Search Patents
  • Process for making styrene using mircochannel process technology
    Patent number: 7847138
    Abstract: The disclosed invention relates to a process for converting ethylbenzene to styrene, comprising: flowing a feed composition comprising ethylbenzene in at least one process microchannel in contact with at least one catalyst to dehydrogenate the ethylbenzene and form a product comprising styrene; exchanging heat between the process microchannel and at least one heat exchange channel in thermal contact with the process microchannel; and removing product from the process microchannel. Also disclosed is an apparatus comprising a process microchannel, a heat exchange channel, and a heat transfer wall positioned between the process microchannel and heat exchange channel wherein the heat transfer wall comprises a thermal resistance layer.
    Type: Grant
    Filed: March 23, 2007
    Date of Patent: December 7, 2010
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Kai Tod Paul Jarosch, Bin Yang, Francis P. Daly, Thomas P. Hickey, Jeffrey Marco, Timothy J. LaPlante, Richard Q. Long
  • Integrated microchannel synthesis and separation
    Patent number: 7820725
    Abstract: A process for carrying out at least two unit operations in series, the process comprising the step of: (a) directing a feed stream into an integrated assembly which comprises a first microchannel unit operation upon at least one chemical of the feed stream to generate a distributed output stream that exits the first microchannel unit operation in a first set of discrete microchannels isolating flow through the discrete microchannels; and (b) directing the distributed output stream of the first microchannel unit operation into a second microchannel unit operation as a distributed input stream, to continue isolating flow between the first set of discrete microchannels, and conducting at least one operation upon at least one chemical of the input stream to generate a product stream that exits the second microchannel unit operation, where the first microchannel unit operation and the second unit operation share a housing.
    Type: Grant
    Filed: September 5, 2006
    Date of Patent: October 26, 2010
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Y. Tonkovich, Robert D. Litt
  • Process for separating nitrogen from methane using microchannel process technology
    Patent number: 7250074
    Abstract: The disclosed invention relates to a process for separating methane or nitrogen from a fluid mixture comprising methane and nitrogen, the process comprising: (A) flowing the fluid mixture into a microchannel separator, the microchannel separator comprising a plurality of process microchannels containing a sorption medium, the fluid mixture being maintained in the microchannel separator until at least part of the methane or nitrogen is sorbed by the sorption medium, and removing non-sorbed parts of the fluid mixture from the microchannel separator; and (B) desorbing the methane or nitrogen from the sorption medium and removing the desorbed methane or nitrogen from the microchannel separator. The process is suitable for upgrading methane from coal mines, landfills, and other sub-quality sources.
    Type: Grant
    Filed: August 26, 2004
    Date of Patent: July 31, 2007
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Dongming Qiu, Terence Andrew Dritz, Paul Neagle, Robert Dwayne Litt, Ravi Arora, Michael Jay Lamont, Kristina M. Pagnotto
  • GASIFICATION PROCESS
    Publication number: 20230382821
    Abstract: The present invention provides integrated process for the production of a useful liquid hydrocarbon product comprising the steps of: 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 a 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.
    Type: Application
    Filed: October 8, 2021
    Publication date: November 30, 2023
    Applicant: VELOCYS TECHNOLOGIES LTD
    Inventors: Ivan Greager, Roger Harris, Rudolph Havenga, Neil Alexander King
  • Integrated microchannel synthesis and separation
    Patent number: 8497308
    Abstract: A process for carrying out at least two unit operations in series, the process comprising the step of: (a) directing a feed stream into an integrated assembly which comprises a first microchannel unit operation upon at least one chemical of the feed stream to generate a distributed output stream that exits the first microchannel unit operation in a first set of discrete microchannels isolating flow through the discrete microchannels; and (b) directing the distributed output stream of the first microchannel unit operation into a second microchannel unit operation as a distributed input stream, to continue isolating flow between the first set of discrete microchannels, and conducting at least one operation upon at least one chemical of the input stream to generate a product stream that exits the second microchannel unit operation, where the first microchannel unit operation and the second unit operation share a housing.
