Conocophillips Company

Tianyan Niu

Harold A Wright

Daxiang Wang

Gloria I Straguzzi

Joe D Allison

Sriram Ramani

Yaming Jin

David M Minahan

Norman Herron

Rafael Luis Espinoza

Kandaswamy Jothimurugesan

Hasan Dindi

William H Manogue

Larry D Swinney

Baili Hu

Kevin L Ricketson

Shuibo Xie

Robin G Cnossen

Mary E Wolf

The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions to prepare synthesis gas and ultimately Chydrocarbons. In particular, preferred embodiments of the present invention comprise catalyst systems comprising a core and an outer region disposed on said core, wherein a substantial amount of the catalytic metal is located in the outer region of the catalyst support matrix. In addition, the catalyst systems are able to maintain high conversion and selectivity values with very low catalytically active metal loadings. The catalyst systems are appropriate for improved syngas, oxidative dehydrogenation and other partial oxidation reactions, including improved reaction schemes for the conversion of hydrocarbon gas to Chydrocarbons.

Catalysts for the conversion of methane to synthesis gas

Rhodium-spinel catalysts with activity for efficiently catalyzing the net partial oxidation of methane at high selectivities for CO and Hproducts are disclosed, along with their method of making. A syngas production process employing such catalysts for the net catalytic partial oxidation of a C-Chydrocarbon (e.g., natural gas or methane) to a product gas mixture comprising CO and His also disclosed. Preferred reaction conditions include maintaining the catalyst at a temperature of about 400-1,200&#xb0; C., superatmospheric pressure, and flow rate sufficient to pass the reactant gas mixture over the catalyst at space velocities of at least about 100,000-25,000,000 hr.

Supported rhodium-spinel catalysts and process for producing synthesis gas

Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and Hand, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500&#xb0; C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Controlled-pore catalyst structures and process for producing synthesis gas

The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions. In particular, preferred embodiments of the present invention comprise rare earth catalyst supports, catalyst compositions having rare earth supports, and methods of preparing and using the catalysts and supports. Accordingly, the present invention also encompasses an improved method for converting a hydrocarbon containing gas and an oxygen containing gas to a gas mixture comprising hydrogen and carbon monoxide, i.e., syngas, using the rare earth catalyst supports in accordance with the present invention. In addition, the present invention contemplates an improved method for converting hydrocarbon gas to liquid hydrocarbons using the novel syngas catalyst supports and compositions described herein.

Rare earth aluminates and gallates supported rhodium catalysts for catalytic partial oxidation of hydrocarbons

A pretreatment method for increasing the average pore size of a catalyst support is disclosed which increases the diffusivity and effectiveness factor &#x3b7;. The pretreatment method includes calcining the support in moisturized air at an elevated temperature sufficient to increase the average pore size. In some embodiments, the support may be treated with an acidic/basic solution prior to the calcination step. Alternatively, the calcination step may occur in a gas mixture including water/air/acidic (or basic) gases.

Hydrothermal pretreatment for increasing average pore size in a catalyst support

Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and Hare disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and Ois passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.

Lanthanide-promoted rhodium catalysts and process for producing synthesis gas

Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

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Ponca City, OK, United States of America

Tianyan Niu