Gulf Research & Development Company

Amoco Corporation

Chevron Research Company

Bp Amoco Corporation

Shell Internationale Research Maatschappij, B.v.

Other

Bp Corporation North America Inc.

Gulf Research & Development

Thaddeus P Kobylinski

Wayne R Pretzer

John E Bozik

Charles L Kibby

David L Beach

Ching-Yong Wu

Mark S Kleefisch

Richard B Pannell

Harold Beuther

Richard G Austin

Carl A Udovich

Harold E Swift

Uthamalingam Balachandran

Elizabeth L Eddy

John P Pellegrini, Jr

Shiyou Pei

Sherry L Morissette

Joseph G Masin

Roger F Vogel

Brian W Taylor

Roger C Williamson

Alakananda A Bhattacharyya

Roger B Poeppel

Bruce K Schmid

Win-Chung Lee

A process for converting organic compounds using composite materials in membrane reactors. The composite materials include a gas-tight ceramic, a porous metallic support, and an interfacial zone therebetween eliminate the need for mechanical seals between two such dissimilar materials. Oxygen ion-conducting dense ceramic membranes are formed on a porous metallic alloy to provide an interfacial zone identifiable by a gradient of composition in at least one metallic element across the interfacial zone between the dense ceramic membrane and the porous support. Processes using composite materials in accordance with the invention are, for example, used for production of synthesis gas comprising carbon monoxide and molecular hydrogen, whereby the synthesis gas is, advantageously, free of deleterious and/or inert gaseous diluents such as nitrogen.

Process for converting organic compounds using composite materials in membrane reactors

Composite materials of the invention, which include a gas-tight ceramic, a porous metallic support, and an interfacial zone therebetween eliminate the need for mechanical seals between two such dissimilar materials. Oxygen ion-conducting dense ceramic membranes are formed on a porous metallic alloy to provide an interfacial zone identifiable by a gradient of composition in at least one metallic element across the interfacial zone between the dense ceramic membrane and the porous support. Processes using composite materials in accordance with the invention are, for example, used for production of synthesis gas comprising carbon monoxide and molecular hydrogen, whereby the synthesis gas is, advantageously, free of deleterious and/or inert gaseous diluents such as nitrogen.

Composite materials for membrane reactors

The present invention relates to devices for conducting, simultaneously, exothermic and endothermic chemical conversions with transfer of heat therebetween. More particularly, this invention relates to autothermic modules using oxygen ion-conducting dense ceramic membranes to separate, selectively, oxygen from an oxygen-containing gas and supply it directly to partial combustion of gaseous organic compounds. Processes using autothermic modules in accordance with this invention are, advantageously, used for production of synthesis gas comprising carbon monoxide and molecular hydrogen which synthesis gas is substantially free of deleterious and/or inert gaseous diluents such as nitrogen. In particular, for conversions, within the integral autothermic module, of natural gas or other forms of gaseous lower alkanes to synthesis gas by means of partial combustion followed by reforming.

Autothermic reactor and process using oxygen ion--conducting dense

The present invention relates to composite materials for membrane reactors which include a gas-tight ceramic, a porous support, and an interfacial zone therebetween. More particularly, this invention relates to composite materials using oxygen ion-conducting dense ceramic membranes formed on a porous support comprising a metallic alloy to provide an interfacial zone identifiable by a gradient of composition in at least one metallic element across the interfacial zone between the dense ceramic membrane and the porous support. Processes using composite materials in accordance with the invention are, for example, used for production of synthesis gas comprising carbon monoxide and molecular hydrogen which synthesis gas is, advantageously, free of deleterious and/or inert gaseous diluents such as nitrogen.

Membrane reactor hollow tube module with ceramic/metal interfacial zone

Preparation, structure, and properties of mixed metal oxide compositions and their uses are described. Mixed metal oxide compositions of the invention have stratified crystalline structure identifiable by means of powder X-ray diffraction patterns. In the form of dense ceramic membranes, the present compositions demonstrate an ability to separate oxygen selectively from a gaseous mixture containing oxygen and one or more other volatile components by means of ionic conductivities.

