Conocophillips Company

Daxiang Wang

Harold A Wright

Gloria I Straguzzi

Tianyan Niu

Yaming Jin

Baili Hu

Rafael Luis Espinoza

Joe D Allison

Sriram Ramani

Beatrice C Ortego

David M Minahan

Sinh Trinh

Larry D Swinney

Vincent H Melquist

Barbara A Belt

Kevin L Ricketson

Yi Jiang

Shuibo Xie

Bang Cheng Xu

Robin G Cnossen

Steve R Landis

The present invention relates to a process for the preparation of synthesis gas (i.e., a mixture of carbon monoxide and hydrogen), typically labeled syngas. More particularly, the present invention relates to a regeneration method for a syngas catalyst. Still more particularly, the present invention relates to the regeneration of syngas catalysts using a re-dispersion technique. One embodiment of the re-dispersion technique involves the treatment of a deactivated syngas catalyst with a re-dispersing gas, preferably a carbon monoxide-containing gas such as syngas. If necessary, the catalyst is then exposed to hydrogen for reduction and further re-dispersion.

Regeneration of synthesis gas catalysts

Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and Hand, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500&#xb0; C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Controlled-pore catalyst structures and process for producing synthesis gas

A porous catalyst support having an increased average pore size is produced from a mixed metal oxide material. In accordance with one embodiment, a method for preparing a mixed metal oxide material includes providing a mixed metal oxide precursor containing at least two metals, calcining the mixed metal oxide precursor at a temperature sufficient to form a thermally and mechanically stable mixed metal oxide material, and leaching the mixed metal oxide material in a leach solution with a constituent that dissolves one metal oxide. Preferably, the calcination temperature is approximately between 300&#xb0; C. and 1300&#xb0; C. The leaching constituent may be chosen from the group including acidic solutions of HCl, HNO, HSO, HPO, and their combinations, or basic solutions of NH, NaOH, KOH, and their combinations.

Modification of the pore structure of metal oxide and mixed metal oxide supports for catalysts synthesis

The present invention is an improvement in the preparation of liquid hydrocarbons from natural gas/methane, oxygen and/or steam. In particular, the present invention relates to processes for the production of synthesis gas, reducing the oxygen concentration from the synthesis gas, and the production of liquid hydrocarbons using the oxygen reduced synthesis gas as a feedstock. More particularly, the present invention described herein identifies catalyst compositions, apparatus and methods of using such catalysts and apparatus for preparing liquid hydrocarbons via oxygen reduced synthesis gas all in accordance with the present invention.

Selective removal of oxygen from syngas

A pretreatment method for increasing the average pore size of a catalyst support is disclosed which increases the diffusivity and effectiveness factor &#x3b7;. The pretreatment method includes calcining the support in moisturized air at an elevated temperature sufficient to increase the average pore size. In some embodiments, the support may be treated with an acidic/basic solution prior to the calcination step. Alternatively, the calcination step may occur in a gas mixture including water/air/acidic (or basic) gases.

Hydrothermal pretreatment for increasing average pore size in a catalyst support

Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and Hare disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and Ois passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.

Lanthanide-promoted rhodium catalysts and process for producing synthesis gas

Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Integration of mixed catalysts to maximize syngas production

The present invention is directed towards a process that allows for the adjustment of hydrogen concentration in a syngas product or Fischer-Tropsch feedstock stream. In particular, the invention is identified as an improved process for producing syngas comprising a secondary chemical reaction, preferably a water gas shift reaction, that allows for the adjustment of the hydrogen concentration in a syngas product stream. Ultimately, the present invention is for an improved process for converting hydrocarbon-containing gas to liquid hydrocarbons.

Hydrocarbon gas to liquid conversion process

Embodiments include methods and apparatus for arranging multiple reaction zones such that at least one hot spot in one of the reaction zones is moderated by a cooler spot in an adjacent reaction zone.

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Ponca City, OK, United States of America

Daxiang Wang