Mobil Oil Corporation

James C Kuo

John J Wise

William E Garwood

Solomon M Jacob

Samuel A Tabak

Charles Dwight Prater

Werner O Haag

Quang N Le

Paul B Weisz

Donald M Nace

Tiberiu M Leib

Anthony Y Kam

W Rodman Derr, Jr

Jonah Smith

An improved Fischer-Tropsch process for hydrocarbon synthesis operated in the fluid mode of the Sasol's Synthol Process provides increased diesel and heavier hydrocarbon yield wherein a Fischer-Tropsch synthesis catalyst modified by a minor amount of a zeolite catalyst selectively converts enough waxy product to prevent adhesion between catalyst particles which might interfere with catalyst flow thereby permitting maximization of diesel oil and heavy hydrocarbon yield.

Fischer-tropsch process

Disclosed is a method and apparatus for producing gasoline and distillate grade products which employs integrating catalytic (or thermal) dehydrogenation of paraffins with MOGD to minimize interstage compression and gas plant separation cost. The process cascades the product from a low temperature propane or butane dehydrogenation zone into a first catalytic reactor zone which operates at low pressure and contains zeolite oligomerization catalysts, where the low molecular weight olefins are reacted to primarily gasoline range materials. These gasoline range materials can then be pressurized to the pressure required for reacting to distillate in a second catalytic reactor zone operating at high pressure and containing zeolite oligomerization catalyst. The first catalytic reactor zone also acts to remove the olefins from the dehydrogenation reactor effluent to allow recycle of the unreacted paraffins.

Integration of paraffin dehydrogenation with MOGD to minimize

The waxy liquid phase of an oil suspension of Fischer-Tropsch catalyst containing dissolved wax is separated out and the wax is converted by hydrocracking, dewaxing or by catalytic cracking with a low activity catalyst to provide a highly olefinic product which may be further converted to premium quality gasoline and/or distillate fuel.

Process for upgrading wax from Fischer-Tropsch synthesis

Dewaxing a waxy feedstock is achieved by dispersing dewaxing catalyst particles within the liquid waxy feedstock and removing gaseous products out of contact with the catalyst by purging a gas stream through the liquid feedstock.

Catalyst dewaxing process using a slurry phase bubble column reactor

Utilizing air, rather than oxygen, to convert coal to synthesis gas containing very high proportions of inert nitrogen; subjecting this entire gas, possibly with intermediate cleanup, e.g., sulfur removal, to conversion over a special metal-zeolite catalyst to produce a product comprising C.sub.5 to C.sub.11 normally liquid hydrocarbons, a gas containing C.sub.1 to C.sub.4 hydrocarbons, carbon dioxide and large proportions of nitrogen, and an aqueous product comprising water; utilizing the gas product to run electric power generation equipment, such as a direct fired turbine, at base load levels; storing and accumulating the liquid product; and intermittently using the liquid product for electric power generation to meet higher than base loads, including peak load situations.

Conversion of coal to electricity

An integrated process for converting coal to high octane gasoline by gasifying the coal in such manner as to form a gas comprising carbon oxides, hydrogen and methane; contacting this gas in one or a series of steps with one or a series of catalysts, respectively comprising a special high silica to alumina ratio zeolite; converting the carbon oxides and hydrogen by such contact to a product comprising water, high octane aromatic gasoline and light hydrocarbon gases; alkylating the C.sub.3 and C.sub.4 olefins with the isobutane in the light gases to produce alkylate gasoline; admixing the aromatic and alkylate gasolines; and subjecting the C.sub.2.sup.- portion of the product to catalytic methanation via a nickel catalyst to produce synthetic natural gas.

Conversion of coal to high octane gasoline

The products of Fischer-Tropsch synthesis boiling below a separated decant oil fraction are subjected to cooling to a temperature of about 100.degree. F and separation of the cooled product to recover Fischer-Tropsch produced water comprising oxygenates, a normally liquid hydrocarbon phase comprising absorbed oxygenates and a gaseous phase normally comprising a substantial amount of C.sub.5 hydrocarbons in combination with lower boiling materials including unreacted synthesis gas and carbon dioxide. Each of said gaseous phase and said normally liquid hydrocarbon phase are thereafter contacted with a selected crystalline zeolite catalyst particularly selective for the formation of gasoline boiling material of high octane.

