Treatment Of Feed Or Recycle Stream Patents (Class 518/705)
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Patent number: 7250449Abstract: A process for converting natural gas to a hydrocarbon liquid wherein a stream of natural gas at a selected pressure is mixed with a hot gas stream which is at a temperature sufficient to affect a chemical reaction and form an intermediate product stream containing reactive hydrocarbons, the intermediate product stream being quenched and the quenched intermediate product stream being reacted in a catalytic liquification zone to produce a hydrocarbon liquid.Type: GrantFiled: October 18, 2002Date of Patent: July 31, 2007Assignee: Bryan Research & Engineering, Inc.Inventors: Keith A. Bullin, Joel G. Cantrell
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Patent number: 7250450Abstract: A process for the production of hydrocarbons from gaseous hydrocarbonaceous feed involving the steps of: i) partial oxidation conversion of the gaseous hydrocarbonaceous feed and oxygen containing gas at elevated temperature and pressure into synthesis gas; ii) catalytical conversion of synthesis gas of step i) using a cobalt based Fischer-Tropsch catalyst into a hydrocarbons comprising stream; iii) separating the hydrocarbons comprising stream of step ii) into a hydrocarbons product stream and a recycle stream; and, iv) removing carbon dioxide from the recycle stream and recycle of carbon dioxide depleted recycle stream to step i).Type: GrantFiled: June 5, 2003Date of Patent: July 31, 2007Assignee: Shell Oil CompanyInventors: Laurent Alain Fenouil, Joannes Ignatius Geijsel, Abdul Razak Mohamad Ali
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Patent number: 7247656Abstract: This disclosure discusses problems associated with using natural gas to produce a variety of synthetic hydrocarbon products by production processes that require syngas feedstocks with varying H2/CO and (H2?CO2)/(CO+CO2) ratios. A number of gas separation membranes are used to vary the composition of the feed streams to different hydrocarbon synthesis units so that different synthetic hydrocarbon products can be produced. The process supplies syngas to an integrated hydrocarbon processing system comprising a number of hydrocarbon synthesis units. Gas (usually a portion of a raw syngas stream) is routed through the separation membrane units, multiple H2-rich and H2-lean streams are produced. These H2-rich and H2-lean streams can then be combined in a controlled fashion to produce feed streams of the desired compositions for the various hydrocarbon synthesis units. A variety of liquid synthetic hydrocarbon products can be produced from a given syngas source as required by market demands.Type: GrantFiled: February 25, 2005Date of Patent: July 24, 2007Assignee: L'Air Liquide, Société Anonyme à Directoire et Conseil de Surveillance pour l'Étude et l'Exploitation des Procedes Georges ClaudeInventors: Chang-Jie Guo, Paul Wentink
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Patent number: 7230034Abstract: The invention relates to methods for prevention of and recovery from a catalyst bed slumping in a gas-agitated multiphase hydrocarbon synthesis reactor, while the reactor is either under non-reactive conditions or under reaction promoting conditions when syngas is converted to products. The reactor contains a catalyst bed comprising catalyst particles and a gas injection zone suitable for injecting a reactor gas feed. A method for preventing bed slumping comprises supplying a supplemental gas to the gas-agitated multiphase reactor to prevent the catalyst bed from slumping due to insufficient reactor gas feed flow. The method may include recycling some or all of the supplemental gas to the reactor. The method may further comprise separating the gas injection zone from the catalyst bed with a porous plate so as to prevent migration of catalyst particles into the gas injection zone and to minimize plugging of gas distributor(s) present in said zone.Type: GrantFiled: March 19, 2004Date of Patent: June 12, 2007Assignee: ConocoPhillips CompanyInventors: Sergio R. Mohedas, Rafael L. Espinoza, Jack E. Cnossen, Todd H. Harkins, Vincent H. Melquist, Larry D. Swinney
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Patent number: 7214720Abstract: The invention relates to an installation and a process for the production of liquid fuels starting from a solid feedstock that contains the organic material in which: a) the solid feedstock is subjected to a gasification stage so as to convert said feedstock into synthesis gas, b) the synthesis gas is subjected to a purification treatment, c) the purified synthesis gas is subjected to a conversion stage that comprises the implementation of a Fischer-Tropsch-type synthesis so as to convert said synthesis gas into a liquid effluent and a gaseous effluent, d) the liquid effluent is fractionated so as to obtain a gaseous fraction, a naphtha fraction, a kerosene fraction and a gas oil fraction, and e) at least a portion of the naphtha fraction is recycled in gasification stage a).Type: GrantFiled: October 25, 2004Date of Patent: May 8, 2007Assignees: Institut Francais du Petrole, Commissariat a l'Energie AtomicInventors: Jérôme Bayle, Guillaume Boissonnet, Eric Marty, Jean-Marie Seiller
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Patent number: 7214721Abstract: A reactor system, plant and a process for the production of methanol from synthesis gas is described in which the reactor system comprises: (a) a first reactor adapted to be maintained under methanol synthesis conditions having inlet means for supply of synthesis gas and outlet means for recovery of a first methanol-containing stream, said first reactor being charged with a first volume of a methanol synthesis catalyst through which the synthesis gas flows and on which in use, partial conversion of the synthesis gas to a product gas mixture comprising methanol and un-reacted synthesis gas will occur adiabatically; and (b) a second reactor adapted to be maintained under methanol synthesis conditions having inlet means for supply of the gaseous first methanol-containing stream, outlet means for recovery of a second methanol-containing stream and cooling means, said second reactor being charged with a second volume of a methanol synthesis catalyst through which the gaseous first methanol-containing stream flowsType: GrantFiled: February 18, 2004Date of Patent: May 8, 2007Assignee: Davy Process Technology LimitedInventor: Philip Henry Donald Eastland
