Search Patents
  • Process using microchannel technology for conducting alkylation or acylation reaction
    Patent number: 9150494
    Abstract: The disclosed invention relates to a process, comprising: flowing a first reactant feed stream comprising a reactant substrate and a second reactant feed stream comprising an alkylating agent, an acylating agent or a mixture thereof, in a process microchannel in contact with each other to form a product comprising at least one alkylation product, at least one acylation product, or a mixture thereof; transferring heat from the process microchannel to a heat sink; and removing the product from the process microchannel.
    Type: Grant
    Filed: November 11, 2005
    Date of Patent: October 6, 2015
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Steven T. Perry, Timothy J. LaPlante, Kai Tod Paul Jarosch, Thomas P. Hickey, Sean Patrick Fitzgerald, Dongming Qiu, Ravi Arora, Timothy J. Sullivan, Paul Neagle
  • Process for cooling a product in a heat exchanger employing microchannels
    Patent number: 7000427
    Abstract: This invention relates to a process for cooling or liquefying a fluid product (e.g., natural gas) in a heat exchanger, the process comprising: flowing a fluid refrigerant through a set of refrigerant microchannels in the heat exchanger; and flowing the product through a set of product microchannels in the heat exchanger, the product flowing through the product microchannels exchanging heat with the refrigerant flowing through the refrigerant microchannels, the product exiting the set of product microchannels being cooler than the product entering the set of product microchannels. The process has a wide range of applications, including liquefying natural gas.
    Type: Grant
    Filed: August 8, 2003
    Date of Patent: February 21, 2006
    Assignee: Velocys, Inc.
    Inventors: James A. Mathias, Ravi Arora, Wayne W. Simmons, Jeffrey S. McDaniel, Anna Lee Tonkovich, William A. Krause, Laura J. Silva, Dongming Qiu
  • Multi-stream microchannel device
    Patent number: 7780944
    Abstract: The invention is a process and device for exchanging heat energy between three or more streams in a microchannel heat exchanger which can be integrated with a microchannel reactor to form an integrated microchannel processing unit. The invention enables the combining of a plurality of integrated microchannel devices to provide the benefits of large-scale operation. In particular, the microchannel heat exchanger of the present invention enables flexible heat transfer between multiple streams and total heat transfer rates of about 1 Watt or more per core unit volume expressed as W/cc.
    Type: Grant
    Filed: December 15, 2005
    Date of Patent: August 24, 2010
    Assignee: Velocys, Inc.
    Inventors: James A. Mathias, G. Bradley Chadwell, Dongming Qiu, Annalee Y. Tonkovich, Steven T. Perry, Matthew B. Schmidt, Sean P. Fitzgerald, David J. Hesse, Thomas D. Yuschak, Bin Yang
  • Tailored and uniform coatings in microchannel apparatus
    Patent number: 8124177
    Abstract: Interior microchannels within microchannel apparatus are uniformly coated. Remarkably, these uniform coatings are formed from materials that are applied to the interior microchannels after an apparatus has been assembled or manufactured. Coatings can be made uniform along the length of a microchannel, in the corner of a microchannel, and/or throughout numerous microchannels in an array of microchannels. Techniques for tailoring the application of washcoats onto microchannels is also described.
    Type: Grant
    Filed: March 23, 2005
    Date of Patent: February 28, 2012
    Assignee: Velocys
    Inventors: Anna Lee Tonkovich, Barry L. Yang, Terry Mazanec, Francis P. Daly, Sean P. Fitzgerald, Ravi Arora, Dongming Qiu, Bin Yang, Steven T. Perry, Kai Jarosh, Paul W. Neagle, David J. Hesse, Rachid Taha, Richard Long, Jeff Marco, Thomas D. Yuschak, Jeffrey J. Ramler, Mike Marchiando
  • Process and apparatus for converting natural gas to higher molecular weight hydrocarbons using microchannel process technology
    Patent number: 7829602
    Abstract: The disclosed invention relates to a process and apparatus for converting natural gas to higher molecular weight hydrocarbons. The process includes steam reforming to form synthesis gas followed by a Fischer-Tropsch reaction to convert the synthesis gas to the high molecular weight hydrocarbons. The reforming and Fischer-Tropsch reactions are conducted in microchannel reactors. The higher molecular weight hydrocarbons may be further treated to form hydrocarbon products such as middle distillate fuels, lubricating oils, and the like. The apparatus includes vessels containing SMR microchannel reactors and Fischer-Tropsch microchannel reactors. A composition comprising a mixture of olefins and paraffins is disclosed.
    Type: Grant
    Filed: January 18, 2008
    Date of Patent: November 9, 2010
    Assignee: Velocys, Inc.
