Abstract: A process for converting oxygenates to hydrocarbons includes introducing a feed stream having at least one oxygenate into a reaction zone, and introducing a hydrogen gas stream into the reaction zone. In the reaction zone the feed stream and the hydrogen gas stream are simultaneously contacted with a catalyst, and the catalyst includes a solid microporous acid component having 8-MR to 10-MR access. The hydrogen gas stream in the reaction zone has a partial pressure from 1 bar (100 kPa) to 48 bar (4800 kPa), and the reaction zone is at a temperature from 350° C. to 500° C.

Abstract: The present invention relates to: a catalyst activation method for Fischer-Tropsch synthesis; a catalyst regeneration method for Fischer-Tropsch synthesis; and a method for producing a liquid or solid hydrocarbon by using the Fischer-Tropsch synthesis reaction. The temperatures required for a metal carbide producing and activating reaction is markedly lower than existing catalyst activation temperatures, and the catalyst can be activated under conditions that are the same as Fischer-Tropsch synthesis reaction conditions, and thus there is no need for separate reduction equipment in the reactor, and a Fischer-Tropsch synthesis catalyst which has been used for a long time can be regenerated within the reactor without the catalyst being isolated or extracted from the reactor.

Abstract: A self-healing reaction process for a chemical reaction is provided by exposing a catalyst a reaction mixture that includes carbon monoxide and hydrogen gas such that hydrocarbons are produced. The catalyst includes Co3O4 nanorods having both Co2+ and Co3+ exposed thereon. The Co3O4 nanorods can have a spinel crystal structure such that the Co3O4 nanorods define a {110} facet having both Co2+ and Co3+ exposed thereon. During reaction conditions, water can oxidize portions of the catalyst, while the exposed Co3+ can reduce any oxidized portions of the catalyst such that the catalyst is self-healing during reaction conditions, especially when the reaction mixture further comprises water.

Abstract: A system for the production of synthesis gas, the system including a mixing apparatus configured for combining steam with at least one carbonaceous material to produce a reformer feedstock; and a reformer comprising a cylindrical vessel containing a plurality of coiled tubes, wherein each of the plurality of coiled tubes has a vertical height in the range of from about 40 feet 12.2 m) to about 100 feet (30.5 m) and a coil length that is at least four times the vertical height; at least one burner configured to combust a fuel and provide heat to maintain the reformer at a reformer temperature; at least one outlet for reformer product comprising synthesis gas; and at least one outlet for flue gas produced via combustion of fuel in the burners. A suitable mixing apparatus is also provided.

Abstract: A system and method of converting natural gases to liquids is provided. The system includes a catalytic partial oxidation (CPO) system with natural gas, air and steam input, a Fischer-Tropsch (F-T) system taking syngas from the CPO system, and supplying product gases to a power engine (PE), after separation of the product liquids. An F-T steam output line is in fluid communication with the CPO-steam input line. The energy output from the PE is supplied to the compressors and condensers, to provide self-sustainability in energy, for the gas-to-liquid separation system.

Abstract: A system for separating particulate from a fluid stream having an inlet solids content, the system comprising: a magnetic dynamic settling vessel comprising at least one magnetic field inside the vessel and/or one magnetized component; at least one inlet for introduction of the fluid stream having a starting solids content; at least one exit for a stream comprising a solids content not greater than the inlet solids content; at least one exit for a fluid stream comprising a solids content not less than the inlet solids content; and a vertical feed conduit extending at least 70% of the distance from the at least one fluid inlet to the at least one exit for a fluid stream comprising a solids content not less than the inlet solids content. A method for separating particulate from a fluid stream having an inlet solids content is also provided.

Abstract: A self-healing reaction process for a chemical reaction is provided by exposing a catalyst a reaction mixture that includes carbon monoxide and hydrogen gas such that hydrocarbons are produced. The catalyst includes Co3O4 nanorods having both Co2+ and Co3+ exposed thereon. The Co3O4 nanorods can have a spinel crystal structure such that the Co3O4 nanorods define a {110} facet having both Co2+ and Co3+ exposed thereon. During reaction conditions, water can oxidize portions of the catalyst, while the exposed Co3+ can reduce any oxidized portions of the catalyst such that the catalyst is self-healing during reaction conditions, especially when the reaction mixture further comprises water.