Method for upgrading Fischer-Tropsch synthesis products

Natural gas is steam reformed to a mixture of carbon monoxide, carbon dioxide and hydrogen which mixture is converted, over a methanol synthesis catalyst, to a mixture of methanol, carbon oxides and hydrogen which methanol is converted to C.sub.5.sup.+ hydrocarbon gasoline, light gas and water, the water is separated out and may be recycled as steam, the portion of the hydrocarbon fraction which comprises light olefins and isobutane is subjected to acid alkylation to product very high octane hydrocarbon gasoline which is admixed with the C.sub.5.sup.+ hydrocarbon gasoline from the methanol conversion. The light fuel gas (C.sub.1 to C.sub.2) produced in the methanol conversion is recycled to the steam reformer and the LPG (C.sub.3 + C.sub.4) produced therein is recovered and sold.

Conversion of natural gas to gasoline and LPG

The total product effluent of Fischer-Tropsch synthesis separated from catalyst fines is passed in contact with a crystalline zeolite catalyst represented by ZSM-5 before separation into desired product fractions and C.sub.5 minus gaseous products are catalytically converted to gasoline boiling components.

The product effluent of a Fischer-Tropsch synthesis is subjected to cooling sufficient to separate a high boiling product fraction boiling above about 400.degree. F from lower boiling product effluent material and comprising water product with formed oxygenates. The total lower boiling product effluent thus obtained is passed in contact with a special class of selective crystalline zeolite catalyst maintained under conditions to improve upon the hydrocarbon products contacted and convert oxygenates for hydrocarbons.

Method for upgrading products of Fischer-Tropsch synthesis

A combination process is provided which upgrades the C.sub.3 to 650.degree. F product of Fischer-Tropsch Synthesis to form gasoline product of improved octane rating by contact with ZSM-5 crystalline zeolite and hydrogenation of light fuel oil to improve its stability and color characteristics. Gaseous products are converted to alkylate in the gasoline boiling range. The yield of light fuel oil may be increased by reducing the end point of the gasoline fraction to about 320.degree. F.

Method for upgrading C.sub.3 plus product of Fischer-Tropsch Synthesis

A combination process is provided for upgrading 650.degree. F minus product of Fischer-Tropsch Synthesis to provide high yield of high octane gasoline along with improved yields of light fuel oil product. Polymerization and alkylation of C.sub.5 minus gaseous material provide products suitable for blending with gasoline and fuel oil product. A ZSM5 catalyst is relied upon to improve the octane rating of C.sub.5 plus gasoline product of an end point within the range of about 320.degree. F up to about 430.degree. F.

Method for upgrading C.sub.5 plus product of Fischer-Tropsch Synthesis

Upgrading of Fischer-Tropsch synthesis product is obtained by separating a 560.degree. F minus hydrocarbon fraction from gaseous C.sub.5 rich material and a water phase comprising oxygenates. Alcohols may be recovered from the water phase for conversion to gasoline boiling components. C.sub.5 rich material is converted to gasoline boiling material with a ZSM-5 crystalline zeolite and upgrading of the 560.degree. F minus hydrocarbon fraction is accomplished with a ZSM-5 crystalline zeolite catalyst.

An integrated process for converting coal to high octane gasoline by gasifying the coal in such manner as to form a gas comprising carbon oxides, hydrogen and methane; contacting this gas in one or a series of steps with one or a series of catalysts, respectively comprising a special high silica to alumina ratio zeolite; converting the carbon oxides and hydrogen by such contact to a product comprising water, high octane aromatic gasoline and light hydrocarbon gases; alkylating the C.sub.3 and C.sub.4 olefins with the isobutane in the light gases to produce alkylate gasoline; admixing the aromatic and alkylate gasoline; and subjecting the C.sub.2 .sup.- portion of the product to steam reforming whereby additional synthesis gas to be admixed with the gas produced by coal gasification is formed.

A process is described for the production of aromatics boiling in the gasoline boiling range from methanol carried out in two stages wherein a heat dissipating diluent is employed in the second stage during contact with a crystalline zeolite catalyst selective for the purpose and the first stage exothermic temperature rise is catalytically restricted.

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Cherry Hill, NJ, United States of America

James C Kuo