    Type: Grant
    Filed: September 5, 2007
    Date of Patent: July 30, 2013
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Y. Tonkovich, Robert D. Litt, Timothy M. Werner, Bin Yang
  • Methods of conducting simultaneous endothermic and exothermic reactions
    Patent number: 7250151
    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: August 15, 2002
    Date of Patent: July 31, 2007
    Assignee: Velocys
    Inventors: Anna Lee Tonkovich, 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, Richard Q. Long, Wm. Allen Rogers, Ravi Arora, Wayne W. Simmons, Barry L. Yang, Yong Wang, Thomas Forte, Robert Jetter
  • Process for producing a synthetic fuel
    Patent number: 11905478
    Abstract: 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: February 28, 2023
    Date of Patent: February 20, 2024
    Assignee: Velocys Technologies Ltd.
    Inventors: Ivan Philip Greager, Roger Allen Harris, Neil Alexander King, Soumitra R. Deshmukh, Zheyan Qiu
  • Hydrogen peroxide production in microchannel reactors
    Patent number: 7959880
    Abstract: The present invention includes methods and apparatuses for producing hydrogen peroxide using microchannel technology. An exemplary process for producing hydrogen peroxide comprises flowing feed streams into intimate fluid communication with one another within a process microchannel to form a reactant mixture stream comprising a hydrogen source and an oxygen source such as, without limitation, hydrogen gas and oxygen gas. Thereafter, a catalyst is contacted by the reactant mixture and is operative to convert a majority of the reactant mixture to hydrogen peroxide that is withdrawn via an egressing product stream. During the hydrogen peroxide chemical reaction, exothermic energy is generated and absorbed by the fluid within the microchannel as well as the microchannel itself.
    Type: Grant
    Filed: June 11, 2008
    Date of Patent: June 14, 2011
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Y. Tonkovich, Bin Yang, William Allen Rogers, Jr., Paul William Neagle, Sean P. Fitzgerald, Kai Tod Paul Jarosch, Dongming Qiu, David J. Hesse, Micheal Lamont
  • Process
    Patent number: 11873458
    Abstract: A process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, 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; recovering at least part of the raw synthesis gas from the gasification zone and supplying at least part of the recovered raw synthesis gas to a partial oxidation zone; equilibrating the H2:CO ratio of the raw synthesis gas in the partial oxidation zone to obtain equilibrated synthesis gas; recovering at least part of the equilibrated synthesis gas from the partial oxidation zone and treating the gas to remove impurities and generate a fine synthesis gas; and converting the optionally adjusted fine synthesis gas into the useful product in a further chemical reaction requiring a usage ratio.
    Type: Grant
    Filed: January 5, 2023
    Date of Patent: January 16, 2024
    Assignee: Velocys Technologies Ltd
    Inventors: Ivan Philip Greager, Roger Allen Harris, Neil Alexander King, Soumitra R. Deshmukh, Zheyan Qiu, Ashish Gupta
  • Catalysts
    Patent number: 9381501
    Abstract: The invention relates to improvements in the design of Fischer-Tropsch catalysts comprising a support and cobalt on the support. A first aspect is the modification of the silica support with at least 11 wt % titania to prevent the formation of cobalt silicates, thereby limiting the deactivation resulting from the silicate formation. A second aspect is the provision of C03O4 particles highly dispersed on the catalyst support with an average particle diameter of the cobalt oxide particle of less than 12 nm in order to improve catalytic activity and selectivity.
    Type: Grant
    Filed: February 7, 2012
    Date of Patent: July 5, 2016
    Assignee: Velocys Technologies Limited
    Inventors: Frank Daly, Laura Richard, Sreekala Rugmini
  • Detonation safety in microchannels
    Patent number: 8517717
    Abstract: The proper sizing of microchannel dimensions and the management of internal features offer the possibility of inherently safe operation within the flammable limits of a combustible fluid stream while preserving the largest-possible flow dimensions for industrial-scale process capacity. Specifically, the microchannel dimensions need not be restricted to gap distances below the quenching distance to be operated safely. Microchannel performance can be engineered to provide adequate heat transfer for flame propagation. However, it is essential to maintain flame characteristics in such a manner that it cannot transition to a detonation flame front. A detonation takes place when the combustion wave propagates at supersonic speeds at the existing local temperature and pressure conditions in the system. It results in a much larger energy release over a much smaller period of time as compared to a laminar flame or deflagration, the later of which is a combustion wave propagating at subsonic speed.
    Type: Grant
    Filed: August 13, 2004
    Date of Patent: August 27, 2013
    Assignee: Velocys, Inc.