Abstract: The present invention provides methods to maintain selectivity to ethanol from syngas during mixed-alcohol synthesis when methanol is being recycled. In some variations, syngas is fed to an alcohol-synthesis reactor that contains a sulfided metal catalyst, and methanol is separated from ethanol to form a methanol recycle stream that contains sulfur-containing compounds. Recycling the methanol stream back to the alcohol-synthesis reactor allows for adding sulfur to, or reducing sulfur loss from, the sulfided metal catalyst. Optionally, additional sulfur compounds may be introduced to maintain sulfur levels in sulfided metal catalysts. Preferred sulfiding agents, concentrations, and recycle strategies are disclosed herein.

Abstract: A catalyst composition is provided for use in the conversion of carbon oxide(s) to saturated hydrocarbons. The catalyst composition comprises a carbon oxide(s) conversion catalyst; and a dehydration/hydrogenation catalyst comprising a silicoalumino phosphate (SAPO) molecular sieve and a metal M, for example Pd. In one embodiment, the target saturated hydrocarbons include LPG, the SAPO comprises SAPO-5 and/or SAPO-37.

Abstract: Processes for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts include the transportation of a modular, portable catalyst activation and/or regeneration unit to Fischer-Tropsch and/or oxygenate production units. An alternative process for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts includes activating and/or regenerating the catalyst in a production unit at a catalyst treatment facility. An alternative process for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts includes activating and/or regenerating the catalyst in a synthesis reactor at a catalyst treatment facility.

Abstract: A process for the regeneration of deactivated catalyst from a Fischer-Tropsch synthesis reactor, the catalyst being a supported cobalt catalyst. The process comprises the following steps: a withdrawal step, in which a portion of deactivated catalyst together with liquid hydrocarbon is withdrawn from the reactor; a concentration step, in which the concentration of the catalyst in the liquid hydrocarbon is increased; a calcination step, in which the deactivated catalyst composition is subjected to an oxidising gas to oxidise carbonaceous material contained in the deactivated catalyst in to gaseous oxides of the components of the carbonaceous material; and a reactivation step, in which the deactivated catalyst composition is reactivated to produced a regenerated catalyst.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe2O3. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: Disclosed is a process for reacting carbon dioxide with hydrogen. In the process a catalyst having carbon dioxide adsorbed thereto is contacted with hydrogen at an elevated temperature. The catalyst can be regenerated by contacting depleted catalyst with a carbon dioxide source, for example a flue gas of a power plant. In a preferred embodiment carbon dioxide is reacted by in situ hydrolysis of water.

Abstract: A method for producing a regenerated Fischer-Tropsch synthesis catalyst obtained by regenerating a spent catalyst used in a Fischer-Tropsch synthesis reaction, comprising a steaming step of bringing the above spent catalyst into contact with a mixed gas comprising 1 to 30% by volume of steam and an inert gas at a pressure of atmospheric pressure to 5 MPa and a temperature of 150 to 350° C., the above spent catalyst being a spent catalyst in which cobalt and/or ruthenium is supported on a carrier comprising silica with an average pore diameter measured by a nitrogen adsorption method of 4 to 25 nm, and of which activity represented by an initial carbon monoxide conversion is 40 to 95%, based on the activity of a corresponding unused catalyst.

Abstract: A catalytic composition is provided for methanol production. The composition includes an alloy of at least two different metals M and M?, where M is selected from Ni, Pd, Ir, and Ru, and M? is selected from Ga, Zn, and Al. A molar ratio of M to M? is in the range of 1:10 to 10:1, and the alloy is configured to catalyze a reduction of CO2 to methanol.

