US3888043A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Production of methane
Assignee: Texaco Inc
•
Filing: 1973-06-25
•
Granted: 1975-06-10
•
Expires: 1993-06-25
Abstract
Abstract Continuous process for the production of a gaseous stream comprising at least 90 mole % of methane (dry basis) from a sulfur containing hydrocarbonaceous fuel without polluting the environment including the steps of: partial oxidation of the hydrocarbonaceous fuel with air; cooling, cleaning, and purifying the process gas stream to produce a stream of feed gas comprising CO, H2 and containing N2 in the range of about 30 to 60 mole % (dry basis); two separate catalytic methanation steps with an intervening water-gas shift reaction step; and finally separating CO2 and N2 from the process gas stream to produce said methane stream. The large amount of nitrogen diluent in the reacting gas during the methanation step helps to control the normally vigorous exothermic methanation reaction. The product gas has a heating value in the range of about 900-1000 BTU/SCF. It may be used as a substitute for natural gas or as a feedstock for organic chemical synthesis.
Inventors
- 👤 Edward T Child
- 👤 Allen M Robin
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 06:34
CPC Classifications
C; C10; C10L; C10L3/00; C10L3/06; C10L3/08; C07; C07C; C07C1/00; C07C1/02; C07C1/04; C07C1/0485; C07C1/12; C10K; C10K3/00; C10K3/02; C10K3/04; Y; Y02; Y02P; Y02P20/00; Y02P20/10; Y02P20/129
Claims Analysis
Total Claims: 49
Claim 1
Independent Claim
9 words
A PROCESS FOR PRODUCING A STREAM COMPRISING METHANE COMPRISING
Claim 2
Dependent Claim
9 words
A PROCESS FOR PRODUCING A STREAM COMPRISING METHANE COMPRISING
Claim 3
Dependent Claim
103 words
PRODUCING A RAW PROCESS GAS STREAM PRINCIPALLY COMPRISING CO, H2, CO2, H2O WITH MINOR AMOUNTS OF CH4, A, H2S, PARTICULATE CARBON AND CONTAINING FROM ABOUT 30 TO 60 MOLE PERCENT OF N2 DRY BASIS BY THE NONCATALYTIC PARTIAL OXIDATION OF A HYDROCARBONACEOUS FEEDSTOCK WITH AIR OR OXYGEN-ENRICHED AIR COMPRISING ABOUT 21 TO 50 MOLE % O2 AND FROM ABOUT 50 TO 79 MOLE % N2, AND OPTINALLY WITH A TEMPERATURE MODERATOR, AT AN AUTOGENOUS TEMPERATURE IN THE RANGE OF ABOUT 1500* TO 3500*F. AND A PRES SURE IN THE RANGE OF ABOUT 1 TO 350 ATOM ABS IA A FREE FLOW. GAS GENERATOR,
Claim 4
Dependent Claim
103 words
PRODUCING A RAW PROCESS GAS STREAM PRINCIPALLY COMPRISING CO, H2, CO2, H2O WITH MINOR AMOUNTS OF CH4, A, H2S, PARTICULATE CARBON AND CONTAINING FROM ABOUT 30 TO 60 MOLE PERCENT OF N2 DRY BASIS BY THE NONCATALYTIC PARTIAL OXIDATION OF A HYDROCARBONACEOUS FEEDSTOCK WITH AIR OR OXYGEN-ENRICHED AIR COMPRISING ABOUT 21 TO 50 MOLE % O2 AND FROM ABOUT 50 TO 79 MOLE % N2, AND OPTINALLY WITH A TEMPERATURE MODERATOR, AT AN AUTOGENOUS TEMPERATURE IN THE RANGE OF ABOUT 1500* TO 3500*F. AND A PRES SURE IN THE RANGE OF ABOUT 1 TO 350 ATOM ABS IA A FREE FLOW. GAS GENERATOR,
Claim 5
Dependent Claim
33 words
COOLING, CLEANING AND PURIFYING THE EFFLUENT GAS STREAM FROM 1 TO PRODUCE A FEED GAS FOR CATALYTIC METHANATION SUBSTANTIALLY COMPRISING CO AND H2 AND CONTAINING FROM ABOUT 32 TO 62 MOLE % NITROGEN.
Claim 6
Dependent Claim
33 words
COOLING, CLEANING AND PURIFYING THE EFFLUENT GAS STREAM FROM 1 TO PRODUCE A FEED GAS FOR CATALYTIC METHANATION SUBSTANTIALLY COMPRISING CO AND H2 AND CONTAINING FROM ABOUT 32 TO 62 MOLE % NITROGEN.
Claim 7
Dependent Claim
33 words
cooling, cleaning and purifying the effluent gas stream from 1 to produce a feed gas for catalytic methanation substantially comprising CO and H2 and containing from about 32 to 62 mole % nitrogen.