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Patent number: 7208530Abstract: A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. A slurry of particles of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor under conditions whereby methane rich producer gases are generated and fed into a steam pyrolytic reformer under conditions whereby synthesis gas comprising hydrogen and carbon monoxide are generated. A portion of the hydrogen generated by the steam pyrolytic reformer is fed through a hydrogen purification filter into the hydro-gasification reactor, the hydrogen therefrom constituting the hydrogen from an internal source. The remaining synthesis gas generated by the steam pyrolytic reformer is either used as fuel for a gaseous fueled engine to produce electricity and/or process heat or is fed into a Fischer-Tropsch or similar reactor under conditions whereby a liquid fuel is produced.Type: GrantFiled: February 4, 2003Date of Patent: April 24, 2007Assignee: The Regents of the University of CaliforniaInventors: Joseph N. Norbeck, Colin E. Hackett, James E. Heumann, Uy Q. Ngo, Nguyen T. Tran, Bilge Yilmaz
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Patent number: 7183328Abstract: A process for producing methanol is described in which a hydrocarbon is steam reformed in a reforming zone, and during the reforming stage, of a cyclic steam reformer having a reforming stage and a regeneration stage, the steam reforming being conducted under conditions effective to produce a first effluent stream containing synthesis gas. A fuel and an oxygen-containing gas are combusted in the regeneration stage of the reformer so as to reheat the reforming zone to a temperature sufficient for the reforming stage and generate a flue gas. At least part of the first effluent stream is contacted with a methanol synthesis catalyst under conditions effective to convert synthesis gas to methanol and form a methanol-containing stream and a tail gas stream comprising unreacted carbon monoxide and hydrogen.Type: GrantFiled: December 17, 2003Date of Patent: February 27, 2007Assignee: ExxonMobil Chemical Patents Inc.Inventors: Frank Hershkowitz, James R. Lattner
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Patent number: 7168265Abstract: An integrated process for producing LNG and GTL products is provided, wherein a CO2-containing natural gas feed to an LNG production zone is first pre-treated to separate at least a portion of the CO2 therefrom, and the resulting CO2 stream obtained thereby is then directed to a GTL production zone and utilized to make GTL products that include methanol and/or methanol derivatives.Type: GrantFiled: March 22, 2004Date of Patent: January 30, 2007Assignee: BP Corporation North America Inc.Inventors: Michael D. Briscoe, Theo H. Fleisch, Michael J. Gradassi, Jeffrey H. Sawchuk, Pedro Ernesto Fischer-Calderon
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Patent number: 7148261Abstract: A process for producing methanol is described in which a hydrocarbon is steam reformed in a reforming zone, and during the reforming stage, of a cyclic steam reformer having a reforming stage and a regeneration stage, the steam reforming being conducted under conditions effective to produce a first effluent stream containing synthesis gas. Fuel and an oxygen-containing gas are combusted in the regeneration stage of the reformer so as to reheat the reforming zone to a temperature sufficient for the reforming stage and generate a flue gas. At least part of the first effluent stream is contacted with a methanol synthesis catalyst under conditions effective to convert synthesis gas to methanol and form a methanol-containing stream and a tail gas stream comprising unreacted carbon monoxide and hydrogen. At least part of the tail gas stream is recycled as fuel for the regeneration stage of the cyclic steam reformer.Type: GrantFiled: December 14, 2004Date of Patent: December 12, 2006Assignee: ExxonMobil Chemical Patents Inc.Inventors: Frank Hershkowitz, James R. Lattner
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Patent number: 7144559Abstract: Installation for chemical conversion of a feedstock by Fischer-Tropsch reaction comprising a reactor that contains a slurry constituted by at least one suspension of at least one solid in a liquid, a gas feed, a circuit, external to the reactor, of continuous circulation of a stream of slurry, whereby said slurry is drawn off at least one point (A) and reintroduced at least in part at least one other point (B), a section for separation of at least one slurry fluid that passes through said external circuit, whereby said installation also comprises: means allowing to shut down the circulation of said slurry in said circuit, means for introducing under pressure at least one fluid for purging the slurry that is contained in the circuit, and means allowing the circulation of the slurry in said external circuit under conditions such that the Reynolds number is greater than 2,500.Type: GrantFiled: June 25, 2002Date of Patent: December 5, 2006Assignees: Institut Francais du Petrole, AGIP Petroli S.p.A, ENI S.p.A. division de AGIPInventors: Jean-Marc Schweitzer, Eric Lenglet, Franck Gaviot-Blanc
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Patent number: 7144923Abstract: Methanol is synthesized from pre-heated methanol synthesis gas in one or more adiabatic synthesis stages with cooling of the resultant gas after each stage. Further methanol synthesis is then effected on the resultant partially reacted synthesis gas in a bed of synthesis catalyst cooled by means of a coolant flowing co-currently through tubes disposed in the catalyst bed. After cooling methanol is separated from the unreacted gas. Part of the unreacted gas is combined with make-up gas and used as the coolant fed to the aforesaid tubes, thus producing the pre-heated synthesis gas to be fed to the adiabatic synthesis stages.Type: GrantFiled: January 12, 2004Date of Patent: December 5, 2006Assignee: Johnson Matthey PLCInventor: Terence James Fitzpatrick