Abstract: A process for regenerating one or more deactivated cobalt comprising Fischer-Tropsch catalyst particle(s), comprising the steps of: (i) oxidising the catalyst particle(s) at a temperature between 20 and 400° C.; (ii) treating the catalyst particle(s) for more than 5 minutes, (iii) drying the catalyst particle(s); and (iv) optionally reducing the catalyst particle(s) with hydrogen or a hydrogen comprising gas. This process may be preceded by a step in which Fischer-Tropsch product is removed from the catalyst particle(s). The treatment is performed using carbon dioxide and a liquid comprising ammonia.

Abstract: A method is disclosed for utilizing a waste product flow discharged from a Fisher-Tropsch reactor, the waste product chiefly consisting of spent catalyst and FT wax. The method is characterized in that waste flow, specifically containing iron catalyst and FT wax, discharged from the FT reactor is passed back to the gasification unit of the BtL process.

Abstract: A process for regenerating a spent particulate wax-containing cobalt-based Fischer-Tropsch synthesis catalyst is provided. The process includes subjecting the spent wax-containing catalyst sequentially to a dewaxing treatment, an oxidation treatment and a reduction treatment. During the dewaxing treatment, the spent wax-containing catalyst is at least partially dewaxed, with dewaxed catalyst particles being produced. During the oxidation treatment, an oxygen-containing gas is passed through a bed of the dewaxed catalyst particles at an operating temperature T° C. where 150<T<450, and the operating temperature is controlled by removing heat from the catalyst particle bed using a cooling device, to obtain oxidized catalyst particles. During the reduction treatment, the oxidized catalyst particles are reduced, thereby regenerating the catalyst.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe203. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: This invention describes gas-solid, liquid-solid and gas-solid-liquid processes in microchannels devices including such processes as heterogeneous catalysis, particle formation, particle attrition, particle separation and adsorption or desorption of selected species. Various processes can be enhanced by the unique properties of microchannels such as the predominance of laminar flow, high rates of shear, high rates of heat transfer and high rates of mass transfer. Also encompassed by this invention are methods for the introduction to and removal from microchannels of particle containing fluid streams.

Abstract: Multi-functional catalyst and processes utilizing the catalyst in single-stage conversion of syngas into hydrocarbon compounds are provided. The multi-functional catalyst, which comprises two or more catalytic materials situated within molecular distances of each other, facilitates conversion of syngas into one or more intermediate compounds and then into desired hydrocarbon compounds, such as high octane gasoline, diesel, jet fuel, olefins, and xylenes.

Abstract: A method of operating a carbon-to-liquids system is provided. The method includes receiving a flow of syngas at the carbon-to-liquids system, shifting the syngas to facilitate increasing a hydrogen to carbon monoxide ratio (H2/CO) of the syngas, adding additional hydrogen to the shifted syngas to increase the H2/CO ratio, reacting the hydrogen/shifted syngas mixture with a catalyst in a vessel, extracting hydrogen from the syngas mixture, recycling the hydrogen to facilitate increasing the H2/CO ratio, and recycling naphta to act as solvent for wax extraction, and to facilitate catalyst recovery.

Abstract: The invention relates to a process for producing a hydrogen-rich stream from a hydrogen-depleted stream. More particularly, the invention relates to a hydrocarbon synthesis process, by way of example, a Fischer Tropsch process, from which both hydrocarbons and high purity hydrogen are obtained. The process comprises contacting the hydrogen-depleted stream with a reverse-selective membrane to provide a CO2-enriched permeate and a hydrogen-containing retentate. The high purity hydrogen is produced from the hydrogen-containing retentate. The high purity hydrogen thus obtained may be used in a process selected from the group consisting of upgrading hydrocarbons produced from the hydrocarbon synthesis process, hydrotreating a natural gas stream, recycling to the hydrocarbon synthesis reaction unit, high purity hydrogen production, catalyst rejuvenation, and combinations thereof.

