surface, and optionally (where a catalyst component of the solution catalyst comprises at least one chromium containing compound) oxidizing at least some of the applied chromium containing compound in a controlled manner.

Abstract: A system includes a fluidization device including a flow passage configured to convey a flow of solid fuel particles in a downstream direction, and a body disposed within the flow passage. The body is configured to direct the flow of solid fuel particles between the body and an outer wall of the flow passage. The fluidization device also includes a carrier gas injection port positioned radially outward from the body. The carrier gas injection port is configured to provide a flow of carrier gas in the downstream direction to break up agglomerations within the flow of solid fuel particles.

Abstract: An FCC apparatus may include a distributor disposed in a recess in a wall of the riser for distributing gaseous hydrocarbon feed to a riser. The distributor may be shielded from upwardly flowing catalyst by a shield. An array of nozzles from the distributor may extend through openings in the shield.

Abstract: A spouted bed device according to the present invention includes a vertically extending cylinder; a decreasing diameter member which is formed on the cylinder, has an inside diameter that decreases progressively downward, and has a gas inlet orifice at a bottom end thereof; and a tubular portion which extends downward from an edge of the gas inlet orifice. A spouted bed is formed in a treatment zone enclosed by a top surface of the decreasing diameter member and an inner wall of the cylinder above the decreasing diameter member.

Abstract: 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.