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Patent number: 7144924Abstract: Hydrocarbons are prepared, liquid at the reaction temperature, by feeding synthesis gas into three-phase turbulent reactors in which the solid phase, consisting of the catalyst in the form of particles, is kept in suspension in the liquid phase by the rising synthesis gas. The reaction product is separated/filtered in continuous from the catalyst dispersed therein by means of at least one filtration device consisting of a hydrocyclone over which there is a first hollow metal element in which a second hollow element is situated, coaxial with the first, made of a material having a porous structure, with an average pore diameter ranging from 0.002 to 0.1 micrometers, suitable for micro/ultrafiltration.Type: GrantFiled: June 18, 2004Date of Patent: December 5, 2006Assignees: ENI S.p.A., Institut Francais du Petrole, Enitechnologie S.p.A.Inventors: Gabriele Carlo Ettore Clerici, Giuseppe Belmonte
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Patent number: 7138434Abstract: Process for converting synthesis gas to higher hydrocarbons, at an elevated temperature and pressure. The process comprises continuously introducing a synthesis gas feed stream comprising 0.1 to 50% by volume of carbon dioxide into a continuous stirred reactor system comprising a reactor vessel containing a suspension of a solid particulate Fischer-Tropsch catalyst suspended in a liquid medium, wherein the solid particulate Fischer-Tropsch catalyst is stable in the presence of carbon dioxide.Type: GrantFiled: May 17, 2002Date of Patent: November 21, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventors: George Albert Huff, Barry Nay
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Patent number: 7125524Abstract: To facilitate operation of a facility for chemical conversion of a feed that comprises a reactor (2) containing a slurry constituted by at least one suspension of at least one solid in a liquid, a gas supply, and a circuit that is external of the reactor, for continuous movement of a slurry stream, wherein the external circuit withdraws slurry from the reactor from at least one point (A) and re-introduces at least a portion of the slurry at at least one other point (B), the facility is further provided with means for stopping circulation of the slurry in the circuit; means for pressurized introduction of at least one fluid for draining the slurry contained in the circuit; and means for circulating the slurry in the external circuit under conditions such that the Reynolds number is more than 2500.Type: GrantFiled: June 5, 2002Date of Patent: October 24, 2006Assignee: Institut Francais du PetroleInventors: Jean-Marc Schweitzer, Eric Lenglet, Franck Gaviot-Blanc
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Patent number: 7115668Abstract: Hydrocarbons are prepared, which are liquid at the reaction temperature, by feeding synthesis gas into three-phase turbulent reactors in which the solid phase, consisting of the catalyst in the form of particles, is kept in suspension in the liquid phase by the rising synthesis gas. The reaction product is extracted in continuous, together with the catalyst dispersed therein, and sent to a separation section which comprises a primary filtration unit and a micro/ultra-filtration unit.Type: GrantFiled: May 14, 2004Date of Patent: October 3, 2006Assignees: ENI S.p.A., Institut Francais du Petrole, Enitecnologie S.p.A.Inventors: Giuseppe Belmonte, Vincenzo Calemma
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Patent number: 7115669Abstract: A gas-agitated multiphase reactor system that is effective for enabling maximum reactor productivity or minimizing reactor volume comprising at least two stages with or without recycle, wherein inlet gas superficial velocity is at least 20 cm/sec at Fischer-Tropsch synthesis, yielding a total syngas conversion of greater than about 90%, while syngas conversion in each reactor is less than 60%. More specifically, the total reactor volume is held to a minimum such that minimum reactor volume is less than 0.02 cubic meters total reactor volume/(kg C5+/hr production).Type: GrantFiled: July 25, 2002Date of Patent: October 3, 2006Assignee: ConocoPhillips CompanyInventors: Jianping Zhang, Harold A. Wright
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Patent number: 7115670Abstract: A process for the conversion of synthesis gas to higher hydrocarbons by synthesis gas, at an elevated temperature and pressure, with a suspension of a particulate Fischer-Tropsch catalyst, in a system comprising at least one high shear mixing zone and a reactor vessel wherein the process comprises: (a) passing the suspension and the gaseous stream through the high shear mixing zone wherein the gaseous stream is broken down into gas bubbles and/or irregularly shaped gas voids; (b) discharging suspension having gas bubbles and/or irregularly shaped gas voids dispersed therein from the high shear mixing zone into the reactor vessel; and (c) maintaining the temperature of the suspension discharged into the reactor vessel at the desired reaction temperature by means of an internal heat exchanger positioned within the suspension in the reactor vessel. At least 5% of the exothermic heat of reaction is removed from the system by means of the internal heat exchanger.Type: GrantFiled: May 17, 2002Date of Patent: October 3, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventors: John Richard Hensman, David Newton