    Inventors: David J. Hesse, Kai Jarosch
  • Integrated Combustion Reactor And Methods Of Conducting Simultaneous Endothermic and Exothermic Reactions
    Publication number: 20140246625
    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: Application
    Filed: February 25, 2013
    Publication date: September 4, 2014
    Applicant: Velocys, Inc.
    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, Richard Q. Long, Wm. Allen Rogers, Ravi Arora, Wayne W. Simmons, Barry L. Yang, David J. Kuhlmann, Yong Wang, Thomas D. Yuschak, Thomas Forte, John Arthur Monahan, Robert Jetter
  • GASIFICATION PROCESS
    Publication number: 20230392090
    Abstract: The present invention provides a process for the manufacture of a useful product from synthesis gas having a desired hydrogen to carbon monoxide molar ratio comprising: 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: Application
    Filed: October 21, 2021
    Publication date: December 7, 2023
    Applicant: VELOCYS TECHNOLOGIES LTD
    Inventors: Ivan Philip Greager, Roger Allen Harris, Rudolph Havenga, Neil Alexander King
  • Method for producing a saleable product from synthesis gas derived from and/or comprising waste material and/or biomass
    Patent number: 11578281
    Abstract: A process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, 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; recovering at least part of the raw synthesis gas from the gasification zone and supplying at least part of the recovered raw synthesis gas to a partial oxidation zone; equilibrating the H2:CO ratio of the raw synthesis gas in the partial oxidation zone to obtain equilibrated synthesis gas; recovering at least part of the equilibrated synthesis gas from the partial oxidation zone and treating the gas to remove impurities and generate a fine synthesis gas; and converting the optionally adjusted fine synthesis gas into the useful product in a further chemical reaction requiring a usage ratio.
    Type: Grant
    Filed: March 16, 2021
    Date of Patent: February 14, 2023
    Assignee: Velocys Technologies Ltd
    Inventors: Ivan Philip Greager, Roger Allen Harris, Neil Alexander King, Soumitra R. Deshmukh, Zheyan Qiu, Ashish Gupta
  • Oxidation process using microchannel technology and novel catalyst useful in same
    Patent number: 7226574
    Abstract: A process is disclosed for converting a hydrocarbon reactant to a product comprising CO and H2. The process comprises: (A) flowing a reactant composition comprising the hydrocarbon reactant and oxygen or a source of oxygen through a microchannel reactor in contact with a catalyst under reaction conditions to form the product, the microchannel reactor comprising at least one process microchannel with the catalyst positioned within the process microchannel, the hydrocarbon reactant comprising methane, the contact time for the reactant composition within the process microchannel being up to about 500 milliseconds, the temperature of the reactant composition and product within the process microchannel being up to about 1150° C., the conversion of the hydrocarbon reactant to carbon oxide being at least about 50%. The product formed in step (A) may be converted to a product comprising CO2 and H2O in a microchannel reactor.
    Type: Grant
    Filed: May 30, 2003
    Date of Patent: June 5, 2007
    Assignee: Velocys, Inc.
    Inventors: Richard Q. Long, Anna Lee Tonkovich, Eric Daymo, Barry L. Yang, Yong Wang, Francis P. Daly
  • Integrated combustion reactor and methods of conducting simultaneous endothermic and exothermic reactions
    Patent number: 9192929
    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: February 25, 2013
    Date of Patent: November 24, 2015
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Gary Roberts, Sean P. Fitzgerald, Paul W. Neagle, Dongming Qui, Matthew B. Schmidt, Steven T. Perry, David J. Hesse, Robert J. Luzenski, G. Bradley Chadwell, Ying Peng, James A. Matthias, Nathan P. Gano, Richard Q. Long, Wm. Allen Rogers, Ravi Arora, Wayne W. Simmons, Barry L. Yang, David J. Kuhlmann, Yong Wang, Thomas D. Yuschak, Thomas Forte, John Arthur Monahan, Robert Jetter
  • Separation process using microchannel technology
    Patent number: 7507274
    Abstract: The disclosed invention relates to a process and apparatus for separating a first fluid from a fluid mixture comprising the first fluid. The process comprises: (A) flowing the fluid mixture into a microchannel separator in contact with a sorption medium, the fluid mixture being maintained in the microchannel separator until at least part of the first fluid is sorbed by the sorption medium, removing non-sorbed parts of the fluid mixture from the microchannel separator; and (B) desorbing first fluid from the sorption medium and removing desorbed first fluid from the microchannel separator. The process and apparatus are suitable for separating nitrogen or methane from a fluid mixture comprising nitrogen and methane. The process and apparatus may be used for rejecting nitrogen in the upgrading of sub-quality methane.
