Search Patents
  • Process for operating a highly productive tubular reactor
    Patent number: 10889762
    Abstract: The present technology is directed to processes for conversion of synthesis gas in a tubular reactor to produce a synthetic product that utilizes high activity carbon monoxide hydrogenation catalysts and a heat transfer structure that surprisingly provides for higher per pass conversion with high selectivity for the desired synthetic product without thermal runaway.
    Type: Grant
    Filed: December 8, 2017
    Date of Patent: January 12, 2021
    Assignee: VELOCYS TECHNOLOGIES LIMITED
    Inventors: Andre Steynberg, Bin Yang, Ravi Arora, Laura Silva, Heinz Robota, Sean Fitzgerald, Paul Neagle, Jason Robinson, Paul Schubert, Steven Perry
  • Loading/unloading of particulates to/from microchannel reactors
    Patent number: 10335759
    Abstract: The invention providing methods of loading and unloading particulate from microchannels in apparatus that contains multiple microchannels, typically apparatus that is designed to operate with hundreds or thousands of particulate-containing microchannels. Aligning a sonicating head at one end of a set of microchannels provides a particularly effective mode for densifying particulate in microchannels.
    Type: Grant
    Filed: November 5, 2008
    Date of Patent: July 2, 2019
    Assignee: Velocys, Inc.
    Inventors: Jeffrey J. Ramler, Anna Lee Tonkovich, Rachid Taha, Kai Jarosch, Robert J. Luzenski, Jeffery D. Slane, Thomas Hickey, Sean Fitzgerald, Harley D. Freeman, Frederick A. Zenz
  • Method for stopping and restarting a Fischer-Tropsch process
    Patent number: 10358604
    Abstract: The disclosed invention relates to a method for restarting a synthesis gas conversion process which has stopped. The synthesis gas conversion process may be conducted in a conventional reactor or a microchannel reactor. The synthesis gas conversion process may comprise a process for converting synthesis gas to methane, methanol or dimethyl ether. The synthesis gas conversion process may be a Fischer-Tropsch process.
    Type: Grant
    Filed: July 13, 2016
    Date of Patent: July 23, 2019
    Assignee: Velocys, Inc.
    Inventors: Roger A. Harris, Deshmukh R. Soumitra, Paul E. Kennedy, Robert Dwayne Litt, Lucas D. Schrader, Andre P. Steynberg, Steven T. Perry
  • Catalysts Having Catalytic Material Applied Directly to Thermally-Grown Alumina and Catalytic Methods Using Same; Improved Methods of Oxidative Dehydrogenation
    Publication number: 20120302811
    Abstract: The invention describes catalysts, methods of making catalysts, methods of making a microchannel reactor, and methods of conducting chemical reactions. It has been discovered that superior performance can be obtained from a catalyst formed by directly depositing a catalytic material onto a (low surface area) thermally-grown alumina layer. Improved methods of conducting oxidative dehydrogenations are also described.
    Type: Application
    Filed: July 31, 2012
    Publication date: November 29, 2012
    Applicant: Velocys Inc.
    Inventors: Richard Long, Junko M. Watson, Francis P. Daly, Terry Mazanec, Barry L. Yang
  • Catalytic oxidative dehydrogenation, and microchannel reactors for catalytic oxidative dehydrogenation
    Patent number: 8106249
    Abstract: Methods of oxidative dehydrogenation (ODH) is provided wherein conducting ODH in microchannels has unexpectedly been found to yield superior performance when compared to the same reactions at the same conditions in larger reactors. ODH methods employing a Mo—V—Mg—O catalyst is also described. Microchannel apparatus for conducting ODH is also disclosed.
    Type: Grant
    Filed: June 28, 2010
    Date of Patent: January 31, 2012
    Assignee: Velocys
    Inventors: John H. Brophy, Kai Jarosch, Terry J. Mazanec, Matthew B. Schmidt, Laura J. Silva, Anna Lee Tonkovich, Fred Pesa, David J. Hesse
  • Catalytic oxidative dehydrogenation, and microchannel reactors for catalytic oxidative dehydrogenation
    Patent number: 7402719
    Abstract: The invention provides methods of oxidative dehydrogenation (ODH). Conducting ODH in microchannels has unexpectedly been found to yield superior performance when compared to the same reactions at the same conditions in larger reactors. ODH methods employing a Mo—V—Mg—O catalyst is also described. Microchannel apparatus for conducting ODH is also disclosed.
