Catalytic reforming process

Claim 2

A PROCESS FOR THE PRODUCTION OF A HYDROGEN-CONTAINING GAS WHICH COMPRISES REACTING A HYDROCARBON FEED STREAM CONSISTING ESSENTIALLY OF CONSTITUENTS BOILING BELOW ABOUT 450* F. WITH STEAM IN A STEAM REFORMING ZONE AND IN THE PRESENCE OF A CARBON-ALKALI METAL CATALYST AT A TEMPERATURE BETWEEN ABOUT 1200* AND ABOUT 1700*F. AND AT A PRESSURE BETWEEN ABOUT ATMOSPHERIC AND ABOUT 5000 PSIG, SAID CATALYST BEING PREPARED BY HEATING AN INTIMATE MIXTURE OF CARBONACEOUS SOLIDS AND AN ALKALI METAL CONSTITUENT TO A TEMPERATURE IN

Claim 3

A method as defined by claim 1 wherein said hydrocarbon feed stream comprises methane.

Claim 4

A method as defined by claim 1 wherein said carbonaceous solids comprise coal.

Claim 5

A method as defined by claim 1 wherein said carbonaceous solids comprise coal char.

Claim 6

A method as defined by claim 1 wherein said alkali metal constituent comprises a potassium compound.

Claim 7

A method as defined by claim 1 wherein said alkali metal constituent comprises a cesium compound.

Claim 8

A method as defined by claim 1 wherein said hydrocarbon feed stream is reacted with said steam at a temperature between about 1200* and about 1400* F.

Claim 9

A method as defined by claim 1 wherein said intimate mixture of carbonaceous solids and said alkali metal constituent is prepared by impregnating said solids with a liquid containing said alkali metal constituent.

Claim 10

A process as defined by claim 1 wherein said hydrocarbon feed stream comprises a naphtha.

Claim 11

A process as defined by claim 1 wherein said hydrocarbon feed stream comprises a methane-rich gas prepared by the hydrogasification of carbonaceous solids.

Claim 12

A process for the manufacture of a synthetic natural gas which comprises reacting hydrogen with carbonaceous solids in a hydrogasification zone maintained at a temperature and pressure sufficient to produce a methane-containing gas; circulating carbonaceous solids from said hydrogasification zone to a steam reforming zone and from said steam reforming zone to said hydrogasification zone; reacting a portion of said methane-containing gas with steam in said steam reforming zone in the presence of carbonaceous solids circulated from said hydrogasification zone and a carbon-alkali metal catalyst at a temperature below the temperature in said hydrogasification zone to produce sufficient hydrogen to replace substantially all of the hydrogen consumed in said hydrogasification zone, exothermic heat from said hydrogasification zone being transferred to said steam reforming zone by said circulating carbonaceous solids in sufficient quantities to supply substantially all of the exothermic heat required in said steam reforming zone; passing hydrogen produced in said steam reforming zone to said hydrogasification zone; and recovering a portion of said methane-containing gas from said hydrogasification zone.

Claim 13

A process for the manufacture of a synthetic natural gas which comprises reacting hydrogen with carbonaceous solids in a hydrogasification zone maintained at a temperature and pressure sufficient to produce a methane-containing gas; circulating carbonaceous solids from said hydrogasification zone to a steam reforming zone and from said steam reforming zone to said hydrogasification zone; reacting a portion of said methane-containing gas with steam in said steam reforming zone in the presence of carbonaceous solids circulated from said hydrogasification zone and a carbon-alkali metal catalyst at a temperature below the temperature in said hydrogasification zone to produce sufficient hydrogen to replace substantially all of the hydrogen consumed in said hydrogasification zone, exothermic heat from said hydrogasification zone being transferred to said steam reforming zone by said circulating carbonaceous solids in sufficient quantities to supply substantially all of the exothermic heat required in said steam reforming zone; passing hydrogen produced in said steam reforming zone to said hydrogasification zone; and recovering a portion of said methane-containing gas from said hydrogasification zone.

Claim 14

A process as defined by claim 11 wherein the temperature in said hydrogasification zone is maintained between about 1400* F. and about 1700* F. and the temperature in said steam reforming zone is maintained between about 1200* F. and about 1700* F., the temperature in said steam reforming zone being maintained below the temperature in said hydrogasification zone.

Claim 15

A process as defined by claim 11 wherein said hydrogen is reacted with said carbonaceous solids in said hydrogasification zone in the presence of a carbon-alkali metal catalyst.

Claim 16

A process as defined by claim 13 wherein the temperatures in said hydrogasification zone and in said steam reforming zone are maintained between about 1200* F. and about 1400* F., the temperature in said steam reforming zone being below the temperature in said hydrogasification zone.