Claim 8
Dependent Claim
33 words
cooling, cleaning and purifying the effluent gas stream from 1 to produce a feed gas for catalytic methanation substantially comprising CO and H2 and containing from about 32 to 62 mole % nitrogen.
Claim 9
Dependent Claim
32 words
The process of claim 1 wherein the pressure in steps 2 to 6 is substantially the same as that in the gas generator in step 1 less ordinary drop in the lines.
Claim 10
Dependent Claim
46 words
cooling, cleaning and purifying the effluent gas stream from 1 to produce a feed gas for catalytic methanation substantially comprising CO and H2 with a mole ratio CO/H2 in the range of about 1 to 1.8, and containing from about 32 to 62 mole % nitrogen;
Claim 11
Dependent Claim
46 words
cooling, cleaning and purifying the effluent gas stream from 1 to produce a feed gas for catalytic methanation substantially comprising CO and H2 with a mole ratio CO/H2 in the range of about 1 to 1.8, and containing from about 32 to 62 mole % nitrogen;
Claim 12
Dependent Claim
67 words
reacting the feed gas stream from 2 in a first catalytic methanation zone at a temperature in the range of about 400* to 1500*F. and a pressure in the range of about 1 to 350 atm. abs. until substantially all of the H2 is reacted with a portion of the CO to produce a process gas stream comprising CO, N2, A, CH4 and optionally CO2 and H2O;
Claim 13
Dependent Claim
67 words
reacting the feed gas stream from 2 in a first catalytic methanation zone at a temperature in the range of about 400* to 1500*F. and a pressure in the range of about 1 to 350 atm. abs. until substantially all of the H2 is reacted with a portion of the CO to produce a process gas stream comprising CO, N2, A, CH4 and optionally CO2 and H2O;
Claim 14
Dependent Claim
32 words
The process of claim 1 wherein the mole ratio H2O/CO of the reacting stream in the water-gas shift conversion zone in step 4 is in the range of about 2 to 4.
Claim 15
Dependent Claim
67 words
reacting the feed gas stream from 2 in a first catalytic methanation zone at a temperature in the range of about 400* to 1500*F. and a pressure in the range of about 1 to 350 atm. abs. until substantially all of the H2 is reacted with a portion of the CO to produce a process gas stream comprising CO, N2, A, CH4 and optionally CO2 and H2O;
Claim 16
Dependent Claim
67 words
reacting the feed gas stream from 2 in a first catalytic methanation zone at a temperature in the range of about 400* to 1500*F. and a pressure in the range of about 1 to 350 atm. abs. until substantially all of the H2 is reacted with a portion of the CO to produce a process gas stream comprising CO, N2, A, CH4 and optionally CO2 and H2O;
Claim 17
Dependent Claim
124 words
REACTING THE FEED GASS STREAM FROM 2 IN A FIRST CATALYTIC METHANATION ZONE AT A TEMPERATURE IN THE RANGE OF ABOUT 400* TO 1500*F. AND A PRESSURE IN THE RANGE OF ABOUT 1 TO 350* TO 1500*F. AND A PRESSURE IN THE RANGE OF ABOUT 1 TO WITH A PORTION OF THE CO TO PRODUCE A PROCESS GAS STREAM COMPRISING CO, N2, A, CH4 AND OPTIONALLY CO2 AND H2O, 4 INTRODUCING THE EFFLUENT GAS STREAM FROM 3 INTO A WATERGAS SHIFT CONVERSION ZONE AT A SUTABLE TEMPERATURE ALONG WITH SUPPLEMENTAL H2O, AND REACTING THEREIN H2O WITH A PORTION OF THE CO IN SAID GAS STREAM TO PRODUCE A PROCESS GAS STREAM COMPRISING H2, CO, CO2, CH4 AND N2, AND REMOVING ANY EXCES WATER THEREFROM,
Claim 18
Dependent Claim
124 words
REACTING THE FEED GASS STREAM FROM 2 IN A FIRST CATALYTIC METHANATION ZONE AT A TEMPERATURE IN THE RANGE OF ABOUT 400* TO 1500*F. AND A PRESSURE IN THE RANGE OF ABOUT 1 TO 350* TO 1500*F. AND A PRESSURE IN THE RANGE OF ABOUT 1 TO WITH A PORTION OF THE CO TO PRODUCE A PROCESS GAS STREAM COMPRISING CO, N2, A, CH4 AND OPTIONALLY CO2 AND H2O, 4 INTRODUCING THE EFFLUENT GAS STREAM FROM 3 INTO A WATERGAS SHIFT CONVERSION ZONE AT A SUTABLE TEMPERATURE ALONG WITH SUPPLEMENTAL H2O, AND REACTING THEREIN H2O WITH A PORTION OF THE CO IN SAID GAS STREAM TO PRODUCE A PROCESS GAS STREAM COMPRISING H2, CO, CO2, CH4 AND N2, AND REMOVING ANY EXCES WATER THEREFROM,
Claim 19
Dependent Claim
54 words
introducing the effluent gas stream from 3 into a water-gas shift conversion zone at a suitable temperature along with supplemental H2O, and reacting therein H2O with a portion of the CO in said gas stream to produce a process gas stream comprising H2, CO, CO2, CH4 and N2, and removing any excess water therefrom;
Claim 20
Dependent Claim
54 words
introducing the effluent gas stream from 3 into a water-gas shift conversion zone at a suitable temperature along with supplemental H2O, and reacting therein H2O with a portion of the CO in said gas stream to produce a process gas stream comprising H2, CO, CO2, CH4 and N2, and removing any excess water therefrom;
Claim 21
Dependent Claim
67 words
The process of claim 1 wherein said hydrocarbonaceous fuel is a liquid hydrocarbon selected from the group consisting of liquefied petroleum gas; petroleum distillates and residues, gasoline, naphtha, kerosine, crude petroleum, asphalt, gas oil, residual oil, tar-sand oil, shale oil, coal oil; aromatic hydrocarbons such as benzene, toluene, xylene fractions, coal tar, cycle gas oil from fluid-catalytic-cracking operation; furfural extract of coker gas oil; and miXtures thereof.
