Process and apparatus for the production of heavier hydrocarbons from gaseous light hydrocarbons
First Claim
1. A process for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons comprising the steps of:
- (a) reacting said gaseous light hydrocarbons with air to partially oxidize a portion thereof and produce a gas stream comprising unreacted light hydrocarbons, hydrogen, carbon monoxide and nitrogen;
(b) reacting the gas stream from step (a) with steam and carbon dioxide in the presence of a steam reforming catalyst to convert a substantial portion of the unreacted light hydrocarbons therein to additional hydrogen and carbon monoxide and to produce a synthesis gas stream containing hydrogen and carbon monoxide in desired proportion;
(c) reacting the synthesis gas stream from step (b) in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from hydrogen and carbon monoxide in said stream;
(d) separating heavier hydrocarbons and water from the product stream of step (c) leaving a residue gas stream comprised of unreacted hydrogen and carbon monoxide, light hydrocarbons, carbon dioxide and nitrogen;
(e) subjecting the residue gas stream from step (d) to catalytic combustion with additional air to form a product stream comprising carbon dioxide, water vapor and nitrogen;
(f) separating carbon dioxide from the product stream of step (e); and
(g) utilizing at least a portion of the carbon dioxide separated in step (f) for carrying out step (b).
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Abstract
A process and apparatus for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons is provided. The process comprises reacting the gaseous light hydrocarbons by autothermal reforming with air in the presence of recycled carbon dioxide and steam to produce a synthesis gas stream containing hydrogen and carbon monoxide. The synthesis gas stream is reacted in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from the hydrogen and carbon monoxide. The heavier hydrocarbons and water are separated, and the resulting residue gas stream is subjected to catalytic combustion with additional air to form a product stream comprising carbon dioxide and nitrogen. The carbon dioxide is separated from the nitrogen to produce a nitrogen product stream, and at least a portion of the separated carbon dioxide is recycled to the autothermal reforming step.
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Citations
20 Claims
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1. A process for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons comprising the steps of:
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(a) reacting said gaseous light hydrocarbons with air to partially oxidize a portion thereof and produce a gas stream comprising unreacted light hydrocarbons, hydrogen, carbon monoxide and nitrogen; (b) reacting the gas stream from step (a) with steam and carbon dioxide in the presence of a steam reforming catalyst to convert a substantial portion of the unreacted light hydrocarbons therein to additional hydrogen and carbon monoxide and to produce a synthesis gas stream containing hydrogen and carbon monoxide in desired proportion; (c) reacting the synthesis gas stream from step (b) in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from hydrogen and carbon monoxide in said stream; (d) separating heavier hydrocarbons and water from the product stream of step (c) leaving a residue gas stream comprised of unreacted hydrogen and carbon monoxide, light hydrocarbons, carbon dioxide and nitrogen; (e) subjecting the residue gas stream from step (d) to catalytic combustion with additional air to form a product stream comprising carbon dioxide, water vapor and nitrogen; (f) separating carbon dioxide from the product stream of step (e); and (g) utilizing at least a portion of the carbon dioxide separated in step (f) for carrying out step (b). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A process for the production of heavier hydrocarbons from one or more gaseous light hydrocarbons comprising the steps of:
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(a) reacting said gaseous light hydrocarbons with air to partially oxidize a portion thereof and produce a gas stream comprising unreacted light hydrocarbons, hydrogen, carbon monoxide and nitrogen; (b) reacting the gas stream from step (a) with steam and carbon dioxide in the presence of a steam reforming catalyst containing nickle to convert a substantial portion of the unreacted light hydrocarbons therein to additional hydrogen and carbon monoxide to produce a synthesis gas stream containing hydrogen and carbon monoxide in a molar ratio of about 2;
1;(c) reacting the synthesis gas stream from step (b) in the presence of a hydrocarbon synthesis catalyst containing cobalt to form heavier hydrocarbons and water from hydrogen and carbon monoxide in said stream; (d) cooling the product stream of step (c) whereby said heavier hydrocarbons and water are condensed; (e) withdrawing said condensed heavier hydrocarbons and water from the resulting residue gas stream; (f) separating said condensed heavier hydrocarbons from said condensed water; (g) utilizing at least a portion of said separated water to form steam used in step (b); (h) subjecting the residue gas stream from step (e) to catalytic combustion with additional air to form a product stream comprising carbon dioxide, water vapor and nitrogen; (i) separating carhon dioxide from the product stream of step (h); (j) utilizing at least a portion of the carbon dioxide separated in step (i) in carrying out step (b); and (k) varying the rates of water utilized in accordance with step (g) and carbon dioxide utilized in accordance with step (j) for carrying out step (b) to thereby control the molar ratio of hydrogen to carbon monoxide in the synthesis gas stream produced in step (b) at about 2;
1. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification