Rentech, Inc.

Pioneer Energy Inc.

James E Siebarth

Mark S Bohn

Robert M Zubrin

Mark H Berggren

Belma Demirel

Charles B Benham

Mark D Ibsen

Thomas Lee Henshaw

Boris Nizamov

Adam M Kortan

Colin Apke

Disclosed is a method that reforms flare gas or other raw natural gas source, using air without steam, to directly produce dimethyl ether (DME), a direct diesel substitute. The method first reforms an air-natural gas mixture at ambient atmospheric pressures, and then compresses the resulting CO-hydrogen-nitrogen gas mixture to 100-2,000 psi, and feeds it through a combined reactor which reacts the gas mixture directly into DME. The nitrogen is returned to the atmosphere. DME is an excellent diesel fuel, and can be used to displace significantly costlier and dirtier petroleum-based diesel fuel, while solving a critical problem with flaring or other wasted natural gas. For example, the roughly 120 billion cubic feet per year that was flared in North Dakota in 2014 could be converted into over 3 million tons of DME using the disclosed method.

Systems and methods for manufacture of dimethyl ether (DME) from natural gas and flare gas feedstock

A mobile system and method that reform flare gas, methane, or natural gas, using air without steam, to directly produce methanol, a clean burning gasoline blend, component, and/or substitute are disclosed. The system first reforms the air-methane mixture at ambient atmospheric pressure, then compresses the resulting CO-hydrogen-nitrogen gas mixture to about 600 psi, and feeds it through a methanol reactor which reacts the gas mixture directly into methanol. The nitrogen is returned by the system back to the atmosphere. Methanol is a clean burning gasoline substitute, and can be used to displace significantly costlier and dirtier petroleum-based fuel, while solving a critical problem with flaring. For example, the over 120 billion cubic feet per year that was flared in North Dakota in 2014 could be converted into over 6 million tons of methanol.

Systems and methods for manufacture of methanol from natural gas and flare gas feedstock

A unique design for a mobile system that reforms flare gas or natural gas, using air without steam, to directly produce dimethyl ether (DME), a diesel substitute, is disclosed. The system first reforms the air-methane mixture at ambient atmospheric pressures, and then compresses the resulting CO-hydrogen-nitrogen gas mixture to up to 600 psi, and feeds it through a combined reactor which reacts the gas mixture directly into dimethyl ether. The nitrogen is returned by the system back to the atmosphere. DME is an excellent diesel fuel, and can be used to displace significantly costlier and dirtier petroleum-based diesel fuel, while solving a critical problem with flaring. For example, the over 120 billion cubic feet per year that is currently flared in North Dakota could be converted into over 3 million tons of DME.

A mobile system and method that reform flare gas, methane, or natural gas, using air without steam, to directly produce methanol, a clean burning gasoline blend, component, and/or substitute are disclosed. The system first reforms the air-methane mixture at ambient atmospheric pressure, then compresses the resulting CO-hydrogen-nitrogen gas mixture to 600 psi, and feeds it through a methanol reactor which reacts the gas mixture directly into methanol. The nitrogen is returned by the system back to the atmosphere. Methanol is a clean burning gasoline substitute, and can be used to displace significantly costlier and dirtier petroleum-based fuel, while solving a critical problem with flaring. For example, the over 120 billion cubic feet per year that was flared in North Dakota in 2014 could be converted into over 6 million tons of methanol.

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

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

Catalyst particles are separated from the wax in a reactor slurry reactor by feeding a portion of the slurry to a dynamic settler. Heavier catalyst particles settle and are removed as the slurry at the bottom of the settler is recycled back to the reactor. Clarified wax is removed at the top of the settler. A multi-channel baffle prevents turbulence, improving retention of the desired heavier catalyst particles.

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Denver, CO, United States of America

James E Siebarth