Oxygen ion-conducting dense ceramic

Preparation, structure, and properties of mixed metal oxide compositions containing at least strontium, cobalt, iron and oxygen are described. The crystalline mixed metal oxide compositions of this invention have, for example, structure represented by

This invention discloses cross-flow electrochemical reactor cells containing oxygen permeable materials which have both electron conductivity and oxygen ion conductivity, cross-flow reactors, and electrochemical processes using cross-flow reactor cells having oxygen permeable monolithic cores to control and facilitate transport of oxygen from an oxygen-containing gas stream to oxidation reactions of organic compounds in another gas stream. These cross-flow electrochemical reactors comprise a hollow ceramic blade positioned across a gas stream flow or a stack of crossed hollow ceramic blades containing a channel or channels for flow of gas streams. Each channel has at least one channel wall disposed between a channel and a portion of an outer surface of the ceramic blade, or a common wall with adjacent blades in a stack comprising a gas-impervious mixed metal oxide material of a perovskite structure having electron conductivity and oxygen ion conductivity. The invention includes reactors comprising first and second zones seprated by gas-impervious mixed metal oxide material material having electron conductivity and oxygen ion conductivity. Prefered gas-impervious materials comprise at least one mixed metal oxide having a perovskite structure or perovskite-like structure. The invention includes, also, oxidation processes controlled by using these electrochemical reactors, and these reactions do not require an external source of electrical potential or any external electric circuit for oxidation to proceed.

Cross-flow electrochemical reactor cells, cross-flow reactors, and use

A process for converting natural gas to synthesis gas includes the steps of subjecting a homogeneous mixture of natural gas and air to partial oxidation in the presence of a bifunctional partial oxidation/steam reforming catalyst and a sufficient amount of water to control reaction temperature, and subjecting the resulting product to steam reforming in order to substantially completely convert unconverted alkanes to carbon monoxide and hydrogen.

Process for converting natural gas to synthesis gas

Catalyst for synthesis gas conversion in which a gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon is prepared by subjecting cobalt or nickel on a refractory metal oxide support to an activation procedure at a temperature of from about 100.degree. to about 450.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

ROR-activated catalyst for synthesis gas conversion

A catalyst for the conversion of synthesis gas comprising cobalt on a high surface area, high purity, low acidity alumina support of gamma-alumina, eta-alumina or mixtures thereof, whereby the catalyst is prepared by (A) impregnation of the alumina support with a non-aqueous, organic solvent impregnation solution of cobalt nitrate containing sufficient amounts of a Group IIIB or IVB metal salt to provide said catalyst with from about 0.05 to about 100 parts by weight of a Group IIIB or IVB metal oxide per 100 parts by weight cobalt, (B) reduction of the impregnated alumina support by heating, in the presence of hydrogen, at a heating rate of from about 0.5.degree. to about 5.degree. C. per minute to a maximum temperature in the range of 180.degree. to about 220.degree. C. for a hold time of 6 to about 24 hours and thereafter heating the impregnated alumina support in the presence of hydrogen while heating up to a maximum hold temperature of from about 250.degree. to about 400.degree. C. for a hold time of 6 to about 65 hours.

Catalyst for conversion of synthesis gas to diesel fuel and process for

Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a catalyst prepared by subjecting a cobalt carbonyl-impregnated alumina or silica support to an activation procedure at a temperature not exceeding 500.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

Activated cobalt catalyst and synthesis gas conversion using same

Synthesis gas is converted to diesel fuel and a high octane gasoline in two stages. In the first stage the synthesis gas is converted to straight chain paraffins mainly boiling in the diesel fuel boiling range utilizing a catalyst consisting essentially of cobalt, preferably promoted with a Group IIIB or IVB metal oxide, on a support of gamma-alumina, eta-alumina or mixtures thereof. A straight chain paraffin portion of the effluent in the C.sub.5 -C.sub.9 range is converted in a second stage to a highly aromatic and branched chain paraffinic gasoline using a platinum group metal catalyst.

Conversion of synthesis gas to diesel fuel and gasoline

Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a catalyst prepared by subjecting cobalt or nickel on a refractory metal oxide support to an activation procedure at a temperature below 500.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

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Gibsonia, PA, United States of America

Thaddeus P Kobylinski