    Inventors: Robert Dwayne Litt, Wayne W. Simmons
  • Process of conducting reactions or separation in a microchannel with internal fin support for catalyst or sorption medium
    Patent number: 7896935
    Abstract: A process of conducting a catalyst reaction or fluid separation in comprising: at least one process microchannel having a height, width and length, the height being up to about 10 mm, the process microchannel having a base wall extending in one direction along the width of the process microchannel and in another direction along the length of the process microchannel; at least one fin projecting into the process microchannel from the base wall and extending along at least part of the length of the process microchannel; and a catalyst or sorption medium supported by the fin.
    Type: Grant
    Filed: December 28, 2006
    Date of Patent: March 1, 2011
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Dongming Qiu, Richard Q. Long, Barry L. Yang, Thomas Yuschak, Steven T. Perry
  • Protected Alloy Surfaces In Microchannel Apparatus and Catalysts, Alumina Supported Catalysts, Catalyst Intermediates, and Methods of Forming Catalysts and Microchannel Apparatus
    Publication number: 20110182804
    Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.
    Type: Application
    Filed: January 24, 2011
    Publication date: July 28, 2011
    Applicant: VELOCYS INC.
    Inventors: Richard Long, Barry L. Yang, Francis P. Daly, Junko M. Watson, Terry Mazanec, Sean P. Fitzgerald, Bradley R. Johnson, Xiaohong Li, Chunshe Cao, Ya-Huei Chin, Anna Lee Tonkovich, Ravi Arora, David J. Hesse, Dongming Qiu, Rachid Taha, Jeffrey J. Ramler, Yong Wang
  • Multi-stream multi-channel process and apparatus
    Patent number: 9441777
    Abstract: Provided is a process and apparatus for exchanging heat energy between three or more streams in a millichannel apparatus, which millichannel apparatus may comprise a heat exchanger which may be integrated with a millichannel reactor to form an integrated millichannel processing unit. The combining of a plurality of integrated millichannel apparatus to provide the benefits of large-scale operation is enabled. In particular, the millichannel heat exchanger enables flexible heat transfer between multiple streams and total heat transfer rates of about 1 Watt or more per core unit volume expressed as W/cc.
    Type: Grant
    Filed: December 31, 2013
    Date of Patent: September 13, 2016
    Assignee: Velocys, Inc.
    Inventors: James A. Mathias, G. Bradley Chadwell, Dongming Qui, Anna Lee Y. Tonkovich, Steven T. Perry, Matthew B. Schmidt, Sean P. Fitzgerald, David J. Hesse, Thomas D. Yuschak, Bin Yang
  • Multiphase reaction process using microchannel technology
    Patent number: 8383872
    Abstract: The disclosed invention relates to a process for conducting a multiphase reaction in a microchannel. The process comprises: forming a multiphase reaction mixture comprising a first reactant and a second reactant; the first reactant comprising at least one liquid; the second reactant comprising at least one gas, at least one liquid, or a combination of at least one gas and at least one liquid; the first reactant forming a continuous phase in the multiphase reaction mixture; the second reactant forming gas bubbles and/or liquid droplets dispersed in the continuous phase; and reacting the first reactant with the second reactant in a process microchannel in the presence of at least one catalyst to form at least one product.
    Type: Grant
    Filed: November 16, 2005
    Date of Patent: February 26, 2013
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, David John Hesse, Paul Neagle, Micheal Jay Lamont, Francis P. Daly, Kai Tod Paul Jarosch, Richard Stevenson, Laura J. Silva
  • Process for making unsaturated hydrocarbons using microchannel process technology
    Patent number: 7923592
    Abstract: The disclosed invention relates to a process for converting a feed composition comprising one or more hydrocarbons to a product comprising one or more unsaturated hydrocarbons, the process comprising: flowing the feed composition and steam in contact with each other in a microchannel reactor at a temperature in the range from about 200° C. to about 1200° C. to convert the feed composition to the product, the process being characterized by the absence of catalyst for converting the one or more hydrocarbons to one or more unsaturated hydrocarbons. Hydrogen and/or oxygen may be combined with the feed composition and steam.
    Type: Grant
    Filed: February 2, 2007
    Date of Patent: April 12, 2011
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Thomas Yuschak, Timothy J. LaPlante, Scott Rankin, Steven T. Perry, Sean Patrick Fitzgerald, Wayne W. Simmons, Terry Mazanec, Eric Daymo
  • Microchannel compression reactor
    Patent number: 8460411
    Abstract: A process unit comprising: (a) a first microchannel module comprising: (i) a first unit operation including microchannels, in which at least a portion of a unit operation takes place, adapted to be in fluid communication with a first inlet stream and a first outlet stream, and (ii) a second unit operation including microchannels adapted to be in thermal communication with the first unit operation, the second unit operation adapted to be in fluid communication with a second inlet stream and a second outlet stream; and (b) a pressurized vessel at least partially containing the first microchannel module adapted to be concurrently occupied by a compressive medium in thermal communication with the first microchannel module.