Abstract: The present invention provides a method to start a steady state process for producing normally gaseous, normally liquid and optionally normally solid hydrocarbons from synthesis gas, which method comprises the steps of: (i) providing an activated catalyst in tubes of a fixed bed reactor, preferably a multitubular fixed bed reactor, the catalyst being suitable to convert synthesis gas to normally gaseous, normally liquid and optionally normally solid hydrocarbons; (ii) contacting the activated catalyst with a liquid to obtain a wetted activated catalyst; (iii) contacting the wetted activated catalyst with synthesis gas and catalytically converting the synthesis gas at an elevated temperature and pressure to obtain the normally gaseous, normally liquid and optionally normally solid hydrocarbons.

Abstract: A catalyst composition and a process of using a catalyst composition for preparing high molecular weight hydrocarbons, such as polymethylene, from a fluid containing hydrogen and carbon monoxide are disclosed. The catalyst composition contains ruthenium and a treated silica support component. The treated silica support component is prepared by a process including contacting a silica support component, such as silicon dioxide, and a treating agent, such as a silicon-containing compound.

Abstract: Processes for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts include the transportation of a modular, portable catalyst activation and/or regeneration unit to Fischer-Tropsch and/or oxygenate production units. An alternative process for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts includes activating and/or regenerating the catalyst in a production unit at a catalyst treatment facility. An alternative process for activating and/or regenerating Fischer-Tropsch and/or oxygenate synthesis catalysts includes activating and/or regenerating the catalyst in a synthesis reactor at a catalyst treatment facility.

Abstract: A catalytic reaction system comprising: a catalytic reactor fluidly connected with at least two slurry loops, wherein the reactor comprises at least as many reactor product outlets and at least as many slurry return inlets as slurry loops; wherein each slurry loop comprises a separation system comprising a separation system inlet, a separation system product outlet, and a concentrated catalyst slurry outlet; a slurry offtake fluidly connecting the separation system inlet with one of the reactor product outlets; and a slurry return fluidly connecting the separation system outlet with one of the slurry return inlets. The system may comprise at least three slurry loops. The system may comprise at least four slurry loops. A method for converting synthesis gas into liquid hydrocarbons via the catalytic reaction system in also disclosed.

Abstract: The invention relates to a process for producing a hydrogen-rich stream from a hydrogen-depleted stream. More particularly, the invention relates to a hydrocarbon synthesis process, by way of example, a Fischer Tropsch process, from which both hydrocarbons and high purity hydrogen are obtained. The process comprises contacting the hydrogen-depleted stream with a first reverse-selective membrane and a second reverse-selective membrane to provide a CO2-enriched permeate and a hydrogen-containing retentate. The high purity hydrogen is produced from the hydrogen-containing retentate. The high purity hydrogen thus obtained may be used in a process selected from the group consisting of upgrading hydrocarbons produced from the hydrocarbon synthesis process, hydrotreating a natural gas stream, recycling to the hydrocarbon synthesis reaction unit, high purity hydrogen production, catalyst rejuvenation, and combinations thereof.

Abstract: Embodiments of the invention relate to processes and apparatus for the washing and recovery of metal-containing catalyst solids in a form suitable for reclamation. More specifically, a catalyst recovery process comprises removing an organic residue with a washing medium from a metal-containing catalyst solids, recovering washed solids, and treating the washed solids under oxidative conditions to form non-reactive solids. The treatment oxidative conditions may be effective to convert the metal(s) into an oxide form and/or may facilitate the removal of remaining organic residue from the washed solids. The treatment of the washed solids may comprise calcination. In some embodiments, the metal-containing catalyst solids may be recovered from a slurry stream, and the process further comprises passing the slurry stream though a separation unit to obtain a catalyst-enriched retentate slurry.

Abstract: This invention is directed to a process for making a methanol product from a synthesis gas (syngas) feed using a fast fluid bed reactor. The reactor is operated at substantially plug flow type behavior. The heat from circulated catalyst is sufficient to initiate the reaction process with little to no preheating of feed required. In addition, little if any internal reactor cooling is needed.

Abstract: 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.

Abstract: 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.

Abstract: The invention relates to a process for producing a hydrogen-rich stream from a hydrogen-depleted stream. More particularly, the invention relates to a hydrocarbon synthesis process, by way of example, a Fischer Tropsch process, from which both hydrocarbons and high purity hydrogen are obtained. The process comprises contacting the hydrogen-depleted stream with a reverse-selective membrane to provide a CO2-enriched permeate and a hydrogen-containing retentate. The high purity hydrogen is produced from the hydrogen-containing retentate. The high purity hydrogen thus obtained may be used in a process selected from the group consisting of upgrading hydrocarbons produced from the hydrocarbon synthesis process, hydrotreating a natural gas stream, recycling to the hydrocarbon synthesis reaction unit, high purity hydrogen production, catalyst rejuvenation, and combinations thereof.

Abstract: 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.

Abstract: A process for converting natural gas to an olefin includes heating the gas to a selected range of temperature to convert a fraction of the gas stream to reactive hydrocarbons, primarily ethylene or acetylene, and reacting with hydrogen in the presence of a catalyst to produce the olefin, usually ethylene. A portion of the incoming natural gas may be used to heat the remainder of the natural gas to the selected range of temperature. Hydrogen resulting from the reactions may be used to make electricity in a fuel cell. Alternatively, hydrogen may be burned to heat the natural gas to the selected range of temperature.

Abstract: The present invention is generally related towards methods for preparing and using a more stable synthesis catalysts. In particular, the present invention is directed towards treating synthesis catalysts with low levels of oxygen to deactivate the smaller more unstable metal crystallites present in the catalyst matrix. The process can be carried out either prior to and/or simultaneously with the synthesis reaction.

Abstract: 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.

Abstract: 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 cataly

Abstract: Methods and apparatus for improving the efficiency and effectiveness of in situ reduction of a Fischer-Tropsch catalyst slurry. The preferred embodiments of the present invention are characterized by a system that utilizes a co-feed of carbon monoxide along with the reducing gas into a reduction vessel maintained at an elevated temperature. As the metal oxide reduces to the active Fischer-Tropsch metal, the carbon monoxide acts as a poison to hydrogenolysis and reduces the loss of liquid from the slurry and the production of methane. The carbon monoxide is generally in parts-per-million quantities and will achieve the desired results in quantities less than 5,000 ppm, preferably less than 2,000 ppm.

Abstract: A process for regenerating a slurry Fischer-Tropsch catalyst, which needs regeneration, involves de-waxing and drying the catalyst sufficiently to produce a free-flowing catalyst powder that is fluidizable; fluidizing the catalyst powder; treating the catalyst powder with an oxygen treatment; reducing the catalyst powder with a reducing gas to form a reduced catalyst powder; and mixing the reduced catalyst powder with hydrocarbons to form a regenerated, slurry catalyst. The oxidation and reduction steps may be repeated. An oxygen treatment includes using a fixed O2 level with ramped temperatures, fixed temperatures with increased O2 levels, or a combination.

Abstract: In a system and method for recovering a catalyst, a slurry comprising said catalyst and residual hydrocarbons is heated so as to vaporize hydrocarbons. The vaporized hydrocarbons are separated from the catalyst. The separated catalyst is preferably further contacted with a stripping medium so as to further remove remaining hydrocarbons. In an embodiment, the catalyst is a Fischer-Tropsch catalyst contained in a reactor, preferably a slurry bubble reactor. In some embodiments, the slurry is diluted with additional hydrocarbons, and the residual hydrocarbons comprise waxy hydrocarbons. In an embodiment, substantially all of the hydrocarbons in the slurry are vaporized. In an embodiment, the catalyst is separated from the vaporized hydrocarbons via centrifugation. In an embodiment, substantially all of the hydrocarbons are removed from the catalyst.

Abstract: A process is disclosed for regenerating a catalyst used in a process for synthesizing hydrocarbons. The synthesis process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream comprising hydrocarbons. The regeneration process involves contacting a deactivated Fischer-Tropsch catalyst with a regeneration gas under regeneration-promoting conditions that include a pressure lower than the mean Fischer-Tropsch reaction pressure, for a period of time sufficient to reactivate the Fischer-Tropsch catalyst.