Claim 22
Dependent Claim
85 words
introducing the effluent gas stream from 3 into a water-gas shift conversion zone at a suitable temperature along with supplemental H2O to provide a H2O/CO ratio in the range of about 2 to 4, and reacting therein H2O with a portion of the CO in said gas stream to produce a process gas stream comprising H2, CO, CO2, CH4 and at least 35 mole % N2, on a dry basis and wherein the mole ratio H2/CO is in the range of about 2.9 to 3.1;
Claim 23
Dependent Claim
85 words
introducing the effluent gas stream from 3 into a water-gas shift conversion zone at a suitable temperature along with supplemental H2O to provide a H2O/CO ratio in the range of about 2 to 4, and reacting therein H2O with a portion of the CO in said gas stream to produce a process gas stream comprising H2, CO, CO2, CH4 and at least 35 mole % N2, on a dry basis and wherein the mole ratio H2/CO is in the range of about 2.9 to 3.1;
Claim 24
Dependent Claim
58 words
cooling the effluent gas stream from 4 to remove the excess water and then heating the dry gas to a temperature in the range of about 400* to 1000*F., and reacting the H2 and CO in said gas stream in a second catalytic methanation zone until substantially all of the H2 and CO are converted into CH4; and
Claim 25
Dependent Claim
58 words
cooling the effluent gas stream from 4 to remove the excess water and then heating the dry gas to a temperature in the range of about 400* to 1000*F., and reacting the H2 and CO in said gas stream in a second catalytic methanation zone until substantially all of the H2 and CO are converted into CH4; and
Claim 26
Dependent Claim
37 words
The process of claim 1 wherein said hydrocarbonaceous fuel is a gaseous hydrocarbon selected from the group consisting of ethane, propane, butane, pentane, water gas, coke-oven gas, refinery gas, acetylene tail gas, ethylene off-gas, and mixtures thereof.
Claim 27
Dependent Claim
58 words
adjusting the temperature of the effluent gas stream from 4 to a temperature in the range of about 400* to 1000*F., and reacting the H2 and CO in said gas stream in a second catalytic methanation zone to produce a gas stream principally comprising CH4, CO2, H2O, N2 and optionally minor amounts of H2, CO and A; and
Claim 28
Dependent Claim
58 words
adjusting the temperature of the effluent gas stream from 4 to a temperature in the range of about 400* to 1000*F., and reacting the H2 and CO in said gas stream in a second catalytic methanation zone to produce a gas stream principally comprising CH4, CO2, H2O, N2 and optionally minor amounts of H2, CO and A; and
Claim 29
Dependent Claim
58 words
ADJUSTING THE TEMPERATURE OF THE EFFLUENT GAS STREAM FROM 4 TO A TEMPERATURE IN THE RANGE OF ABOUT 400* TO 1000*F, AND REACTING THE H2, AND CO IN SAID GAS STREAM IN A SECOND CATALYTIC METHANATION ZONE TO PRODUCE A GAS STREAM PRINCIPALLY COMPRISING CH4, COE, H2O, N2 AND OPTIONALLY MINOR AMOUNTS OF H2, CO AND A, AND
Claim 30
Dependent Claim
58 words
ADJUSTING THE TEMPERATURE OF THE EFFLUENT GAS STREAM FROM 4 TO A TEMPERATURE IN THE RANGE OF ABOUT 400* TO 1000*F, AND REACTING THE H2, AND CO IN SAID GAS STREAM IN A SECOND CATALYTIC METHANATION ZONE TO PRODUCE A GAS STREAM PRINCIPALLY COMPRISING CH4, COE, H2O, N2 AND OPTIONALLY MINOR AMOUNTS OF H2, CO AND A, AND
Claim 31
Dependent Claim
19 words
COOLING THE EFFLUENT GAS STREAM FROM 5 AND SEPARATING IMPURITIES THEREFROM TO PRODUCE SAID PRODUCT STREAM PRINCIPALLY COMPRISING ETHANE.
