[특허]Conversion of petroleum residua to methane

[미국특허] Conversion of petroleum residua to methane 원문보기

IPC분류정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	C10J-003/16
출원번호	US-0090034 (2002-03-05)
발명자 / 주소	Nahas, Nicholas Charles
출원인 / 주소	Petro 2020, LLC
인용정보	피인용 횟수 : 42 인용 특허 : 6

초록 ▼

This invention discloses improvements on previous inventions for catalytic conversion of coal and steam to methane. The disclosed improvements permit conversion of petroleum residua or heavy crude petroleum to methane and carbon dioxide such that nearly all of the heating value of the converted hydrocarbons is recovered as heating value of the product methane. The liquid feed is distributed over a fluidized solid particulate catalyst containing alkali metal and carbon as petroleum coke at elevated temperature and pressure from the lower stage and transported to the upper stage of a two-stage reactor. Particulate solids containing carbon and alkali metal are circulated between the two stages. Superheated steam and recycled hydrogen and carbon monoxide are fed to the lower stage, fluidizing the particulate solids and gasifying some of the carbon. The gas phase from the lower stage passes through the upper stage, completing the reaction of the gas phase.

대표청구항 ▼

1. A process for the conversion of petroleum residua to methane comprising the steps of:preheating a petroleum residue feedstock to a temperature between 300° F. and 800° F.; injecting the preheated feedstock into a reaction vessel maintained at a temperature between 1100° F. and 1400° F. and at a pressure between 300 psig and 1000 psig, wherein the reaction vessel contains fluidized solid particles comprising: more than 50% by mass petroleum coke; more than 30% and less than 50% by mass alkali metal, wherein the alkali metal is selected from the group consisting of potassium, rubidium, cesium, or any mixture thereof; and less then 10% by mass of other inorganic constituents, wherein the fluidized solid particles are fluidized by an upwardly flowing gaseous mixture at the bottom of the reaction vessel comprising: more than 50% steam; more than 20% and less than 40% hydrogen; and more than 3% and less than 20% carbon monoxide, wherein the gaseous mixture is preheated to a temperature in excess of 1300° F., wherein the mass flow rate of the steam of the gaseous mixture is maintained at between 1.8 and 2.0 times the mass flow rate of the injected preheated feedstock, and wherein the hourly mass flow rate of the injected preheated feedstock is maintained at between 0.3 and 0.6 times the mass of the alkali metal; withdrawing from the reaction vessel a gaseous product mixture comprising unreacted steam, methane, carbon dioxide, hydrogen, carbon monoxide, hydrogen sulfide and ammonia; recovering methane from the gaseous product mixture; and recovering hydrogen and carbon monoxide; and recycling the recovered hydrogen and carbon monoxide into the upwardly flowing gaseous mixture at the bottom of the reaction vessel. 2. The process of claim 1, wherein the composition of the fluidized particles in the reaction vessel is maintained within the specified range of more than 50% by mass petroleum coke; more than 30% and less than 50% by mass alkali metal; and less than 10% by mass other organic constituents, by periodically withdrawing solids and adding alkali metal compound to the reaction vessel.3. The process of claim 2, wherein the alkali metal compound is dispersed as a fine powder admixed with the petroleum residue feedstock at a concentration of less than 1% by mass, maintained in suspension by agitation, and injected into the reaction vessel with the preheated injected feedstock.4. The process of claim 1, wherein the reaction vessel consists of at least two stages, an upper and lower stage, wherein the upwardly flowing gaseous mixture is fed into a lower stage, and wherein the solid fluidized particles are circulated between the upper and lower stages.5. The process of claim 4, wherein the solid fluidized particles are circulated from upper to lower stages by one or more standpipes, and the solid fluidized particles are circulated from lower to upper stages by one or more aerated risers.6. The process of claim 5, wherein the preheated petroleum residue feedstock is injected into at least one aerated riser.7. The process of claim 6, wherein the mass flow rate of the fluidized solid particles in the aerated riser is between 5 and 20 times the mass flow rate of the injected preheated feedstock.8. The process of claim 6, wherein the gaseous product mixture is withdrawn through at least one pair of cyclone separators in series, the series of cyclone separators consisting of a primary cyclone separator and secondary cyclone separator, wherein the primary cyclone separator discharges into the inlet of a secondary cyclone separator, wherein each cyclone separator is equipped with a pipe dipleg at the bottom apex of its conical section to discharge the collected fine particles separated from the gaseous product mixture, and wherein the dipleg of the secondary cyclone separator discharges into a collection zone coupled to the inlet of a jet ejector and wherein the jet ector discharges the collected fine particles into the riser below the level of the feedstock injection.9. The process of claim 8, wherein the jet ejector is operated with sufficient motive fluid to induce a down-flow of gas and entrained solids in the dipleg of the secondary cyclone separator, wherein the gas and solids proceed downwardly with a superficial velocity of more than 0.1 meter per second and less than 1 meter per second.