Abstract: The present invention provides a process for managing hydrogen in a hydrocarbon gas to liquid plant. The process includes passing a syngas feed stream produced by a partial oxidation reactor to a Fischer-Tropsch reactor, thereby converting the syngas to hydrocarbon liquids. The hydrogen management process further includes passing a second hydrogen rich stream produced by an auxiliary source to a hydrogen user such as an FT water stripper, an FT catalyst regeneration unit, and an FT product upgrading unit. The auxiliary source could be a process for converting hydrocarbons to syngas, a process for converting hydrocarbons to olefins, a process for converting hydrocarbons to aromatics, a process for catalytically dehydrogenating hydrocarbons, a process for catalytically cracking hydrocarbons, a process for refining petroleum, and a process for converting hydrocarbons to carbon filaments.

Abstract: 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.

Abstract: A process for activating a cobalt-containing catalyst by contacting the catalyst with hydrogen in a reaction system suitable for use in a Fischer-Tropsch synthesis wherein a first gaseous stream comprising 0.25 to 5% by volume of hydrogen and 95 to 99.75% by volume of inert gas is continuously introduced into the reaction system and a second gaseous stream is continuously withdrawn from the reactor system wherein the activation procedure comprises the steps of: (A) heating the contents of the reactor system to a temperature which is in a range of 25 to 5° C. below a critical activation temperature; (B) thereafter increasing the temperature at a rate of up to 20° C. per hour to a first hold temperature which is in a range of from the critical activation temperature to a temperature which is at most 20° C. above the critical activation temperature; and (C) maintaining the contents of the reactor system approaches the hydrogen content of the first gaseous stream.

Abstract: An in situ process for conducting regeneration of spent hydrocarbon synthesis catalyst. Regenerated, but not yet re-activated, catalyst (15) may be introduced into an operating HCS reactor (1) that has catalyst rejuvenation means (14). Any combination of a fresh, activated catalyst, a fresh, passivated catalyst or short-term or long-term deactivated catalysts may already be present in the HCS reactor (1). The regenerated, but not yet re-activated catalyst is activated in the HCS reactor (1) with rejuvenation means (14) at normal process conditions. The HCS reactor (1) receives syngas through the inlet line (3) and releases liquid hydrocarbons through outlet line (4) and gaseous hydrocarbon and unreacted syngas through the offgas line (2). Catalyst is removed from the HCS reactor (1) through the slipstream line (5) and into a filtration unit (6) which is fed with a stripping fluid (7). The filtered catalyst proceeds to the regeneration unit (9) which is fed a regenerative fluid (10).

Abstract: The present invention is generally related towards the regeneration of hydrocarbon synthesis catalysts. In particular, the present invention is directed towards the regeneration of deactivated Fischer-Tropsch type catalysts using a two step process wherein the catalyst is first prepared using a dry gas and then regenerated using a hydrogen rich gas. The regeneration process is carried out at temperatures and pressures that are generally different than the operating temperatures and pressures for a typical hydrocarbon synthesis reaction.

Abstract: A process is disclosed for regenerating a catalyst used in a process for synthesizing hydrocarbons. The synthesis process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream comprising hydrocarbons. The regeneration process involves contacting a deactivated Fischer-Tropsch catalyst with a regeneration gas under regeneration-promoting conditions that include a pressure lower than the mean Fischer-Tropsch reaction pressure, for a period of time sufficient to reactivate the Fischer-Tropsch catalyst.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe2O3. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: Methods and apparatus for separating liquid products and catalyst fines from a slurry used in a Fischer-Tropsch reactor. A settling system continuously or intermittently removes catalyst fines from the slurry and is coupled with catalyst-liquid separation system that separates liquid products from the slurry. The preferred separation system produces a sub-particle rich stream and a catalyst-lean stream that are removed from the system. The systems of the present invention act to reduce the concentration of catalyst fines in the reactor, thereby increasing the effectiveness of a catalyst-liquid separation system.