Non-oxidative conversion of gas to liquids

• US 20030144565A1
• Filed: 05/06/2002
• Published: 07/31/2003
• Est. Priority Date: 01/28/2002
• Status: Active Grant

• Current Assignee: Conoco Incorporated (ConocoPhillips)
• Original Assignee: Conoco Incorporated (ConocoPhillips)
• Inventors: Allison, Joe D., Jack, Doug S., Ledoux, Marc J., Meldrum, Neil
• Granted Patent: US 7,019,184 B2
• Time in Patent Office: Days
• US Class Current: 585/418
• CPC Class Codes: C07C 15/00 Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
• CPC Class Codes: C07C 2/76 by condensation of hydrocarbons with partial elimination of hydrogen
• CPC Class Codes: Y10S 585/943 Synthesis from methane or inorganic carbon source, e.g. coal

Abstract

he present invention provides a process for natural gas in the form, e.g., of stranded gas or associated gas to transportable liquids. More particularly, the present invention provides a process in which the gas is non-oxidatively converted to aromatic liquid, preferably in proximity to the wellhead, which may be onshore or offshore. In one aspect, the present invention provides integration of separation of wellhead fluids into associated gas and crude with blending of the aromatic liquid derived from the gas with the crude. Alternatively, or in combination, in another aspect, the present invention provides integration of conversion of byproduct hydrogen to power with non-oxidative conversion of gas to aromatic liquid.

Claims

1. A process for converting a gaseous hydrocarbon stream to an aromatic hydrocarbon stream, comprising:

(a) passing the gaseous stream from a wellhead to a non-oxidative conversion zone proximous to the wellhead; and

(b) contacting the gaseous stream with a catalyst so as to produce the aromatic liquid stream, wherein the catalyst is contained in the conversion zone.

2. The process according to claim 1 wherein the production of the aromatic liquid stream proceeds directly from the gaseous stream, without intermediate reaction.

3. The process according to claim 1 wherein the gaseous stream comprises at least 40% methane.

4. The process according to claim 1 wherein the gaseous stream comprises at least 50% methane.

5. The process according to claim 1 wherein the aromatic stream comprises aromatic hydrocarbons selected from the group consisting of benzene, xylenes, and naphthalene.

6. The process according to claim 1 wherein the conversion zone is located onshore.

7. The process according to claim 1 wherein the conversion zone is located on an offshore facility.

8. The process according to claim 7 wherein the offshore facility comprises a fixed platform.

9. The process according to claim 7 wherein the offshore facility comprises a floating structure.

10. The process according to claim 1 further comprising:

(c) passing byproduct hydrogen produced from contact of the gaseous stream with the catalyst to a power generation unit.

11. The process according to claim 10 wherein the power generation unit comprises a fuel cell.

12. The process according to claim 10 wherein the power generation unit comprises a combustion chamber adapted for combustion of hydrogen.

13. The process according to claim 10 further comprising:

(d) passing power from the power generation unit to a power consuming unit.

14. The process according to claim 13 wherein the power consuming unit comprises the conversion zone.

15. The process according to claim 13 wherein the conversion zone is located on an offshore facility.

16. The process according to claim 15 wherein the power consuming unit comprises the facility.

17. The process according to claim 16 wherein the facility comprises a floating structure.

18. The process according to claim 15 wherein the power consuming unit comprises a system located on or within the facility.

19. A process for converting wellhead fluids to blended crude, comprising:

(a) separating the fluids into associated gas and crude oil;

(b) passing a methane-containing feed stream derived from the associated gas to a non-oxidative conversion zone so as to produce an aromatic liquid; and

(c) blending the aromatic liquid with the crude oil so as to produce the blended crude.

20. The process according to claim 19 further comprising

(d) processing the associated gas to produce the methane-containing feed stream.

21. The process according to claim 20 wherein the feed stream comprises at least 40% methane.

22. The process according to claim 20 wherein the feed stream comprises at least 50% methane.

23. The process according to claim 19 wherein the aromatic liquid comprises aromatic hydrocarbons selected from the group consisting of benzene, xylenes, and naphthalene.

24. The process according to claim 19 wherein the conversion zone is located onshore.

25. The process according to claim 19 wherein the conversion zone is located on an offshore facility.

26. The process according to claim 24 wherein the offshore facility comprises a fixed platform.

27. The process according to claim 25 wherein the offshore facility comprises a floating structure.

28. The process according to claim 19 further comprising:

(d) passing byproduct hydrogen produced from contact of the gaseous stream with the catalyst to a power generation unit.

29. The process according to claim 28 wherein the power generation unit comprises a fuel cell.

30. The process according to claim 28 wherein the power generation unit comprises a combustion chamber adapted for combustion of hydrogen.

31. The process according to claim 28 further comprising:

(e) passing power from the power generation unit to a power consuming unit.

32. The process according to claim 31 wherein the power consuming unit comprises the conversion zone.

33. The process according to claim 31 wherein the conversion zone is located on an offshore facility.

34. The process according to claim 33 wherein the power consuming unit comprises the facility.

35. The process according to claim 33 wherein the facility comprises a floating structure.

36. The process according to claim 33 wherein the power consuming unit comprises a system located on or within the facility.

37. A process for delivering a blended crude to a destination comprising:

(a) separating wellhead fluids into associated gas and crude oil;

(b) passing a methane-containing feed stream derived from the associated gas to a non-oxidative conversion zone so as to produce an aromatic liquid; and

(c) blending the aromatic liquid with the crude oil so as to produce the blended crude.

(d) transporting the blended crude to the destination.

38. The process according to claim 37 wherein the blended crude is transported by a pipeline.

39. The process according to claim 37 wherein the blended crude is transported by shuttle tanker.