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Patent number: 7112613Abstract: Process for converting synthesis gas to hydrocarbons which comprises contacting a gaseous stream comprising synthesis gas, at an elevated temperature and pressure, with a suspension comprising a particulate Fischer-Tropsch catalyst having a particle size in the range 5 microns to 500 microns, suspended in a liquid medium, in a system comprising at least one high shear mixing zone and a reactor vessel. The suspension and the gaseous stream is passed through the high shear mixing zone(s) wherein the gaseous stream is broken down into gas bubbles. The suspension having gas bubbles dispersed therein is discharged from the high shear mixing zone(s) into the reactor vessel, and suspension comprising the particulate Fischer-Tropsch catalyst suspended in the liquid medium and liquid hydrocarbon products is withdrawn from the reactor vessel and at least a portion of the suspension is recycled to the high shear mixing zone(s) via an external conduit at a flow rate of at least 10,000 m3 of suspension per hour.Type: GrantFiled: May 17, 2002Date of Patent: September 26, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventors: Timothy Douglas Gamlin, Carole Graham, John Richard Hensman, Barry Nay, David Newton
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Patent number: 7098251Abstract: Hydrocarbons are prepared, liquid at the reaction temperature, by feeding synthesis gas into three-phase turbulent reactors wherein the solid phase, consisting of the catalyst in particle form, is kept in suspension in the liquid phase by the rising synthesis gas. The reaction product is separated/filtrated in continuous from the catalyst dispersed therein, by means of a separation/filtration unit consisting of several filtration cartridges, each consisting of at least two porous filtering elements, the first having an average pore diameter ranging from 0.5 to 15 ?m, whereas the second has an average pore diameter ranging from 0.002 to 0.1 ?m.Type: GrantFiled: May 5, 2004Date of Patent: August 29, 2006Assignees: ENI S.p.A., Institut Francais du Petrole, Enitecnologie S.p.A.Inventors: Gabriele Carlo Ettore Clerici, Giuseppe Belmonte
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Patent number: 7087651Abstract: Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor; the resulting gas mixture can then be used to perform Fischer-Tropsch synthesis in a second catalytic reactor. In performing the steam/methane reforming, the gas mixture is passed through a narrow flow channel containing a catalyst structure on a metal substrate, and adjacent to a source of heat, in a time less than 0.5 s, so that only those reactions that have comparatively rapid kinetics will occur. Both the average temperature and the exit temperature of the channel are in the range 750° to 900° C. The ratio of steam to methane should preferably be 1.4 to 1.6, for example about 1.5. Almost all the methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After performing Fischer-Tropsch synthesis, the remaining hydrogen is preferably used to provide heat for the reforming reaction.Type: GrantFiled: December 2, 2002Date of Patent: August 8, 2006Assignee: GTL Microsystems AGInventors: Clive Derek Lee-Tuffnell, Ian Frederick Zimmerman, Michael Joseph Bowe, Jason Andrew Maude
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Patent number: 7071238Abstract: Process for the conversion of synthesis gas to hydrocarbons, at least a portion of which are liquid at ambient temperature and pressure, by contacting the synthesis gas at an elevated temperature and pressure with a suspension comprising a particulate Fischer-Tropsch catalyst suspended in a liquid medium, in a reactor system comprising at least one high shear mixing zone and a reactor vessel. The process comprises passing the suspension and synthesis gas through the high shear mixing zone(s) where the synthesis gas is broken down into gas bubbles and/or irregularly shaped gas voids; discharging suspension having gas bubbles and/or irregularly shaped gas voids dispersed therein from the high shear mixing zone(s) into the reactor vessel; and introducing a liquid coolant into the reactor system.Type: GrantFiled: May 17, 2002Date of Patent: July 4, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventors: Timothy Douglas Gamlin, Lawrence Trevor Hardy, David Newton
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Patent number: 7067560Abstract: Natural gas is processed to generate longer-chain hydrocarbons, the process comprising subjecting the gas to steam reforming to generate a mixture of carbon monoxide and hydrogen, and then subjecting this mixture to Fischer-Tropsch synthesis. The reforming reaction (20) is performed at 0.4–0.5 MPa and the Fischer-Tropsch synthesis (50) at 1.8–2.1 MPa, and two compressors (36, 44) are used to raise the pressure, the gas mixture being cooled (26, 32, 40) before and after the first compressor (36). This reduces both the operating cost and capital cost of the plant.Type: GrantFiled: March 14, 2005Date of Patent: June 27, 2006Assignee: GTL Microsystems AGInventor: Michael Joseph Bowe
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Patent number: 7067558Abstract: A process for the production of methanol from liquid or gaseous starting materials, in which the emission of carbon dioxide is reduced or completely eliminated.Type: GrantFiled: March 25, 2003Date of Patent: June 27, 2006Assignee: Lurgi AGInventors: Mauricio Grobys, Hermann Göhna, Thomas Wurzel
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Patent number: 7045553Abstract: The invention provides a method for producing liquid hydrocarbons by first generating in a pressure swing reformer a synthesis gas stream having a mole ratio of H2:CO greater than 2:1. Then, a portion of the hydrogen is separated to produce a synthesis gas stream having a mole ratio of H2:CO of about 2:1 which steam is then introduced into a hydrocarbon synthesis reactor for conversion to liquid products.Type: GrantFiled: February 4, 2004Date of Patent: May 16, 2006Assignee: ExxonMobil Research and Engineering CompanyInventor: Frank Hershkowitz
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Patent number: 7037948Abstract: A method of increasing the production in an existing process plant for converting natural gas into a product, where the natural gas is first converted to a synthesis gas in a synthesis gas section, the synthesis gas is brought to reaction in a reactor for synthesis of the product, where non-converted synthesis gas and product are separated into two streams, where a product-rich stream is taken off the process, while a product-poor stream is re-circulated back as feed to the reactor together with fresh synthesis gas, and where part of the re-circulating stream is taken off the re-circulation loop as a purge gas, where the purge gas is separated into hydrogen-rich and hydrogen-poor streams, where hydrogen-rich streams are introduced in stages of the process where addition of hydrogen is desirable, and where the residual thermal value of the hydrogen-poor stream may be used for heating prior to the stream being discharged, wherein the synthesis gas from the synthesis gas section receives a hydrogen-rich stream fType: GrantFiled: June 27, 2002Date of Patent: May 2, 2006Assignee: Statoil ASAInventors: Roger Hansen, Jostein Sogge, Bjorn Jarle Veland, Ola Olsvik
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Patent number: 7034062Abstract: Process for the conversion of synthesis gas to higher hydrocarbons. A gaseous stream comprising synthesis gas is contacted at an elevated temperature and pressure with a suspension comprising a particulate Fischer-Tropsch catalyst suspended in a liquid medium, in a reactor system comprising at least one high shear mixing zone and a tubular loop reactor. The suspension and the gaseous stream are passed through the high shear mixing zone(s) wherein the gaseous stream is broken down into gas bubbles and/or irregularly shaped gas voids. Suspension having gas bubbles and/or irregularly shaped gas voids dispersed therein is discharged from the high shear mixing zone(s) into the tubular loop reactor, the discharged suspension is circulated around the tubular loop reactor, and a product suspension stream comprising at least a portion of the circulating suspension is withdrawn from the tubular loop reactor.Type: GrantFiled: May 17, 2002Date of Patent: April 25, 2006Assignees: BP Exploration Operatiing Company Limited, Davy Process Technology LimitedInventors: Josephus Johannes Helena Maria Font Freide, David Newton, Christopher Sharp
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Patent number: 7030166Abstract: A process to optimize a slurry Fischer-Tropsch catalyst life and to further optimize removal of debris from a slurry Fischer-Tropsch process is provided. The process passes a part of a Fischer-Tropsch Reactor slurry inventory to another upstream Fischer-Tropsch Reactor where the Fischer-Tropsch reactors are connected in series. The process utilizes either multiple or a single transfer vessel and optionally, a motive gas.Type: GrantFiled: April 8, 2005Date of Patent: April 18, 2006Assignee: Syntroleum CorporationInventors: James Leahy, Juan Inga
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Patent number: 7017661Abstract: A coal formation may be treated using an in situ thermal process. A mixture of hydrocarbons, H2, and/or other formation fluids may be produced from the formation. Heat may be applied to the formation to raise a temperature of a portion of the formation to a synthesis gas production temperature. A synthesis gas producing fluid may be introduced into the formation to generate synthesis gas. Synthesis gas may be produced from the formation in a batch manner or in a substantially continuous manner.Type: GrantFiled: April 24, 2001Date of Patent: March 28, 2006Assignee: Shell Oil CompanyInventors: Harold J. Vinegar, Scott Lee Wellington, Eric Pierre de Rouffignac, John Michael Karanikas, Ilya Emil Berchenko, George Leo Stegemeier, Kevin Albert Maher, Etuan Zhang, Thomas David Fowler, Robert Charles Ryan, Robert Martijn Van Hardeveld
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Patent number: 7019038Abstract: Methods for reducing the average molecular weight of liquid hydrocarbons in a Fischer-Tropsch reactor are disclosed. The preferred embodiments of the present invention are characterized by feeding a hydrocarbon stream, which lowers the average molecular weight of the hydrocarbon liquids inside the reactor, and more preferably by recycling a portion of low-molecular weight hydrocarbon products back into the reactor. Lowering the molecular weight of the hydrocarbon liquids inside the reactor increases the mass transfer and solubility, and diffusivity of the reactants in the hydrocarbons present in the slurry.Type: GrantFiled: May 23, 2003Date of Patent: March 28, 2006Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Harold A. Wright, Jianping Zhang
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Patent number: 7012102Abstract: The present invention provides a process for the conversion of synthesis gas to hydrocarbons comprising the steps of: a) contacting synthesis gas at an elevated temperature and pressure with a particulate Fischer-Tropsch catalyst in a Fischer-Tropsch reactor system to generate hydrocarbons comprising gaseous and liquid hydrocarbons; b) in a gas separation zone, separating a gaseous phase comprising saturated gaseous hydrocarbons from a liquid phase comprising liquid hydrocarbons and from the particulate Fischer-Tropsch catalyst; c) passing at least a portion of the separated gaseous phase to a dehydrogenation reactor where at least a portion of the saturated gaseous hydrocarbons are converted to unsaturated hydrocarbons; and d) recycling at least a portion of said unsaturated hydrocarbons back to the Fischer-Tropsch reactor system.Type: GrantFiled: May 17, 2002Date of Patent: March 14, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventors: Josephus Johannes Helena Maria Font Freide, Stephen Anthony Leng, Christopher Sharp
