Johnson Matthey Inc.

Johnson Matthey Public Limited Company

Imperial Chemical Industries Limited

Peter Edward James Abbott

Martin Fowles

Richard James Beavis

Mark McKenna

Gary Bevan Combes

Peter William Farnell

Norman Macleod

Bernard John Crewdson

Gordon Edward Wilson

Philip Charles Southerden

Martin John Fernie

Mark Mckenna

A process for producing a methane-containing gas mixture includes the steps of:

Process for production of methane-containing gas mixture

A process for the conversion of a hydrocarbon to COand electrical power is described which includes subjecting a gas mixture of a hydrocarbon feed stream and steam to an integrated reforming process including stages of steam reforming in a gas-heated reformer and secondary reforming to generate a reformed gas mixture, increasing the hydrogen content of the reformed gas mixture by subjecting it to one or more water-gas-shift stages, cooling the resulting hydrogen-enriched reformed gas and separating condensed water therefrom, passing the resulting de-watered hydrogen-enriched reformed gas to one or more stages of carbon dioxide separation to recover carbon dioxide, combusting the remaining hydrogen-containing fuel stream with an oxygen containing gas in a gas turbine to generate electrical power and passing the exhaust gas mixture from the gas turbine to a heat recovery steam generation system that feeds one or more steam turbines to generate additional electrical power.

Conversion of hydrocarbons to carbon dioxide and electrical power

Process for increasing the hydrogen content of a synthesis gas containing one or more sulphur compounds, the synthesis gas including hydrogen, carbon oxides and steam, and having a ratio defined as R&#x2550;(H&#x2014;C0)/(CO+C0)&#x2266;0.6 and a steam to carbon monoxide ratio &#x2266;1.8, includes the steps of (i) adjusting the temperature of the synthesis gas; (ii) passing at least a portion of the heated synthesis gas adiabatically through a first bed of sulphur-tolerant water-gas shift catalyst disposed in a first shift vessel at a space velocity &#x2267;12,500 hourto form a pre-shifted gas stream; and (iii) forming a shifted gas stream by subjecting at least a portion of the pre-shifted gas stream to a second stage of water-gas shift in a second shift vessel containing a second bed of sulphur-tolerant water-gas shift catalyst that is cooled in heat exchange with a gas stream including the synthesis gas.

Process for increasing hydrogen content of synthesis gas

A process for increasing the hydrogen content of a synthesis gas containing one or more sulphur compounds, the synthesis gas including hydrogen, carbon oxides and steam, and having a ratio, R, defined as R=(H&#x2212;CO)/(CO+CO)&#x2266;0.6 and a steam to carbon monoxide ratio &#x2266;1.8, includes the steps of (i) adjusting the synthesis gas temperature, (ii) passing the temperature-adjusted synthesis gas through an adiabatic pre-shift vessel containing a bed of sulphur-tolerant water-gas shift catalyst at a space velocity &#x2267;12,500 hourto form a pre-shifted gas stream, and (iii) subjecting at least a portion of the pre-shifted gas stream to one or more further stages of water-gas shift.

Process for increasing the hydrogen content of a synthesis gas containing one or more sulphur compounds, the synthesis gas including hydrogen, carbon oxides and steam, and having a ratio defined as R=(H&#x2212;CO)/(CO+CO)&#x2266;0.6 and a steam to carbon monoxide ratio &#x2266;1.8, including the steps of (i) heating the synthesis gas; (iii) subjecting at least a portion of the heated synthesis gas to a first stage of water-gas shift in a first shift vessel containing a first sulphur-tolerant water-gas shift catalyst that is cooled in heat exchange with boiling water, to form a pre-shifted gas stream; and (iii) forming a shifted gas stream by subjecting at least a portion of the pre-shifted gas stream to a second stage of water-gas shift in a second shift vessel containing a second sulphur-tolerant water-gas shift catalyst that is cooled in heat exchange with a gas stream including the synthesis gas.

Process for synthesizing hydrocarbons includes: reforming a hydrocarbon feedstock containing inert gases in reforming stages to generate a synthesis gas including the inert gases, steam, hydrogen and carbon monoxide; cooling the synthesis gas below the dew point to obtain a dewatered synthesis gas; synthesizing hydrocarbons from the dewatered synthesis gas by the Fischer-Tropsch reaction and separating at least part of the synthesized hydrocarbons, to give a tail gas; subjecting a mixture of at least part of the tail gas and steam to the water-gas shift reaction, to form shifted tail gas having increased hydrogen and carbon dioxide contents; subjecting the shifted tail gas to one or more membrane separation stages thereby generating an inert gas-containing gas mixture and one or more of a hydrogen-, carbon dioxide- and a hydrocarbon-containing gas mixture; and using one or more of the hydrogen-, carbon dioxide- and hydrocarbon-containing gas mixture in a reformer feed stream.

Synthesis gas and Fischer Tropsch integrated process

A process for reducing the thiophene content in a synthesis gas mixture, comprises the steps of (i) passing a synthesis gas mixture comprising hydrogen and carbon oxides and containing thiophene over a copper-containing sorbent disposed in a sorbent vessel at an inlet temperature in the range 200-280&#xb0; C., (ii) withdrawing a thiophene depleted synthesis gas containing methanol from the sorbent vessel, and (iii) adjusting the temperature of the methanol-containing thiophene-depleted synthesis gas mixture. The resulting gas mixture may be used for production of chemicals, e.g. methanol production or for the Fischer-Tropsch synthesis of liquid hydrocarbons, for hydrogen production by using water gas shift, or for the production of synthetic natural gas.