이 특허에 인용된 특허 (6) 인용/피인용 타임라인 분석

Lomas, David A.; Hammershaimb, Harold U., Catalyst treatment and flow conditioning in an FCC reactor riser.
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Leas Arnold M., Catalytic gasification process and system.
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Skaggs Bill D. (428 W. Ghent St. Glendora CA 91740), Fluid jet ejector and ejection method.
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Machado, Reinaldo Mario; Broekhuis, Robert Roger, Gas-liquid reaction process including ejector and monolith catalyst.
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Koh ; Kwang K. ; Nahas ; Nicholas C. ; Pennington ; Robert E. ; Vernon ; Lonnie W., Integrated catalytic gasification process.
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Soung Wen Y. (Houston TX), Recovery of alkali metal constituents from catalytic coal conversion residues.
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이 특허를 인용한 특허 (42) 인용/피인용 타임라인 분석

Robinson, Earl T.; Keckler, Kenneth P.; Raman, Pattabhi K.; Sirdeshpande, Avinash, Agglomerated particulate low-rank coal feedstock and uses thereof.
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Robinson, Earl T.; Keckler, Kenneth P.; Raman, Pattabhi K.; Sirdeshpande, Avinash, Agglomerated particulate low-rank coal feedstock and uses thereof.
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Robinson, Earl T.; Keckler, Kenneth P.; Raman, Pattabhi K.; Sirdeshpande, Avinash, Agglomerated particulate low-rank coal feedstock and uses thereof.
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Raman, Pattabhi K.; Hippo, Edwin J.; Yee, Nelson, Biomass compositions for catalytic gasification.
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Robinson, Earl T., Carbonaceous fines recycle.
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Rappas, Alkis S.; Salem, George Frederick; Hippo, Edwin J., Catalyst-loaded coal compositions, methods of making and use.
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Raman, Pattabhi K.; Yee, Nelson, Catalytic gasification particulate compositions.
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Rappas, Alkis S.; Spitz, Robert A., Catalytic gasification process with recovery of alkali metal from char.
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Nahas, Nicholas Charles, Catalytic steam gasification of petroleum coke to methane.
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Hippo, Edwin J.; Reiling, Vincent G.; Robinson, Earl T.; Raman, Pattabhi K.; Smith, Jeffery; Mims, Charles; Nahas, Nicholas Charles, Char methanation catalyst and its use in gasification processes.
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Hippo, Edwin J.; Raman, Pattabhi K., Co-feed of biomass as source of makeup catalysts for catalytic coal gasification.
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Rappas, Alkis S.; Salem, George Frederick, Coal compositions for catalytic gasification.
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Rappas, Alkis S.; Salem, George Frederick, Coal compositions for catalytic gasification.
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Robinson, Earl T.; Raman, Pattabhi K.; Wu, Wenyuan, Conversion of liquid heavy hydrocarbon feedstocks to gaseous products.
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Raman, Pattabhi K.; Jiradilok, Veeraya; Robinson, Earl T.; Sirdeshpande, Avinash, Hydromethanation of a carbonaceous feedstock.
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Robinson, Earl T.; Raman, Pattabhi K., Hydromethanation of a carbonaceous feedstock.
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Sirdeshpande, Avinash, Hydromethanation of a carbonaceous feedstock.
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Sirdeshpande, Avinash, Hydromethanation of a carbonaceous feedstock.
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Rappas, Alkis S.; Spitz, Robert A., Hydromethanation of a carbonaceous feedstock with nickel recovery.
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Rappas, Alkis S.; Spitz, Robert A., Hydromethanation of a carbonaceous feedstock with vanadium recovery.
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Preston, William E., Integrated enhanced oil recovery process.
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Raman, Pattabhi K., Integrated enhanced oil recovery process.
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Wallace, Paul, Integrated enhanced oil recovery process.
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Powell, Charles Allen; Raman, Pattabhi K.; Robinson, Earl T.; Sirdeshpande, Avinash, Integrated hydromethanation fuel cell power generation.
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Sirdeshpande, Avinash, Integrated hydromethanation fuel cell power generation.
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Anand, Madhu; Yao, Jianhua; Sughrue, II, Edward L., MoS2 catalyst for the conversion of sugar alcohol to hydrocarbons.
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Reiling, Vincent G.; Robinson, Earl T.; Nahas, Nicholas Charles; Smith, Jeffery; Mims, Charles, Processes for gasification of a carbonaceous feedstock.
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Robinson, Earl T.; Lau, Francis S.; Raman, Pattabhi K.; Reiling, Vincent G.; Dodson, Dwain; Rahman, Mustafiz; Nahas, Nicholas Charles, Processes for gasification of a carbonaceous feedstock.
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Robinson, Earl T.; Reiling, Vincent G.; Raman, Pattabhi K.; Gal, Eli, Processes for gasification of a carbonaceous feedstock.
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Reiling, Vincent G.; Robinson, Earl T.; Sirdeshpande, Avinash; Nahas, Nicholas Charles, Processes for hydromethanation of a carbonaceous feedstock.
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Robinson, Earl T.; Raman, Pattabhi K.; Reiling, Vincent G., Processes for hydromethanation of a carbonaceous feedstock.
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Sirdeshpande, Avinash; Robinson, Earl T., Processes for hydromethanation of a carbonaceous feedstock.
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Robinson, Earl T., Processes for making syngas-derived products.
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Rappas, Alkis S.; Spitz, Robert A., Processes for preparing a catalyzed carbonaceous particulate.
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Rappas, Alkis S.; Spitz, Robert A.; Salem, George Frederick, Processes for preparing a catalyzed coal particulate.
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Raman, Pattabhi K.; Lau, Francis S.; Robinson, Earl T., Processes for the separation of methane from a gas stream.
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Raman, Pattabhi K.; Lau, Francis S.; Robinson, Earl T.; Anthony, Donald, Reduced carbon footprint steam generation processes.
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Liu, Guohai; Vimalchand, Pannalal; Peng, WanWang, Second stage gasifier in staged gasification and integrated process.
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Raman, Pattabhi K.; Lau, Francis S.; Robinson, Earl T., Sour shift process for the removal of carbon monoxide from a gas stream.
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Lau, Francis S.; Robinson, Earl T., Steam generating slurry gasifier for the catalytic gasification of a carbonaceous feedstock.
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Raman, Pattabhi K.; Anthony, Donald, Steam generation processes utilizing biomass feedstocks.
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Sirdeshpande, Avinash; Keckler, Kenneth P.; Robinson, Earl T.; Raman, Pattabhi K., Use of contaminated low-rank coal for combustion.
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[미국특허] Conversion of petroleum residua to methane 원문보기