    Type: Grant
    Filed: March 2, 2006
    Date of Patent: March 24, 2009
    Assignee: Velocys, Inc.
    Inventors: Anna Lee Tonkovich, Steven T. Perry, Ravi Arora, Dongming Qiu, Michael Jay Lamont, Deanna Burwell, Terence Andrew Dritz, Jeffrey S. McDaniel, William A. Rogers, Jr., Laura J. Silva, Daniel J. Weidert, Wayne W. Simmons, G. Bradley Chadwell
  • Microchannel compression reactor assembly
    Patent number: 7807113
    Abstract: The present invention includes a removable microchannel unit including an inlet orifice and an outlet orifice in fluid communication with a plurality of microchannels distributed throughout the removable microchannel unit, and a pressurized vessel adapted have the removable microchannel unit mounted thereto, the pressurized vessel adapted to contain a pressurized fluid exerting a positive gauge pressure upon at least a portion of the exterior of the removable microchannel unit. The invention also includes a microchannel unit assembly comprising a microchannel unit operation carried out within a pressurized vessel, where pressurized vessel includes a pressurized fluid exerting a positive gauge pressure upon an exterior of the microchannel unit operation, and where the microchannel unit operation includes an outlet orifice in fluid communication with an interior of the pressurized vessel.
    Type: Grant
    Filed: April 15, 2009
    Date of Patent: October 5, 2010
    Assignee: Velocys, Inc.
    Inventors: William Allen Rogers, Paul William Neagle, Michael Alan Marchiando, Christopher Paul Weil, Robert Dwayne Litt, Ronald Chester Pasadyn, G. Bradley Smith, Charles Robert Miele, Thomas Peter Forte, Jimmy Glen Pelham
  • Microchannel compression reactor assembly
    Patent number: 7569195
    Abstract: The present invention includes a removable microchannel unit including an inlet orifice and an outlet orifice in fluid communication with a plurality of microchannels distributed throughout the removable microchannel unit, and a pressurized vessel adapted have the removable microchannel unit mounted thereto, the pressurized vessel adapted to contain a pressurized fluid exerting a positive gauge pressure upon at least a portion of the exterior of the removable microchannel unit. The invention also includes a microchannel unit assembly comprising a microchannel unit operation carried out within a pressurized vessel, where pressurized vessel includes a pressurized fluid exerting a positive gauge pressure upon an exterior of the microchannel unit operation, and where the microchannel unit operation includes an outlet orifice in fluid communication with an interior of the pressurized vessel.
    Type: Grant
    Filed: February 7, 2005
    Date of Patent: August 4, 2009
    Assignee: Velocys, Inc.
    Inventors: William Allen Rogers, Paul William Neagle, Michael Alan Marchiando, Christopher Paul Well, Robert Dwayne Litt, Ronald Chester Pasadyn, G. Bradley Smith, Charles Robert Miele, Thomas Peter Forte, Jimmy Glen Pelham
  • Control of pressurized microchannel processes
    Patent number: 7445650
    Abstract: A method of starting up and shutting down a microchannel process is provided. Included are the steps of providing a first multi-planar process unit, preferably adapted to process an endothermic reaction, a second multi-planar process unit, preferably adapted to process an exothermic reaction, providing a containment vessel, the containment vessel containing at least a portion of the first, and preferably the second, process unit. In startup, the microchannel process is first checked for pressure integrity by pressurizing and checking the important components of the process for leaks. Subsequently, the process units are heated by introducing a dilute low-thermal energy density material, preferably to the second process unit, followed by the introduction of a dilute high-thermal energy density material, and adjusting the proportion of high-thermal energy density material as required. In shutdown, a purge material from the containment vessel is introduced into the first, and preferably the second, process unit.
    Type: Grant
    Filed: March 11, 2005
    Date of Patent: November 4, 2008
    Assignee: Velocys, Inc.
    Inventors: Christopher P. Weil, Robert D. Litt, William Allen Rogers, Jr., Richard K. Bennett, Elizabeth A. De Lucia
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