Enhancement of Fischer-Tropsch process for hydrocarbon fuel formulation in a GTL environment

• US 8,889,746 B2
• Filed: 09/08/2011
• Issued: 11/18/2014
• Est. Priority Date: 09/08/2011
• Status: Active Grant

• Current Assignee: Expander Energy Inc.
• Original Assignee: Expander Energy Inc.
• Inventors: Kresnyak, Steve
• Primary Examiner(s): PARSA, JAFAR F
• Application Number:
  US13/228,042
• Publication Number:
  US 20130065974A1
• Time in Patent Office: 1,167 Days
• Field of Search: 518/700, 518702-705
• US Class Current: 518/700
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0405 Purification by membrane separation
• CPC Class Codes: C01B 2203/0435 Catalytic purification
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/062 Hydrocarbon production, e.g. Fischer-Tropsch process
• CPC Class Codes: C01B 2203/0844 the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
• CPC Class Codes: C01B 2203/0872 Methods of cooling
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 2203/1258 Pre-treatment of the feed
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/143 Three or more reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/145 At least two purification steps in parallel
• CPC Class Codes: C01B 2203/147 Three or more purification steps in series
• CPC Class Codes: C01B 3/38 using catalysts
• CPC Class Codes: C01B 3/382 Multi-step processes
• CPC Class Codes: C10G 2/30 from carbon monoxide with hydrogen

Abstract

An enhanced Fischer-Tropsch process for the synthesis of sulfur free, clean burning, hydrocarbon fuels, examples of which include syndiesel and aviation fuel. Naphtha is destroyed in a syngas generator and recycled as feedstock to an Fischer-Tropsch (FT) reactor in order to enhance the production of syndiesel from the reactor. The process enhancement results is the maximum production of formulated syndiesel without the formation of low value by-products.

Claims

1. A process for synthesizing hydrocarbons, comprising the steps of:

(a) formulating a hydrogen rich stream with a syngas generator;

(b) catalytically converting said stream to produce the hydrocarbons, containing at least naphtha;

(c) recycling at least a portion of said naphtha to said syngas generator to form an enhanced hydrogen rich stream; and

(d) re-circulating said enhanced hydrogen rich stream from step (c) for conversion in step (b) to enhance the synthesis of hydrocarbons.

2. The process as set forth in claim 1, wherein conversion is achieved using Fischer-Tropsch reactor.

3. The process as set forth in claim 1, wherein an auxiliary source gas comprising of hydrogen is added to said syngas generator.

4. The process as set forth in claim 1, wherein the naphtha is generated in addition to heavier hydrocarbons, light hydrocarbons and a refinery fuel.

5. The process as set forth in claim 1, wherein said syngas generator comprises a steam methane reformer (SMR).

6. The process as set forth in claim 1, wherein said syngas generator comprises an autothermal reformer (ATR).

7. The process as set forth in claim 1, wherein said syngas generator comprises a combination of an autothermal reformer and a steam methane reformer.

8. The process as set forth in claim 1, wherein said syngas generator comprises a merged unit having an autothermal reformer merged in a single unit with a steam methane reformer (XTR).

9. The process as set forth in claim 4, wherein at least a portion of the refinery fuel from step (d) is selected from the group consisting of tail gas from a Fischer-Tropsch unit, offgas from a hydrocarbon upgrades unit or a combination thereof.

10. The process as set forth in claim 3, wherein said auxiliary source comprises natural gas.

11. The process as set forth in claim 4, further including the step of separating at least a portion of said heavier hydrocarbons from said naphtha.

12. The process as set forth in claim 1, further including the step of treating a portion of said hydrogen rich stream in a hydrogen purification unit.

13. The process as set forth in claim 12, wherein said hydrogen purification unit comprises a pressure swing adsorption or membrane unit.

14. The process as set forth in claim 1, wherein said hydrogen rich stream from said syngas generator is treated to a carbon dioxide removal operation prior to catalytic conversion.

15. The process as set forth in claim 1, wherein the catalytically converted stream is treated to a hydrocarbon upgrading operation.

16. The process as set forth in claim 1, wherein energy recovered from said syngas generator is used in the production of power.

17. The process as set forth in claim 1, wherein energy recovered from the catalytic conversion of said hydrogen rich stream is used in the production of power.

18. A process for synthesizing hydrocarbons, comprising the steps of:

providing a source of hydrocarbons at least containing naphtha, recycling said naphtha to a syngas generator to form hydrogen rich stream; and

catalytically converting said hydrogen rich stream to synthesize the hydrocarbons.

19. The process as set forth in claim 18, further including the steps of providing a syngas generator comprising a merged ATR and SMR.

20. The process as set forth in claim 19, further including the step of balancing feedstreams to each of said ATR and SMR for optimizing hydrocarbon synthesis yield.

21. The process as set forth in claim 20, further including the step of employing recycled gas to offset the natural gas load fed to said SMR.