Abstract:
This invention relates to a process for converting a carbonaceous material to a desired product comprising methane, methanol and/or dimethyl ether, the process comprising: gasifying the carbonaceous material at a temperature in excess of about 700° C. to form synthesis gas; and flowing the synthesis gas through two or more reaction zones in a microchannel reactor to convert the synthesis gas to the desired product.
Abstract:
The invention describes catalysts, methods of making catalysts, methods of making a microchannel reactor, and methods of conducting chemical reactions. It has been discovered that superior performance can be obtained from a catalyst formed by directly depositing a catalytic material onto a (low surface area) thermally-grown alumina layer. Improved methods of conducting oxidative dehydrogenations are also described.
Abstract:
The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.
Abstract:
The disclosed invention relates to a process for converting a feed composition comprising one or more hydrocarbons to a product comprising one or more unsaturated hydrocarbons, the process comprising: flowing the feed composition and steam in contact with each other in a microchannel reactor at a temperature in the range from about 200° C. to about 1200° C. to convert the feed composition to the product, the process being characterized by the absence of catalyst for converting the one or more hydrocarbons to one or more unsaturated hydrocarbons. Hydrogen and/or oxygen may be combined with the feed composition and steam.
Abstract:
A microchannel reactor is described which has at least one process microchannel and at least one heat exchange zone. The microchannel reactor may be used for conducting a Fischer-Tropsch synthesis reaction.
Abstract:
The disclosed technology relates to a process for conducting a chemical reaction between at least one liquid reactant and at least one gaseous reactant in a process microchannel containing at least one catalyst, the catalyst comprising a solid phase catalyst or a homogeneous catalyst immobilized on a solid. In one embodiment, the process microchannel comprises a processing zone containing one or more structures for disrupting fluid flow and a reaction zone containing one or more structures for contacting and/or supporting the catalyst, the one or more structures for contacting and/or supporting the catalyst containing openings to permit the reactants to flow through the one or more structures and contact the catalyst. The process comprises: forming a reactant mixture comprising at least one liquid reactant and the at least one gaseous reactant; flowing the reactant mixture in the processing zone in contact with the one or more structures for disrupting fluid flow to enhance mixing of the liquid reactant and the gaseous reactant; flowing the reactant mixture in openings in the one or more structures for contacting and/or supporting the catalyst in contact with catalyst; and reacting the at least one liquid reactant with the at least one gaseous reactant to form at least one product. In one embodiment, the process relates to a process for conducting a Fischer-Tropsch synthesis in a process microchannel containing at least one Fischer-Tropsch synthesis catalyst, the catalyst comprising a solid phase catalyst or a homogeneous catalyst immobilized on a solid, the process comprising: flowing reactants comprising H2 and CO in the process microchannel, the inlet superficial velocity of the reactants being at least about 0.1 m/s; contacting the Fischer-Tropsch synthesis catalyst with the reactants; and reacting the reactants in the presence of the catalyst to form at least one product.
Abstract:
The invention describes microchannel apparatus and catalysts that contain a layer of a platinum aluminide. The invention includes chemical processes conducted through apparatus described in the specification.
Abstract:
Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described for transporting oxygen from any oxygen-containing gas to any gas or mixture of gases that consume oxygen. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces. The element may further comprise (1) a porous substrate, (2) an electron-conductive metal, metal oxide or mixture thereof and/or (3) a catalyst. The reactor cell may further comprise a catalyst in the zone which comprises a passageway from an entrance end to an exit end of the element. Processes described which may be conducted with the disclosed reactor cells and reactors include, for example, the partial oxidation of methane to produce unsaturated compounds or synthesis gas, the partial oxidation of ethane, substitution of aromatic compounds, extraction of oxygen from oxygen-containing gases including oxidized gases, ammoxidation of methane, etc. The extraction of oxygen from oxidized gases may be used for flue or exhaust gas cleanup.
Abstract:
This invention relates to a process for converting ethylene to ethylene oxide comprising: flowing reactants comprising ethylene and oxygen or a source of oxygen in a microchannel reactor in contact with a catalyst to form a product comprising ethylene oxide, the reactants undergoing an exothermic reaction in the microchannel reactor; and transferring heat from the microchannel reactor to a heat exchanger.
Abstract:
The disclosed invention relates to a process for conducting an equilibrium limited chemical reaction in a microchannel reactor. The process involves the use of active heat exchange and is suitable for conducting exothermic and endothermic reactions. The process is particularly suitable for synthesizing methanol and dimethyl ether.