Gas conversion using synthesis gas produced hydrogen for catalyst rejuvenation and hydrocarbon conversion

Abstract

A gas conversion process in which both hydrocarbons and hydrogen are produced from a synthesis gas feed which comprises a mixture of H 2 and CO, uses hydrogen from a portion of the feed for one or more of (i) hydrocarbon synthesis catalyst rejuvenation and (ii) hydroconversion upgrading of at least a portion of the synthesized hydrocarbons. Hydrogen is produced from a slipstream of the synthesis gas fed into the hydrocarbon synthesis reactor by one or more of (i) physical separation means such as pressure swing adsorption and (ii) chemical means such as a water gas shift reactor. If a shift reactor is used due to insufficient capacity of the synthesis gas generator, physical separation means such as pressure swing adsorption will still be used to separate a pure stream of hydrogen from the shift reactor gas effluent.

What is claimed is:  
     
       1. A gas conversion process comprising 
       (a) reacting a gaseous hydrocarbonaceous material, oxygen and optionally steam at conditions effective to form a synthesis gas comprising a mixture of H 2  and CO,  
       (b) contacting a portion of said synthesis gas with a hydrocarbon synthesis catalyst at reaction conditions effective to react said H 2  and CO and form hydrocarbons and reversibly deactivate said catalyst,  
       (c) producing hydrogen from another portion of said synthesis gas, and  
       (d) using the hydrogen for at least one of (i) rejuvenating said catalyst, and (ii) hydroconverting at least a portion of said synthesized hydrocarbons.  
     
     
       2. A process according to  claim 1  wherein said hydrogen is produced from said synthesis gas by at least one of (i) physical separation means and (ii) chemical means. 
     
     
       3. A process according to  claim 2  wherein said hydrogen is produced from said synthesis gas by means comprising physical separation. 
     
     
       4. A process according to  claim 2  wherein said hydrogen production means includes a water gas shift reaction. 
     
     
       5. A process according to  claim 3  wherein said hydrocarbon synthesis catalyst comprises a Fischer-Tropsch type of catalyst and wherein at least a portion of said synthesized hydrocarbons are solid at standard room temperature conditions of temperature and pressure. 
     
     
       6. A process according to  claim 5  wherein said catalyst comprises a catalytic cobalt component. 
     
     
       7. A process according to  claim 6  wherein said hydrocarbon synthesis reaction occurs in a slurry comprising said hydrocarbon synthesis catalyst and bubbles of said H 2  and CO in a slurry liquid which comprises said synthesized hydrocarbons which are liquid at said reaction conditions. 
     
     
       8. A process according to  claim 7  wherein said hydrogen is used to rejuvenate said catalyst. 
     
     
       9. A process according to  claim 3  wherein physically separating said hydrogen from said synthesis gas produces an offgas comprising a CO rich offgas which is used for said hydrocarbon synthesis. 
     
     
       10. A process according to  claim 8  wherein physically separating said hydrogen from said synthesis gas produces an offgas comprising a CO rich offgas which is used for said hydrocarbon synthesis. 
     
     
       11. A process according to  claim 3  wherein said physical separation comprises passing said synthesis gas through membrane separation means to produce a hydrogen-rich permeate which is passed through pressure swing adsorption means to produce a high purity hydrogen stream. 
     
     
       12. A process according to  claim 7  wherein said physical separation comprises passing said synthesis gas through membrane separation means to produce a hydrogen-rich permeate which is passed through pressure swing adsorption means to produce a high purity hydrogen stream. 
     
     
       13. A process according to  claim 8  wherein said physical separation comprises passing said synthesis gas through membrane separation means to produce a hydrogen-rich permeate which is passed through pressure swing adsorption means to produce a high purity hydrogen stream. 
     
     
       14. A process according to  claim 7  wherein said synthesized hydrocarbons comprise C 5+    hydrocarbons.   
     
     
       15. A process according to  claim 14  wherein at least a part of said C 5+    hydrocarbons are subjected to conversion.   
     
     
       16. A process according to  claim 15  wherein said C 5+    hydrocarbons are subjected to a catalytic process in which the molecular structure of a least a portion of said hydrocarbon is changed.   
     
     
       17. A process according to  claim 15  wherein said C 5+    hydrocarbons are subjected to a non - catalytic process in which the molecular structure of at least a portion of said hydrocarbon is changed.   
     
     
       18. A process according to  claim 16  wherein a diesel fuel is the product of said catalytic processes.