    Type: Grant
    Filed: May 19, 2003
    Date of Patent: July 22, 2008
    Assignee: Velocys
    Inventors: John H. Brophy, Kai Jarosch, Terry J. Mazanec, Matthew B. Schmidt, Laura J. Silva, Anna Lee Tonkovich, Fred Pesa, David J. Hesse
  • Catalysts, methods of making catalysts, and methods of combustion
    Patent number: 7326394
    Abstract: Catalysts are described in which an active catalyst is disposed on a low surface area, oxide support. Methods of forming catalysts are described in which a Cr-containing metal is oxidized to form a chromium oxide layer and an active catalyst is applied directly on the chromium oxide layer. Methods of making new catalysts are described in which the surface is sonicated prior to depositing the catalyst. Catalyst systems and methods of oxidation are also described. The inventive systems, catalysts and methods are, in some instances, characterized by surprisingly superior results.
    Type: Grant
    Filed: March 7, 2003
    Date of Patent: February 5, 2008
    Assignee: Velocys
    Inventors: Barry Lee-Mean Yang, Ruiqiang Long, Junko M. Watson, Abhishek Gupta
  • STEAM REFORMING METHODS AND CATALYSTS
    Publication number: 20130023407
    Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.
    Type: Application
    Filed: October 1, 2012
    Publication date: January 24, 2013
    Applicant: VELOCYS INC.
    Inventors: Junko M. Watson, Francis P. Daly, Yong Wang, Steven T. Perry, Anna Lee Tonkovich, Sean P. Fitzgerald, Laura J. Silva, Rachid Taha, Enrique Aceves de Alba, Ya-Huei Chen, Robert Rozmiarek, XiaoHong Li
  • Regeneration of catalyst
    Patent number: 11173483
    Abstract: A catalyst is regenerated by an inventive process using a heat exchange fluid such as superheated steam to remove heat during the process relying on efficient heat transfer (e.g., enabled by the microchannel reactor construction) in comparison with prior art heat exchange relying on a phase change, e.g. between water and (partial or complete vaporization) steam, allows simplification of the protocols to enable transition at higher temperatures between steps which translates in reduced duration of the regeneration process and avoids potential water hammering risks.
    Type: Grant
    Filed: June 4, 2020
    Date of Patent: November 16, 2021
    Assignee: VELOCYS TECHNOLOGIES LIMITED
    Inventors: Soumitra R. Deshmukh, Ivan Philip Greager, Roger Allen Harris, Heinz Robota
  • Process for producing hydrogen peroxide using microchannel technology
    Patent number: 7029647
    Abstract: This invention relates to a process for making hydrogen peroxide in a microchannel reactor. The process comprises flowing a process feed stream and a staged addition feed stream in a process microchannel in contact with each other to form a reactant mixture comprising O2 and H2, and contacting a catalyst with the reactant mixture in the process microchannel to convert the reactant mixture to a product comprising hydrogen peroxide; transferring heat from the process microchannel to a heat exchanger; and removing the product from the process microchannel.
    Type: Grant
    Filed: January 27, 2004
    Date of Patent: April 18, 2006
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Kai Tod Paul Jarosch, David John Hesse
  • Process for converting a hydrocarbon to an oxygenate or a nitrile
    Patent number: 9108904
    Abstract: This invention relates to a process for converting a hydrocarbon reactant to a product comprising an oxygenate or a nitrile, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, through a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A); and (C) quenching the product from step (A).
    Type: Grant
    Filed: August 10, 2007
    Date of Patent: August 18, 2015
    Assignee: Velocys, Inc.
    Inventors: John H. Brophy, Frederick A. Pesa, Anna Lee Tonkovich, Jeffrey S. McDaniel, Kai Tod Paul Jarosch
  • Porous electrolessly deposited coatings
    Patent number: 9893364
    Abstract: A new electroless plating approach to generate a porous metallic coating is described in which a metal is electrolessly deposited on a surface. Microparticles in the metal are removed to leave pores in the metal coating. Another method of forming electroless coatings is described in which a blocking ligand is attached to the surface, followed by a second coating step. The invention includes coatings and coated apparatus formed by methods of the invention. The invention also includes catalyst structures comprising a dense substrate and a porous metal adhered to the dense substrate, which is further characterized by one or more of the specified features.
    Type: Grant
    Filed: June 17, 2015
    Date of Patent: February 13, 2018
    Assignee: Velocys, Inc.
    Inventors: Richard Q. Long, Francis Daly, Haibiao Chen, Terry J. Mazanec
  • Steam reforming methods and catalysts
    Patent number: 8569202
    Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.
    Type: Grant
    Filed: October 1, 2012
    Date of Patent: October 29, 2013
    Assignee: Velocys Corp.