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Patent number: 7008968Abstract: Process of contacting a gaseous reactant stream comprising synthesis gas at elevated temperature and pressure with a suspension of a particulate Fischer-Tropsch catalyst comprising cobalt in a liquid medium in a reactor system comprising at least one high shear mixing zone and a reactor vessel, by a) contacting the particulate Fischer-Tropsch catalyst with a reducing gas at elevated temperature and pressure outside of the high shear mixing zone(s) and the reactor vessel and subsequently suspending the particulate Fischer-Tropsch catalyst in the liquid medium; b) passing the suspension from step a) through the high shear mixing zone(s) where the gaseous reactant stream comprising synthesis gas is mixed with the suspension; c) discharging a mixture comprising the synthesis gas and the suspension from the high shear mixing zone(s) into the reactor vessel; and d) converting the synthesis gas to liquid hydrocarbons in the reactor vessel to form a product suspension comprising the particulate Fischer-Tropsch catalyType: GrantFiled: May 17, 2002Date of Patent: March 7, 2006Assignees: BP Exploration Operation Company Limited, Davy Process Technology LimitedInventors: Josephus Johannes Helena Maria Font Freide, Barry Nay, Christopher Sharp
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Patent number: 7008967Abstract: A process (10) for producing synthesis gas includes, in a gasification stage (12), gasifying a carbonaceous feestock to provide a raw synthesis gas which includes at least H2, CO and CH4 and, in a partial oxidation stage (14), subjecting the raw synthesis gas to partial oxidation in the presence of oxygen to provide an upgraded synthesis gas which includes less CH4 and more H2 and CO than the raw synthesis gas. The invention extends to a process for producing a synthesis gas derived product.Type: GrantFiled: October 27, 2003Date of Patent: March 7, 2006Assignee: Sasol Technology (Proprietary) LimitedInventors: Martin Jakobus Keyser, Margaretha Coertzen
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Patent number: 7005456Abstract: A method of starting up a Fischer-Tropsch reaction in a system comprising at least one high shear mixing zone and a reactor vessel which method comprises a) passing a suspension of a particulate Fischer-Tropsch catalyst in a liquid medium through the high shear mixing zone(s) into the reactor vessel and recycling at least a portion of the suspension to the high shear mixing zone(s) in the substantial absence of a gaseous reactant feed stream comprising synthesis gas; b) increasing the temperature and/or pressure within the reactor vessel until a threshold temperature and/or pressure is reached and subsequently introducing a gaseous reactant stream comprising synthesis gas into the high shear mixing zone(s) where the gaseous reactant stream is mixed with the suspension; c) discharging a mixture comprising synthesis gas and the suspension from the high shear mixing zone(s) into the reactor vessel; d) converting the synthesis gas to liquid hydrocarbons in the reactor vessel to form a product suspension comprisinType: GrantFiled: May 17, 2002Date of Patent: February 28, 2006Assignees: BP Exploration Operating Company Limited, Davy Process Technology LimitedInventor: Josephus Johannes Helena Maria Font Freide
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Patent number: 7001927Abstract: A method for water removal in hydrocarbon product reactors operating at Fischer-Tropsch conditions. The water removal decreases the concentration of water in the reactor. In one embodiment, a method of reducing the concentration of water in a Fischer-Tropsch reactor containing a water-rich hydrocarbon product includes removing water from the water-rich hydrocarbon product of the reactor by a water removal means so as to form a water-reduced hydrocarbon product and returning that product to the reactor.Type: GrantFiled: December 16, 2002Date of Patent: February 21, 2006Assignee: ConocoPhillips CompanyInventors: Jianping Zhang, Harold A. Wright, Yi Jiang, Joe D. Allison, Kenneth M. York, Sergio R. Mohedas, Vincent H. Melquist
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Patent number: 6992112Abstract: The present invention is an improvement in the preparation of liquid hydrocarbons from natural gas/methane, oxygen and/or steam. In particular, the present invention relates to processes for the production of synthesis gas, reducing the oxygen concentration from the synthesis gas, and the production of liquid hydrocarbons using the oxygen reduced synthesis gas as a feedstock. More particularly, the present invention described herein identifies catalyst compositions, apparatus and methods of using such catalysts and apparatus for preparing liquid hydrocarbons via oxygen reduced synthesis gas all in accordance with the present invention.Type: GrantFiled: April 12, 2004Date of Patent: January 31, 2006Assignee: ConocoPhillips CompanyInventors: Daxiang Wang, Harold A. Wright, Beatrice C. Ortego, Sinh Trinh, Rafael Espinoza
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Patent number: 6992113Abstract: CO2 emissions from syngas conversion processes are reduced by use of a multi-stage Fischer-Tropsch reaction system. A process for the conversion of syngas using a Fischer-Tropsch reactor comprises forming a first syngas and reacting at least a portion of the first syngas in a Fischer-Tropsch reactor to form a first hydrocarbonaceous product and a second syngas. The second syngas is mixed with a hydrogen-containing stream to provide an adjusted syngas, at least a portion of which is reacted in a dual functional syngas conversion reactor to form a second hydrocarbonaceous product and a third syngas comprising a reduced amount of CO2 than was present in the adjusted syngas.Type: GrantFiled: November 25, 2003Date of Patent: January 31, 2006Assignee: Chevron U.S.A. Inc.Inventors: Dennis J. O'Rear, Charles L. Kibby