Claim 32
Dependent Claim
19 words
COOLING THE EFFLUENT GAS STREAM FROM 5 AND SEPARATING IMPURITIES THEREFROM TO PRODUCE SAID PRODUCT STREAM PRINCIPALLY COMPRISING ETHANE.
Claim 33
Dependent Claim
19 words
cooling the effluent gas stream from 5 and separating impurities therefrom to produce said product stream principally comprising methane.
Claim 34
Dependent Claim
19 words
cooling the effluent gas stream from 5 and separating impurities therefrom to produce said product stream principally comprising methane.
Claim 35
Dependent Claim
47 words
The process of claim 1 wherein said hydrocarbonaceous fuel is an oxygenated hydrocarbonaceous organic material selected from the group consisting of carbohydrates, cellulosic materials, aldehydes, organic acids, alcohols, ketones, oxygenated fuel oil, waste liquids and by-products from chemical processes containing oxygenated hydrocarbonaceous organic materials and mixtures thereof.
Claim 36
Dependent Claim
27 words
cooling the effluent gas stream from 5 and separating therefrom CO2, N2 and A thereby producing said product gas stream comprising at least 90 mole % methane.
Claim 37
Dependent Claim
27 words
cooling the effluent gas stream from 5 and separating therefrom CO2, N2 and A thereby producing said product gas stream comprising at least 90 mole % methane.
Claim 38
Dependent Claim
44 words
The process of claim 1 wherein said hydrocarbonaceous fuel is a pumpable slurry of solid carbonaceous fuels selected from the group consisting of coal, particulate carbon, petroleum cokes, concentrated sewer sludge in a vaporizable carrier such as water, liquid hydrocarbon fuel and mixtures thereof.
Claim 39
Dependent Claim
38 words
The process of claim 1 further provided with the step of preheating the hydrocarbonaceous fuel to a temperature up to 1200*F. but below its cracking temperature prior to introducing said fuel into the gas generator in step 1.
Claim 40
Dependent Claim
49 words
The process of claim 1 wherein the temperature moderator in step 1 is selected from the group consisting of H2O, CO2, a portion of cooled clean process gas, by-product nitrogen from an air separation unit or from a cryogenic gas purification zone, and mixtures of the aforesaid temperature moderators.
Claim 41
Dependent Claim
14 words
A process for producing a stream comprising at least 90 mole % methane comprising
Claim 42
Dependent Claim
14 words
A process for producing a stream comprising at least 90 mole % methane comprising
Claim 43
Dependent Claim
37 words
The process of claim 10 where in step 4 said H2O is reacted with a portion of the CO in a catalytic water-gas shift conversion zone at a temperature in the range of about 600* to 1000*F.
Claim 44
Dependent Claim
39 words
The process of claim 10 where in step 4 said H2O is reacted with a portion of the CO in a noncatalytic thermal direct water-gas shift conversion zone at a temperature in the range of about 1500* to 2800*F.
Claim 45
Dependent Claim
32 words
The process of claim 10 wherein the pressure in steps 2 to 6 is substantially the same as that in the gas generator in step 1 less ordinary drop in the lines.
Claim 46
Dependent Claim
22 words
The process of claim 10 wherein said hydrocarbonaceous feedstock is a liquid hydrocarbon fuel and steam is used as a temperature moderator.
Claim 47
Dependent Claim
56 words
The process of claim 10 wherein the cooling of the raw process gas stream in step 2 is effected by indirect heat exchange with water in a waste heat boiler thereby producing steam, and at least a portion of said steam is introduced into the water-gas shift conversion zone in step 4 as said supplemental H2O.
Claim 48
Dependent Claim
18 words
The process of claim 10 wherein said hydrocarbonaceous fuel is comprised of a slurry of coal and water.
Claim 49
Dependent Claim
46 words
The process of claim 10 wherein the catalyst in steps 3 and 5 comprises Nickel oxide and aluminum oxide and the space velocity in each methanation zone is in the range of about 100 to 10,000 standard volumes of gas per volume of catalyst per hour.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-06-09 | 1978-12-09 | 1979-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-06-09 | 1982-12-09 | 1983-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-06-09 | 1986-12-09 | 1987-06-10 | $7700.00 | Window Closed / Lapsed |