    Inventors: Junko M. Watson, Francis P. Daly, Yong Wang, Steven T. Perry, Anna Lee Tonkovich, Sean P. Fitzgerald, Laura J. Silva, Rachid Taha, Enrique Aceves de Alba, Ya-Huei Chen, Robert Rozmiarek, XiaoHong Li
  • Dehydrogenation reactions in narrow reaction chambers and integrated reactors
    Patent number: 7754935
    Abstract: Methods of dehydrogenating hydrocarbons to yield unsaturated compounds are described. Reactor configurations useful for dehydrogenation are also described. Hydrocarbons can be dehydrogenated, for relatively long periods of time-on-stream, in a reaction chamber having a dimension of 2 mm or less to produce H2 and an olefin. Techniques have been developed that reduce coke and allow stable, relatively long-term operation in small reactors.
    Type: Grant
    Filed: July 8, 2008
    Date of Patent: July 13, 2010
    Assignee: Velocys
    Inventors: John H. Brophy, Gary Roberts, G. Bradley Chadwell, Matthew B. Schmidt, Anna Lee Tonkovich
  • Microchannel apparatus and methods of conducting catalyzed oxidative dehydrogenation
    Patent number: 7999144
    Abstract: Methods of oxidative dehydrogenation are described. Surprisingly, Pd and Au alloys of Pt have been discovered to be superior for oxidative dehydrogenation in microchannels. Methods of forming these catalysts via an electroless plating methodology are also described. An apparatus design that minimizes heat transfer to the apparatus' exterior is also described.
    Type: Grant
    Filed: September 1, 2006
    Date of Patent: August 16, 2011
    Assignee: Velocys
    Inventors: Anna Lee Tonkovich, Bin Yang, Steven T. Perry, Terry Mazanec, Ravi Arora, Francis P. Daly, Richard Long, Thomas D. Yuschak, Paul W. Neagle, Amanda Glass
  • Stable, catalyzed, high temperature combustion in microchannel, integrated combustion reactors
    Patent number: 8062623
    Abstract: Catalysts containing 30 weight percent or more platinum have surprisingly been discovered to possess superior stability and activity for catalyzing combustion reactions. The addition of rhenium improves catalyst performance in fuel lean conditions but has undesirable effects in fuel rich conditions. The invention provides integrated combustion microreactors, chemical systems utilizing these integrated combustion microreactors, methods of combustion, and methods of providing heat to endothermic reactions in integrated combustion microreactors.
    Type: Grant
    Filed: October 15, 2004
    Date of Patent: November 22, 2011
    Assignee: Velocys
    Inventors: Francis P. Daly, Junko M. Watson, Yong Wang, Jianli Hu, Chunshe Cao, Richard Long
  • Catalysts having catalytic material applied directly to thermally-grown alumina and catalytic methods using same, improved methods of oxidative dehydrogenation
    Patent number: 8378163
    Abstract: The invention describes catalysts, methods of making catalysts, methods of making a microchannel reactor, and methods of conducting chemical reactions. It has been discovered that superior performance can be obtained from a catalyst formed by directly depositing a catalytic material onto a (low surface area) thermally-grown alumina layer. Improved methods of conducting oxidative dehydrogenations are also described.
    Type: Grant
    Filed: March 23, 2005
    Date of Patent: February 19, 2013
    Assignee: Velocys Corp.
    Inventors: Junko Ida, Francis P. Daly, Terry Mazanec, Barry L. Yang, Richard Long
  • Steam reforming method
    Patent number: 8277773
    Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.
    Type: Grant
    Filed: February 1, 2010
    Date of Patent: October 2, 2012
    Assignee: Velocys Corp.
    Inventors: Junko M. Watson, Francis P. Daly, Yong Wang, Steven T. Perry, Anna Lee Tonkovich, Sean P. Fitzgerald, Laura J. Silva, Rachid Taha, Enrique Aceves de Alba, Ya-Huei Chen, Robert Rozmiarek, XiaoHong Li
  • Fluidization and Solids Processing In Microchannel Devices
    Publication number: 20110039955
    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.
    Type: Application
    Filed: October 25, 2010
    Publication date: February 17, 2011
    Applicant: VELOCYS INC.
    Inventors: Kai Jarosch, Anna Lee Tonkovich, David J. Hesse, Eric Daymo, Steven T. Perry, Laura J. Silva
  • Process and apparatus for improved methods for making vinyl acetate monomer (VAM)
    Patent number: 8029748
    Abstract: The invention provides methods, apparatus and chemical systems for making vinyl acetate from ethylene, oxygen, and acetic acid.
    Type: Grant
    Filed: November 18, 2008
    Date of Patent: October 4, 2011
    Assignees: Velocys, Inc, Celanese International Corporation
    Inventors: Terry Mazanec, Victor J. Johnston, Michael Huckman, Sean P. Fitzgerald, James A. Foster, Daniel Lindley, Anna Lee Tonkovich, Francis P. Daly, Leslie Wade, Tony Hammock, Thomas Yuschak, Bin Yang, Kai Jarosch
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