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Patent number: 6974844Abstract: A process for starting up a Fischer-Tropsch reactor includes establishing, in the reactor, an initial charge of molten wax. The initial reactor temperature is below the line-out reactor temperature but is sufficiently high for a Fischer-Tropsch reaction to take place. The reactor contains, in contact with the molten wax, at least a portion of its line-out catalyst inventory. Syngas is fed into the reactor at an initial flow rate below the line-out syngas flow rate. Initially a syngas H2:CO molar ratio is maintained at a higher value than its line-out value, whereafter the syngas H2:CO molar ratio is decreased to its line-out value. The syngas flow rate and the reactor temperature are then increased to their line-out values.Type: GrantFiled: August 10, 2004Date of Patent: December 13, 2005Assignee: Sasol Technology (Proprietary) LimitedInventor: André Peter Steynberg
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Patent number: 6956063Abstract: The present invention relates to a method and apparatus for water removal in multi-phase reactors operating at Fischer-Tropsch conditions. In a preferred embodiment of the present invention, a method of reducing the concentration of water in a multi-phase reactor for Fisher-Tropsch synthesis containing an expanded slurry bed and a water-rich slurry region includes removing a portion of water from the water-rich slurry from a predetermined region in the reactor, removing the water from the water-rich slurry to form a water-reduced slurry, and returning the water-reduced slurry back to the reactor. Preferably the water-rich slurry region is located between ½ H to H and ½ R to R, where H is the height of the expanded slurry bed and R is the radius of the expanded slurry bed.Type: GrantFiled: December 10, 2002Date of Patent: October 18, 2005Assignee: ConocoPhillips CompanyInventors: Jianping Zhang, Rafael L. Espinoza
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Patent number: 6946494Abstract: A process for the heterogeneous synthesis of chemical compounds such as methanol and ammonia through catalytic conversion of the respective gaseous reactants that are made to pass through a first (2) and a second (3) reaction zone connected in series with each other, in which they react in pseudoisothermal conditions, distinguishes itself in that in the first reaction zone (2) the gaseous reactants are made to flow through a fixed mass of an appropriate catalyst in which a plurality of substantially box-like, plate-shaped heat exchangers (21), arranged side-by-side and crossed by a heat exchange operating fluid, is dipped.Type: GrantFiled: October 2, 2002Date of Patent: September 20, 2005Assignee: Methanol Casale S.A.Inventors: Ermanno Filippi, Enrico Rizzi, Mirco Tarozzo
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Patent number: 6946493Abstract: The present invention provides a process for managing hydrogen in a hydrocarbon gas to liquid plant. The process includes feeding a syngas stream produced by a partial oxidation reactor to a Fischer-Tropsch reactor, thereby converting the syngas to hydrocarbon liquids. It also includes passing a substantially oxygen-free feed stream comprising hydrocarbon gas and water to a steam reformer, thereby producing a hydrogen-rich stream. The H2/CO ratio in the syngas feed stream can be adjusted to a desired value by introducing a first portion of the hydrogen-rich stream to the syngas feed stream. A second portion of the hydrogen-rich stream can be passed to one or more hydrogen users, e.g., a catalyst regeneration unit, in the GTL plant.Type: GrantFiled: March 15, 2003Date of Patent: September 20, 2005Assignee: ConocoPhillips CompanyInventors: Sergio R. Mohedas, Stephen R. Landis, Rafael L. Espinoza, Ralph T. Goodwin, III, Barbara A. Belt
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Patent number: 6921778Abstract: The invention relates to a process for converting a synthesis gas into liquid hydrocarbons used in at least two reactors that are arranged in series and that contain a catalytic suspension of at least one solid catalyst in suspension in a liquid phase, in which said reactors are essentially perfectly mixed, the last reactor is at least in part fed by at least a portion of at least one of the gaseous fractions that are collected at the outlet of at least one of the other reactors, at least one reactor is fed by a flow of catalytic suspension that is obtained directly from another reactor, and at least one flow of catalytic suspension that is obtained from a reactor is at least in part separated so as to obtain a liquid product that is essentially free of catalyst and a catalytic suspension that is high in catalyst, which is recycled.Type: GrantFiled: November 20, 2002Date of Patent: July 26, 2005Assignees: Institut Francais du Petrole, AGIP Petroli S.p.A., ENI S.p.A.Inventors: Ari Minkkinen, Reynald Bonneau, Alexandre Rojey
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Patent number: 6903139Abstract: Embodiments include a method and apparatus for producing synthesis gas in a catalytic partial oxidation reactor by adding hydrogen to the reactor feed stream.Type: GrantFiled: November 21, 2002Date of Patent: June 7, 2005Assignee: ConocoPhillips CompanyInventors: Stephen R. Landis, Lisa M. Carmichael, Kevin L. Ricketson, Thomas R. Ruddy, II
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Patent number: 6900247Abstract: A process for the production of hydrocarbons and ammonia, and more particularly a process for optimizing the production of hydrocarbons and ammonia using a combined hydrocarbon synthesis plant and ammonia synthesis plant. Synthesis gas exiting a reforming section of the hydrocarbon synthesis process is sent to a hydrogen extraction unit, where it is divided into a hydrogen-rich stream and a hydrogen-poor stream. The hydrogen-rich stream is then fed into an ammonia synthesis process. The hydrogen-poor stream may be returned to the hydrocarbon synthesis process or may be used as a fuel gas. The process reduces emission of CO2 into the atmosphere, and requires only one reforming section and one air separation unit for both processes. Removal of hydrogen from the hydrocarbon synthesis process before the synthesis gas enters a Fischer-Tropsch reactor also lowers the H2/CO ratio of the synthesis gas, therefore resulting in better hydrocarbon selectively.Type: GrantFiled: January 25, 2002Date of Patent: May 31, 2005Assignee: Sasol Technology (Proprietary) LimitedInventors: Julian Graham Price, Barry Antony Tindall