    Type: Grant
    Filed: June 21, 2010
    Date of Patent: June 11, 2013
    Assignee: Velocys, Inc.
    Inventors: William Allen Rogers, Jr., Christopher Paul Weil, Robert Dwayne Litt, Ronald Chester Pasadyn, George Bradley Smith, Charles Robert Miele, Thomas Peter Forte, Jimmy Glen Pelham
  • PROCESS
    Publication number: 20220177796
    Abstract: The present invention provides a process for obtaining solid recovered fuel and synthesis gas from a waste-based feedstock, comprising the steps of: I. converting the feedstock into a solid recovered fuel by means of a number of parameters pertaining to waste sorting, selection, comminution and/or screening; II. gasifying under suitable reaction conditions at least a portion of the solid recovered fuel to produce synthesis gas and by-product(s); and III. optionally cleaning at least a portion of the synthesis gas to produce clean synthesis gas and wastewater, wherein one or more of the solid recovered fuel, synthesis gas, and by-product(s) of the gasification are analysed during operation of the process, and wherein data from said analysis is used to control one or more parameters of step I) in order to influence reaction conditions in step II, and optionally step III).
    Type: Application
    Filed: December 3, 2021
    Publication date: June 9, 2022
    Applicant: Velocys Technologies Ltd
    Inventors: Ivan Philip GREAGER, Roger Allen HARRIS, Martin HOPKINS, Neil Alexander KING, Malcolm John WARD
  • Process for cooling a product in a heat exchanger employing microchannels for the flow of refrigerant and product
    Patent number: 6622519
    Abstract: This invention relates to a process for cooling a product in a heat exchanger, the process comprising: flowing a refrigerant through a set of first microchannels in the heat exchanger; flowing a refrigerant through a set of second microchannels in the heat exchanger, the refrigerant flowing through the set of second microchannels being at a lower temperature, a lower pressure or both a lower temperature and a lower pressure than the refrigerant flowing through the set of first microchannels; and flowing a product through a set of third microchannels in the heat exchanger, the product exiting the set of third microchannels having a cooler temperature than the product entering the set of third microchannels. This process is suitable for liquefying gaseous products including natural gas.
    Type: Grant
    Filed: August 15, 2002
    Date of Patent: September 23, 2003
    Assignee: Velocys, Inc.
    Inventors: James A. Mathias, Ravi Arora, Wayne W. Simmons, Jeffrey S. McDaniel, Anna Lee Tonkovich, William A. Krause, Laura J. Silva
  • Gasification process
    Patent number: 11572512
    Abstract: An integrated process for the production of a useful liquid hydrocarbon product comprises: feeding a gasification zone with an oxygen-containing feed and a first carbonaceous feedstock comprising waste materials and/or biomass, gasifying the first carbonaceous feedstock in the gasification zone to produce first synthesis gas, partially oxidising the first synthesis gas in a partial oxidation zone to generate partially oxidised synthesis gas, combining at least a portion of the first synthesis gas and/or the partially oxidised synthesis gas and at least a portion of electrolysis hydrogen obtained from an electrolyser in an amount to achieve the desired hydrogen to carbon monoxide molar ratio of from about 1.5:1 to about 2.5:1, and to generate a blended synthesis gas, wherein the electrolyser operates using green electricity; and subjecting at least a portion of the blended synthesis gas to a conversion process effective to produce the liquid hydrocarbon product.
    Type: Grant
    Filed: October 12, 2021
    Date of Patent: February 7, 2023
    Assignee: Velocys Technologies Ltd.
    Inventors: Ivan Greager, Roger Harris, Rudolph Havenga, Neil King
  • Gasification process
    Patent number: 11834614
    Abstract: A process for the manufacture of a useful product from synthesis gas having a desired hydrogen to carbon monoxide molar ratio comprises gasifying a first carbonaceous feedstock comprising waste materials and/or biomass in a gasification zone to produce a first synthesis gas; optionally partially oxidising the first synthesis gas in a partial oxidation zone to generate oxidised synthesis gas; reforming a second carbonaceous feedstock to produce a second synthesis gas, the second synthesis gas having a different hydrogen to carbon ratio from that of the first raw synthesis gas; combining at least a portion of the first synthesis gas and at least a portion of the second synthesis gas in an amount to achieve the desired hydrogen to carbon molar ratio and to generate a combined synthesis gas and subjecting at least part of the combined synthesis gas to a conversion process effective to produce the useful product.
    Type: Grant
    Filed: October 20, 2021
    Date of Patent: December 5, 2023
    Assignee: Velocys Technologies Ltd
    Inventors: Ivan Philip Greager, Roger Allen Harris, Rudolph Havenga, Neil Alexander King
  • Protected alloy surfaces in microchannel apparatus and catalysts, alumina supported catalysts, catalyst intermediates, and methods of forming catalysts and microchannel apparatus
    Patent number: 8206597
    Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.