Process for generating a synthetic natural gas

A process for passivation of surfaces of heat exchange apparatus exposed to a synthesis gas containing carbon monoxide, includes the steps of:

Metal passivation of heat-exchanger exposed to synthesis gas

A process for increasing the hydrogen content of a synthesis gas containing one or more sulphur compounds is described, comprising the steps of (i) heating the synthesis gas and (ii) passing at least part of the heated synthesis gas and steam through a reactor containing a sour shift catalyst, wherein the synthesis gas is heated by passing it through a plurality of tubes disposed within said catalyst in a direction co-current to the flow of said synthesis gas through the catalyst. The resulting synthesis gas may be passed to one or more additional reactors containing sour shift catalyst to maximize the yield of hydrogen production, or used for methanol production, for the Fischer-Tropsch synthesis of liquid hydrocarbons or for the production of synthetic natural gas.

A method for passivating low-alloy steel surfaces in apparatus operating in the temperature range 350 to 580&#xb0; C. and exposed to a carbon monoxide containing gas mixture comprises adding a passivating compound containing at least one phosphorus (P) atom to the gas mixture. The gas mixture is preferably a reformed gas and also described is a process for producing a synthesis gas wherein, prior to cooling a reformed gas mixture to a temperature between 350 and 580&#xb0; C. in apparatus having low-alloy steel surfaces downstream of one or more reforming steps, a passivating compound containing at least one phosphorus (P) atom is combined with the gas mixture.

Metal passivation

A process for the generation of a synthesis gas comprising: (a) forming a raw synthesis gas, (b) dividing the raw synthesis gas into first and second streams, (c) subjecting the first stream to the water gas shift reaction to form a shifted gas mixture, (d) cooling the second raw synthesis gas stream and shifted gas mixture to below the dew point to form a dry raw synthesis gas mixture, and a dry shifted gas mixture respectively, (e) feeding the dry raw synthesis gas mixture and a dry shifted gas mixture to a gas-washing unit operating by counter-current solvent flow, such that the solvent flowing through said unit contacts first with the dry raw gas mixture and then the dry shifted gas mixture, and (f) collecting from said gas-washing unit a synthesis gas having a stoichiometry ratio, R=(H&#x2212;CO)/(CO+CO), in the range 1.4 to 3.3.

Process for the generation of a synthesis gas

A method for reducing the interaction between carbon monoxide present in a heat exchange medium and metals on the shell side of heat exchange reformer apparatus used for reforming of hydrocarbons by treatment of the shell-side of said apparatus with an effective amount of at least one passivation compound containing at least one element selected from phosphorus, tin, antimony, arsenic, lead, bismuth, copper, germanium, silver or gold is described. Where volatile compounds are formed by the passivation compound, the method further comprises compound recovery to prevent contamination and deactivation of subsequent process steps. The method reduces side reactions, provides improved reformer tube lifetime and allows tubes to be treated in-situ without the need for process shutdown.

Metal passivation in a heat exchange reformer

Propane and/or butanes are separated from a hydrocarbon feedstock contaminated with alkyl mercaptans by fractional distillation at such a pressure that the separated overheads stream containing said propane and/or butanes is at a temperature in the range 50 to 100&#xb0; C. Sufficient oxygen is introduced into the hydrocarbon feedstock to oxidise the mercaptans therein and the resultant mixture is subjected to the fractional distillation in a column including at least one bed of a catalyst capable, under the prevailing conditions, of oxidising the mercaptans to higher boiling point sulphur compounds. These higher boiling point sulphur compounds are separated as part of the liquid phase from the distillation.

Desulphurisation

A process for the production of hydrocarbons is described including; a) subjecting a mixture of a hydrocarbon feedstock and steam to catalytic steam reforming to form a partially reformed gas, b) subjecting the partially reformed gas to partial combustion with an oxygen-containing gas and bringing the resultant partially combusted gas towards equilibrium over a steam reforming catalyst to form a reformed gas mixture, c) cooling the reformed gas mixture to below the dew point of the steam therein to condense water and separating condensed water to give a de-watered synthesis gas, d) synthesising hydrocarbons from side de-watered synthesis gas by the Fischer-Tropsch reaction and e) separating the hydrocarbons from co-produced water, characterised in that at least part of said co-produced water is fed to a saturator wherein it is contacted with hydrocarbon feedstock to provide at least part of the mixture of hydrocarbon feedstock and steam subjected to steam reforming.

Production of hydrocarbons by steam reforming and Fischer-Tropsch reaction

A process for production of hydrocarbons including a) reforming a divided hydrocarbon feedstock stream, mixing the first stream with steam, passing the mixture over a catalyst disposed in heated heat exchange reformer tubes to form a primary reformed gas, forming a secondary reformer feed stream including the primary reformed gas and the second hydrocarbon stream, partially combusting the secondary reformer feed stream and bringing the partially combusted gas towards equilibrium over a secondary catalyst, and producing a partially cooled reformed gas, b) further cooling the partially cooled reformed gas below the dew point of steam therein to condense water and separating condensed water to give a de-watered synthesis gas, c) synthesising hydrocarbons from the de-watered synthesis gas by the Fischer-Tropsch reaction and separating some of the synthesised hydrocarbons into a tail gas, and d) incorporating part of the tail gas into the secondary reformer feed stream before partial combustion thereof.

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Eaglescliffe, United Kingdom

Peter Edward James Abbott