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Patent number: 6897246Abstract: A process for reducing C2-C9 olefin formation by recycling them to a Fischer-Tropsch hydrocarbon synthesis process and promoting recycled olefins chain growth comprises contacting a gas feed comprising a mixture of H2 and CO with a catalyst in a reactor system at conditions effective to produce a hydrocarbon product stream including C2-C9 olefins, separating a C2-C9 olefins-rich stream from the hydrocarbon product stream to form a light olefin recycle stream and recycling the light olefin recycle stream to the reactor system at a point in the reactor system where the H2:CO ratio is low relative to the H2:CO ratio in the rest of the reactor system. Depending on whether the initial H2:CO ratio is greater or less than the usage ratio of the selected catalyst, the recycled olefins can be returned to the system up- or downstream of the reactor system.Type: GrantFiled: November 12, 2002Date of Patent: May 24, 2005Assignee: ConocoPhillips CompanyInventors: Rafael L. Espinoza, Ajoy P. Raje, Doug S. Jack
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Patent number: 6887390Abstract: Methods for producing clean liquid/wax products from a slurry used in a Fischer-Tropsch reactor are disclosed. In general, one embodiment of the present invention comprises a solid/liquid filtration system having a filter medium comprising a substrate and a filter cake deposited on the substrate, wherein the filter cake is generated by deposition of solids from the slurry. The thickness of the filter cake can be maintained within a desired range by controlling the slurry velocity and/or the pressure differential across the filter medium. This invention relates to a method of operation of such filtration system which increases filtration cycle time and improved filtrate quality resulting in very low solid content in filtrate.Type: GrantFiled: April 16, 2003Date of Patent: May 3, 2005Assignee: ConocoPhillips CompanyInventors: Sergio R. Mohedas, Rafael L. Espinoza, Doug S. Jack, Oluwasei A. Odueyungbo, James Dale Ortego, Jr.
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Patent number: 6887907Abstract: In a process for the use of a hydrocarbon feedstock (10) by reacting the feedstock in a reactor (11) with oxygen (9) to form a synthesis gas containing at least carbon monoxide, carbon dioxide and hydrogen and subjecting the synthesis gas to a conversion process comprising an exothermic reaction to produce dimethyl ether in a converter (15), the converter operating at an operating pressure, said oxygen being provided to the reactor at an oxygen pressure, the synthesis gas is produced at a pressure higher than the operating pressure of the converter.Type: GrantFiled: February 9, 2004Date of Patent: May 3, 2005Assignee: L'Air Liquide - Societe Anonyme a Directoire et Conseil de Surveillance pour l'Etude et l'Exploitation des Procedes Georges ClaudeInventors: Alain Guillard, Emmanuel Schmidt
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Patent number: 6881758Abstract: In a process-for the use of a hydrocarbon feedstock (10) by reacting the feedstock in a reactor (11) with oxygen (9) to form a synthesis gas containing at least carbon monoxide, carbon dioxide and hydrogen and subjecting the synthesis gas to a conversion process comprising an exothermic reaction to produce methanol as a final product in a converter (15), the converter operating at an operating pressure, said oxygen being provided to the reactor at an oxygen pressure, the synthesis gas is produced at a pressure higher than the operating pressure of the converter.Type: GrantFiled: February 9, 2004Date of Patent: April 19, 2005Assignee: L'Air Liquide - Societe Anonyme a Directoire et Conseil de Surveillance pour l'Etude et l'exploitation des Procedes Georges ClaudeInventors: Alain Guillard, Emmanuel Schmidt
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Patent number: 6881326Abstract: A process where the need to circulate hydrogen through the catalyst is eliminated. This is accomplished by mixing and/or flashing the hydrogen and the oil to be treated in the presence of a solvent or diluent in which the hydrogen solubility is “high” relative to the oil feed. The type and amount of diluent added, as well as the reactor conditions, can be set so that all of the hydrogen required in the hydroprocessing reactions is available in solution. The oil/diluent/hydrogen solution can then be fed to a plug flow reactor packed with catalyst where the oil and hydrogen react. No additional hydrogen is required, therefore, hydrogen recirculation is avoided and trickle bed operation of the reactor is avoided. Therefore, the large trickle bed reactors can be replaced by much smaller tubular reactor.Type: GrantFiled: June 3, 2002Date of Patent: April 19, 2005Assignee: Process Dynamics, Inc.Inventors: Michael D. Ackerson, Michael S. Byars
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Patent number: 6881759Abstract: The present invention is a novel process for methanol production in a liquid phase reactor from a synthesis gas comprising of hydrogen, carbon dioxide and carbon monoxide. The liquid phase reactor contains a solid catalyst suspended in methanol. In this innovation, methanol acts both as a product and as a suspension medium for the catalyst. The new innovation exploits the condensing conditions for methanol production. By operating at condensing conditions, the methanol partial pressure at equilibrium is higher than the boiling pressure of methanol at the given temperature. Hence the produced methanol of the equilibrium composition condenses creating the potential of more gas to be converted. Since equilibrium is not a limiting factor, high conversions can be obtained.Type: GrantFiled: March 23, 2004Date of Patent: April 19, 2005Assignee: Haldor Topsoe A/SInventors: Poul Erik Højlund Nielsen, Cecilia Jaksland, Jens Perregaard