    Type: Grant
    Filed: January 24, 2011
    Date of Patent: June 26, 2012
    Assignee: Velocys, Inc.
    Inventors: Barry L. Yang, Anna Lee Tonkovich, Junko M. Watson, Francis P. Daly, Sean P. Fitzgerald, Chunshe Cao, Xiaohong Li, Terry Mazanec, Bradley R. Johnson, Ravi Arora, David J. Hesse, Dongming Qiu, Rachid Taha, Jeffrey J. Ramler, Yong Wang, Richard Long, Ya-Huei Chin
  • Gasification process
    Patent number: 11840668
    Abstract: An integrated process for the production of a useful liquid hydrocarbon product comprises: feeding a gasification zone with an oxygen-containing feed and a first carbonaceous feedstock comprising waste materials and/or biomass, gasifying the first carbonaceous feedstock in the gasification zone to produce first synthesis gas, partially oxidising the first synthesis gas in a partial oxidation zone to generate partially oxidised synthesis gas, combining at least a portion of the first synthesis gas and/or the partially oxidised synthesis gas and at least a portion of electrolysis hydrogen obtained from an electrolyser in an amount to achieve the desired hydrogen to carbon monoxide molar ratio of from about 1.5:1 to about 2.5:1, and to generate a blended synthesis gas, wherein the electrolyser operates using green electricity; and subjecting at least a portion of the blended synthesis gas to a conversion process effective to produce the liquid hydrocarbon product.
    Type: Grant
    Filed: January 3, 2023
    Date of Patent: December 12, 2023
    Assignee: Velocys Technologies Ltd
    Inventors: Ivan Greager, Roger Harris, Rudolph Havenga, Neil King
  • Protected alloy surfaces in microchannel apparatus and catalysts, alumina supported catalysts, catalyst intermediates, and methods of forming catalysts and microchannel apparatus
    Patent number: 7874432
    Abstract: The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.
    Type: Grant
    Filed: March 23, 2005
    Date of Patent: January 25, 2011
    Assignee: Velocys
    Inventors: Barry L. Yang, Francis P. Daly, Junko M. Watson, Terry Manzanec, Sean P. Fitzgerald, Bradley R. Johnson, Xiaohong Li, Chunshe Cao, Ya-Huei Chin, Anna Lee Tonkovich, Ravi Arora, David J. Hesse, Dongming Qiu, Rachid Taha, Jeffrey J. Ramler, Yong Wang, Richard Long
  • Integrated combustion reactors and methods of conducting simultaneous endothermic and exothermic reactions
    Patent number: 7931875
    Abstract: Integrated Combustion Reactors (ICRs) and methods of making ICRs are described in which combustion chambers (or channels) are in direct thermal contact to reaction chambers for an endothermic reaction. Particular reactor designs are also described. Processes of conducting reactions in integrated combustion reactors are described and results presented. Some of these processes are characterized by unexpected and superior results, and/or results that can not be achieved with any prior art devices.
    Type: Grant
    Filed: July 3, 2007
    Date of Patent: April 26, 2011
    Assignee: Velocys
    Inventors: Anna Lee Tonkovich, Gary Roberts, Sean P. Fitzgerald, Paul W. Neagle, Dongming Qiu, Matthew B. Schmidt, Steven T. Perry, David J. Hesse, Robert J. Luzenski, G. Bradley Chadwell, Ying Peng, James A. Mathias, Nathan P. Gano, Ravi Arora, Barry L. Yang, David J. Kuhlmann, Thomas D. Yuschak, John Arthur Monahan
  • Manufacture of a synthetic fuel
    Patent number: 11618860
    Abstract: The present invention provides a process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, the process comprising the steps of: continuously providing the carbonaceous feedstock of fluctuating compositional characteristics to a gasification zone; gasifying the carbonaceous feedstock in the gasification zone to obtain raw synthesis gas; sequentially removing ammoniacal, sulphurous and carbon dioxide impurities from the raw synthesis gas to form desulphurised gas and recovering carbon dioxide in substantially pure form; converting at least a portion of the desulphurised synthesis gas to a useful product. Despite having selected a more energy intensive sub-process i.e. physical absorption for removal of acid gas impurities, the overall power requirement of the facility is lower on account of lower steam requirements and thereby leading to a decrease in the carbon intensity score for the facility.
    Type: Grant
    Filed: April 7, 2021
    Date of Patent: April 4, 2023
    Assignee: Velocys Technologies Ltd.
    Inventors: Ivan Philip Greager, Roger Allen Harris, Neil Alexander King, Soumitra R. Deshmukh, Zheyan Qiu
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