Integration of mixed catalysts to maximize syngas production
AssigneeConoco Inc.
InventorsJoe D. Allison, Sriram Ramani, Daxiang Wang, Tianyan Niu, Yaming Jin, Gloria I. Straguzzi
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Abstract
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.
Claims36
A method of reacting a primary feed stream comprising a hydrocarbon and an oxygen containing gas, the method comprising:
- providing first and second serially aligned stacked reaction zones;
- providing a first catalyst in the first reaction zone;
- providing a second catalyst in the second reaction zone;
- and
- feeding the primary feed stream through the first and second reaction zones sequentially at reaction promoting conditions;
- wherein the first supported catalyst catalyzes primarily the net partial oxidation of the hydrocarbon;
- wherein the second supported catalyst catalyzes primarily either a WGS reaction, net partial oxidation, steam reforming, or dry reforming.
A method of reacting a primary feed stream comprising a hydrocarbon and an oxygen containing gas, the method comprising:
- providing first, second, and third serial aligned stacked reaction zones;
- providing a first supported catalyst in the first reaction zone on a first catalyst support;
- providing a second supported catalyst in the second reaction zone on a second catalyst support;
- providing a third supported catalyst in the third reaction zone on a third catalyst support;
- and
- feeding the feed stream through the first, second, and third reaction zones sequentially at reaction promoting conditions;
- wherein the first supported catalyst catalyzes primarily the net partial oxidation of the hydrocarbons;
- wherein the second supported catalyst catalyzes primarily either the WGS reaction, net partial oxidation, steam reforming, or dry reforming;
- and
- wherein the third supported catalyst catalyzes primarily either the WGS reaction, net partial oxidation, steam reforming or dry reforming.
A method of reacting a primary feed stream comprising a hydrocarbon and an oxygen containing gas, the method comprising:
- providing first and second serially aligned stacked reaction zones;
- providing a first catalyst in the first reaction zone;
- providing a second catalyst in the second reaction zone, wherein the second catalyst catalyzes primarily the net partial oxidation of the hydrocarbon;
- and
- feeding the primary feed stream through the first and second reaction zones sequentially at reaction promoting conditions.
A means for partially oxidizing a hydrocarbon in a feed stream comprising a hydrocarbon-containing gas and an oxygen-containing gas, the means comprising;
- a first reaction zone comprising a highly thermally stable means for catalyzing the reaction of the feed stream to an effluent stream comprising synthesis gas;
- and
- a second reaction zone comprising a highly selective means for catalyzing the first reaction zone effluent stream to a product stream comprising synthesis gas;
- wherein the feed stream is fed through the first reaction zone and second reaction zone in series at syngas reaction promoting conditions.
Dependencies are inferred from the claim text.