Exxonmobil Research and Engineering Company

Exxon Research and Engineering Company

Exxonmobil Upstream Research Company

Solid Carbon Products, LLC

Exxon Chemical Patents, Inc.

Exxon Mobil Chemical, Inc.

Russell John Koveal

Michel A Daage

Thomas H Vanderspurt

Terry A Ring

Daniel Paul Leta

Mark Alan Greaney

Dallas B Noyes

Mark Michael Disko

Sutinder K Behal

Angela V Klaus

Robert B Harris

Robert D Denton

Janet Renee Clark

Alla Jurievna Krylova

Albert L'Vovich Lapidus

Lilia Vadimovna Sineva

Jeffrey Lawrence Brinen

James John Mcalpin

David C Long

Leroy Russell Clavenna

Albert L'vovich Lapidus

Charles H Mauldin

Claude C Culross

Trikur Anantharaman Ramanarayanan

Eric B Shen

David O Marler

Min Chang

James Dirickson Mumford

Michael A Daage

Trikur Anantharaman Ramanarayaman

Shawn Paul Brennan

Dennis George Alexion

Kenneth R Miller

David Owen Marler

Charles Harrison Mauldin

David Chester Long

Claude Clarence Culross

Methods and systems are provided for forming carbon allotropes. An exemplary method includes forming a feedstock that includes at least about 10 mol % oxygen, at least about 10 mol % carbon, and at least about 20 mol % hydrogen. Carbon allotropes are formed from the feedstock in a reactor in a Bosch reaction at a temperature of at least about 500&#xb0; C., and the carbon allotropes are separated from a reactor effluent stream.

Feedstocks for forming carbon allotropes

Systems and a method for removing carbon nanotubes from a continuous reactor effluent are provided herein. The method includes flowing the continuous reactor effluent through a separation vessel, separating carbon nanotubes from the continuous reactor effluent in the separation vessel, and generating a stream including gaseous components from the continuous reactor effluent.

Removing carbon nanotubes from a continuous reactor effluent

Methods and a system for removing carbon nanotubes from a water stream are provided herein. The system includes a purification vessel, wherein the purification vessel is configured to form a carbon oxide from the carbon nanotubes within the water stream.

Removing carbon nanotubes from a water system

Systems and a method for forming carbon allotropes are described. An exemplary reactor system for the production of carbon allotropes includes a hybrid reactor configured to form carbon allotropes from a reactant gas mixture in a Bosch reaction. The hybrid reactor includes at least two distinct zones that perform different functions including reaction, attrition, catalyst separation, or gas separation.

Reactor system for the production of carbon allotropes

Methods and systems are provided for forming carbon allotropes. An exemplary method includes treating a carbonaceous compound to form a feedstock that includes at least about 10 mol % oxygen, at least about 10 mol % carbon, and at least about 20 mol % hydrogen. Carbon allotropes are formed from the feedstock in a reactor in a Bosch reaction at a temperature of at least about 500&#xb0; C. The carbon allotropes are separated from a reactor effluent stream.

Carbonaceous feedstocks for forming carbon allotropes

A system and methods for forming carbon allotropes are described. The system includes a reactor configured to use a catalyst to form a carbon allotrope from a feed stock in a Bosch reaction. The catalyst includes a roughened metal surface.

Generating catalysts for forming carbon allotropes

There is provided a process for regenerating the activity of used metal catalysts for the hydrogenation of carbon monoxide comprising decreasing the hydrocarbon content thereof, calcining under an oxidant-containing atmosphere, impregnating with a solution of at least one of a metal compound, calcining under an oxidant-containing atmosphere and activating by contacting with a hydrogen-contacting gas at elevated temperatures to form an active catalyst. The process regenerates and enhances both supported and dispersed active metal (DAM) catalysts. Used catalysts enhanced by the process are initially treated to decrease their hydrocarbon content. The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst may be withdrawn from a reactor and returned to at least one reactor, both preferably during operation thereof. Up to all steps may be effected in a subsequent reactor, or in specialized apparatus.

Catalyst regeneration

There is provided a process for renewing the activity of supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, preferably by contact with hydrogen-containing gas at elevated temperatures, impregnating under a non-oxidizing atmosphere with a solution of at least one of an ammonium salt and an alkyl ammonium salt, optionally in combination with up to five moles of ammonia per liter of solution to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume; oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step.