Claim 17

A process as defined by claim 13 wherein said catalyst comprises cesium.

Claim 18

A process as defined by claim 11 wherein said hydrogasification zone and said steam reforming zone are located within a single reaction vessel.

Claim 19

A process as defined by claim 11 wherein said hydrogasification zone and said steam reforming zone are located in separate reaction vessels.

Claim 20

A process as defined by claim 13 wherein said catalyst comprises carbonaceous solids containing from 1 to about 50% by weight of an alkali metal constituent, based on the total weight of carbonaceous solids and alkali metal constituent.

Claim 21

A process as defined by claim 18 wherein said alkali metal constituent comprises potassium.

Claim 22

A process as defined by claim 19 wherein said catalyst is introduced into said steam reforming zone by impregnating carbonaceous solids with a solution of a potassium compound and thereafter introducing the impregnating solids into said reforming zone.

Claim 23

A process for the manufacture of a synthetic natural gas which comprises contacting a hydrogen-rich gas with coal solids in a hydrogasification zone at a temperature in the range between about 1400* F. and about 1700* F. and at a pressure between about 500 psig and about 5000 psig to produce a methane-containing gas; circulating coal solids from said hydrogasification zone to a steam reforming zone and from said steam reforming zone to said hydrogasification zone; contacting a portion of the methane-containing gas produced in said hydrogasification zone with steam in said reforming zone in the presence of a carbon-alkali metal catalyst at a temperature in the range betwen about 1200* F. and about 1700* F. to produce sufficient hydrogen to replace substantially all of the hydrogen consumed in said hydrogasification zone, the temperature in said steam reforming zone being about 50* to about 300* F. lower than the temperature in said hydrogasification zone and exothermic heat being transferred from said hydrogasification zone to said steam reforming zone by said circulating coal solids in a quantity sufficient to supply substantially all of the exothermic heat required to produce said hydrogen in said steam reforming zone; recovering hydrogen produced in said hydrogasification zone and in said steam reforming zone; introducing the recovered hydrogen into said hydrogasification zone; and recovering methane from a portion of said methane-containing gas produced in said hydrogasification zone.

Claim 24

A process for the manufacture of a synthetic natural gas which comprises contacting a hydrogen-rich gas with coal solids in a hydrogasification zone at a temperature in the range between about 1400* F. and about 1700* F. and at a pressure between about 500 psig and about 5000 psig to produce a methane-containing gas; circulating coal solids from said hydrogasification zone to a steam reforming zone and from said steam reforming zone to said hydrogasification zone; contacting a portion of the methane-containing gas produced in said hydrogasification zone with steam in said reforming zone in the presence of a carbon-alkali metal catalyst at a temperature in the range betwen about 1200* F. and about 1700* F. to produce sufficient hydrogen to replace substantially all of the hydrogen consumed in said hydrogasification zone, the temperature in said steam reforming zone being about 50* to about 300* F. lower than the temperature in said hydrogasification zone and exothermic heat being transferred from said hydrogasification zone to said steam reforming zone by said circulating coal solids in a quantity sufficient to supply substantially all of the exothermic heat required to produce said hydrogen in said steam reforming zone; recovering hydrogen produced in said hydrogasification zone and in said steam reforming zone; introducing the recovered hydrogen into said hydrogasification zone; and recovering methane from a portion of said methane-containing gas produced in said hydrogasification zone.

Claim 25

A process as defined by claim 21 wherein said hydrogen-rich gas is contacted with said coal solids in said hydrogasification zone in the presence of a carbon-alkali Metal catalyst.

Claim 26

A process for the production of a hydrogen-rich gas which comprises introducing a hydrocarbon feed gas into a reaction zone containing a carbon-alkali metal catalyst, reacting said feed gas with steam in the presence of said catalyst at a temperature between about 1200* and about 1700* F. and at a pressure between atmospheric and about 5000 psig, and withdrawing from said reaction zone a product gas having a higher hydrogen content and a lower hydrocarbon content than said feed gas.

Claim 27

A process for the production of a hydrogen-rich gas which comprises introducing a hydrocarbon feed gas into a reaction zone containing a carbon-alkali metal catalyst, reacting said feed gas with steam in the presence of said catalyst at a temperature between about 1200* and about 1700* F. and at a pressure between atmospheric and about 5000 psig, and withdrawing from said reaction zone a product gas having a higher hydrogen content and a lower hydrocarbon content than said feed gas.

Claim 28

A process as defined by claim 23 wherein said feed gas comprises methane.

Claim 29

A process as defined by claim 23 wherein said catalyst is supported on an inert carrier.