Rentech, Inc.

Res Usa, LLC

Gtl Energy, Ltd.

Charles B Benham

Mark S Bohn

Dennis L Yakobson

Belma Demirel

Harold A Wright

Jesse Wade Taylor

Sara L Rolfe

Mark D Ibsen

James E Siebarth

Dawid J Duvenhage

Pandurang V Nikrad

Olga Ionkina

Dan Fraenkel

Peter S Pedersen

Richard A Bley

Claude C Corkadel, Iii

Robert A Reeves

Robert R French

Bahman Rejai

Olga P Ionkina

Sara Rolfe

A method of strengthening a precipitated unsupported iron catalyst by: preparing a precipitated unsupported iron catalyst containing copper and potassium; adding a solution comprising a structural promoter to the previously prepared catalyst; drying the mixture; and calcining the dried catalyst. A method for preparing an iron catalyst, the method comprising: precipitating a catalyst precursor comprising iron phases selected from hydroxides, oxides, and carbonates; adding a promoter to the catalyst precursor to yield a promoted precursor; drying the promoted precursor to yield dried catalyst; and calcining the dried catalyst, wherein the catalyst further comprises copper and potassium. A method of preparing a strengthened precipitated iron catalyst comprising: co-precipitating iron, copper, magnesium, and aluminum; washing the precipitate; alkalizing the precipitate; and drying the precipitate to yield a dried catalyst precursor. The dried catalyst precursor may be calcined and treated with a gas comprising carbon monoxide.

Strengthened iron catalyst for slurry reactors

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, FeO. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Method and apparatus for regenerating an iron-based Fischer-Tropsch catalyst

A method for meeting both base-load and peak-load demand in a power production facility. By integrating a Fischer-Tropsch (FT) hydrocarbon production facility with an electrical power generating facility, peak-load power demand can be met by reducing the temperature of the FT reactor thereby increasing the quantity of tail gases and using FT tail gases to fuel a gas turbine generator set. The method enables rapid power response and allows the synthesis gas generating units and the FT units to operate with constant flow rates.

Method for providing auxiliary power to an electric power plant using fischer tropsch technology

A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe:Feratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe:Feratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

Precipitated iron catalyst for hydrogenation of carbon monoxide

A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe:Feratio in the range of about 0.01%: 99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe:Feratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

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, Fe0. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Method and apparatus for regenerating an iron-based fischer-tropsch catalyst

A method of activating an iron Fischer-Tropsch catalyst by introducing an inert gas into a reactor comprising a slurry of the catalyst at a first temperature, increasing the reactor temperature from the first temperature to a second temperature at a first ramp rate, wherein the second temperature is in the range of from about 150&#xb0; C. to 250&#xb0; C., introducing synthesis gas having a ratio of H:CO to the reactor at a space velocity, and increasing the reactor temperature from the second temperature to a third temperature at a second ramp rate, wherein the third temperature is in the range of from about 270&#xb0; C. to 300&#xb0; C. The iron Fischer-Tropsch catalyst may be a precipitated unsupported iron catalyst, production of which is also provided.

Method for activating strengthened iron catalyst for slurry reactors

Method for providing auxiliary power to an electric power plant using fischer-tropsch technology

The invention provides a method by which low-rank coal may be processed to provide a high-energy feedstock for coal gasification and synthesis gas production. Preliminary coal, preparation, which may include washing and drying, is followed by wax-impregnation to produce a high-energy, low-moisture, stable feedstock. The wax is preferably obtained from an on-site Fischer-Tropsch reactor that also produces diesel fuel and naptha.

Method of forming a feed for coal gasification

Increased hydrocarbon yields from natural gas and reduced oxygen consumption improvements are obtained by recycling hydrogen to a Fischer-Tropsch reactor, which can have a catalyst exhibiting either a low water gas shift activity such as cobalt, or a high water gas shift activity such as iron. At least a portion of the remaining tail gas, either before or after the hydrogen has been removed, is recycled to the inlet of the synthesis gas production reactor.

Producing liquid hydrocarbons from natural gas

Catalyst particles are separated from the wax in a Fischer-Tropsch reactor by feeding a portion of the reactor slurry to a dynamic settler which does not require any pump. As the slurry flows down a pipe in the center of the settler, the slurry flows into the surrounding annular region at the bottom of the settler. The heavier catalyst particles settle down and are removed as the slurry at the bottom of the settler is recycled back to the reactor. The wax rises up in the annular section and this clarified wax is removed by a wax outlet pipe. In an embodiment with an expanded diameter section above the Fischer-Tropsch reactor an additional dynamic settler can be placed inside this section. The Fischer-Tropsch catalyst can be regenerated by purging the catalyst with an inert gas for a period of time and by treating the catalyst with naphtha.

Catalyst/wax separation device for slurry Fischer-Tropsch reactor

A process of converting a feed of hydrocarbon-containing gases into liquid hydrocarbon products including a first reaction of converting the feed into one to 2.5 parts of hydrogen to one part carbon monoxide in the presence of carbon dioxide and then secondly reacting the hydrogen and carbon monoxide in a Fischer-Tropsch synthesis reactor using a promoted iron oxide catalyst slurry to form liquid hydrocarbon products, wherein the carbon dioxide from the first and second reactions is separated from the product streams and at least a portion of the separated carbon dioxide is recycled into the first reaction feed and the hydrocarbon products are separated by distillation and a normally gaseous portion of the separated products are further reacted in another Fischer-Tropsch synthesis reactor to produce additional liquid hydrocarbon product.

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Arvada, CO, United States of America

Charles B Benham