Supported catalyst treatment

A process for enhancing metal catalysts for carbon monoxide hydrogenation comprising reducing the catalyst so that at least a portion is in the metallic state, impregnating under a non-oxidative atmosphere with a solution of a salt of at least one metal, optionally in combination with at least one of an ammonium salt, an alkyl ammonium salt, a weak organic acid and ammonia, oxidizing with a gaseous oxidant in the presence of the impregnating solution, and reducing to form an active catalyst. Used catalysts enhanced by the process are initially treated to decrease their hydrocarbon content. The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst may be withdrawn from a reactor and returned to at least one reactor, both preferably during operations. Up to all steps may be effected in a subsequent reactor, or in specialized apparatus.

Catalyst enhancement

There is provided a process for hydrocarbon synthesis wherein a supported metal catalyst for hydrogenating carbon monoxide to form a mixture of hydrocarbons is regenerated by decreasing its hydrocarbon content, impregnating under a non-oxidative atmosphere with a solution of at least one member selected from the group consisting of ammonium salts, alkyl ammonium salts and weak organic acids, optionally including ammonia, oxidizing with a gaseous oxidant in the presence of the impregnating solution, activating the catalyst by reduction with hydrogen at elevated temperatures and reusing the catalyst. The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst has been withdrawn therefrom and returned to at least one reactor. Up to all steps subsequent to decreasing the hydrocarbon content may be effected in a subsequent reactor, or in specialized apparatus.

Fischer-tropsch catalyst enhancement

A process for activating a supported metal catalyst or catalyst precursor useful for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons, comprising reducing with a hydrogen-containing gas at elevated temperature so that at least a portion is in the metallic state, impregnating under a non-oxidizing atmosphere with a solution of at least one member selected from the group consisting of ammonium salts, alkyl ammonium salts and weak organic acids, optionally further including ammonia, to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume, oxidizing with a gaseous oxidant in the presence of the impregnating solution and reducing with hydrogen-containing gas at elevated temperatures to form an active catalyst. The steps beginning with the impregnation may be repeated. Optionally, the catalyst may be calcined after the oxidation step and/or passivated after activation.

Supported catalyst activation

There is provided a process for renewing the activity of used, supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, impregnating said catalyst under an non-oxidative atmosphere with a solution at least one weak organic acid, preferably a mono- or di-carboxylic acid, to the point where it has absorbed a volume of said solution equal to at least about 10% of its calculated pore volume, oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step. A preferred means of decreasing the hydrocarbon content of the catalyst is contacting it with a hydrogen-containing gas at elevated temperatures.

Supported catalyst regeneration

A process of enhancing both the activity and the methane selectivity of a Dispersed Active Metal (&ldquo;DAM&rdquo;) hydrogenation catalyst is disclosed wherein the DAM undergoes low temperature oxidation in a slurry phase to form a stable, unique oxidized catalyst precursor that is subsequently reduced to form an enhanced catalyst by treatment with hydrogen-containing gas at elevated temperature, wherein reducible promoter metals comprising one or more of rhenium, ruthenium, palladium, iron and cobalt are added to the DAM. The promoter metals are mixed with the oxidized catalyst precursor as a solution of their reducible salts. The oxidized catalyst precursors are again recovered from the mixture and treated with hydrogen-containing gas to simultaneously form the metals and reactivate the DAM catalyst.

Fischer-tropsch catalyst enhancement (JSS-0005)

Fischer-Tropsch catalyst enhancement

There is provided an improved system and process for the catalytic hydrogenation of carbon monoxide to form a mixture of hydrocarbons utilizing a plurality of reactors in series. Synthesis gas entering the system under pressure is partially converted in at least one initial stage reactor and the effluent therefrom introduced into a final stage reactor. In the at least one initial stage reactor, a portion of the catalyst is continuously or periodically removed with some hydrocarbons and treated to renew, or renew and enhance it, and returned. The treatment comprises reducing the hydrocarbon context of the withdrawn mixture, heating to a temperature above at least one of the metals in the catalyst thereby forming a melt, removing any slag forming on the melt, cooling the melt and reducing the particle size of the resulting solid to a fine powder of renewed catalyst. The renewed catalyst may be treated to further enhance its properties by slurry low temperature oxidation or passivated before being returned to the at least one initial stage reactor. The final stage reactor, which has a catalyst of the same type or differing from that in the at least one initial stage reactor, receives a feed therefrom having a substantially reduced level of impurities, thereby enhancing the efficiency and longevity of the catalyst contained therein. The system can further employ at least one intermediate stage reactor configured so that all stages are operably connected in series and all reactors with a given stage are operably connected in parallel.

Fischer-tropsch process

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Baton Rouge, LA, United States of America

Russell John Koveal