Patent EA-000674-B1 (EA)
Title: Turbine-powered, synthesis-gas system and method
Inventor: AGEE KENNETH L
IPC: C07C29/151
Filed: 1997-03-10
Abstract: 1. A natural-gas-conversion method for the conversion of normally gaseous hydrocarbons into liquid organic products, the method comprising the steps of: a. compressing air; b. reacting a feed stream consisting substantially of gaseous hydrocarbons in the presence of the compressed air from step (a) in a first autothermal reformer reactor to create an intermediate feed stream containing carbon monoxide and molecular hydrogen; c. reacting the intermediate stream in the presence of a catalyst in a second Fischer-Tropsch reactor to produce a hydrocarbon product stream of substantially C5+ hydrocarbons; and d. combusting the residue gas from the second reactor in a gas turbine, which is used for compressing a portion of the compressed air in step (a). 2. The method of claim 1 wherein step (a) comprises compressing enriched air. 3. The method of claim 1 further comprising the step of further compressing the intermediate stream before step (c). 4. The method of claim 1 further comprising the step of further compressing the residue gas before the residue is delivered to the gas turbine in step (d). 5. The method of claim 1 wherein normally gaseous hydrocarbons are converted to liquid organic products that , are at least as heavy as C5. 6. The method of claim 1 wherein normally gaseous hydrocarbons are converted to dimethyl ether. 7. The method of claim 1 wherein the combusting of step (d) is conducted in the presence of a combustion-promoting catalyst. 8. The method of claim 1 further comprising the steps of: e. removing excess heat energy developed during the reacting step (b); and f. using the excess heat energy from step (e) to compress additional air in combination with step (a). 9. The method of claim 1 further comprising the steps of: e. removing excess heat energy developed during the reacting step (c); and f. using the excess heat energy from step (e) to compress additional air in combination with step (a). 10. The method of claim 1 further comprising the steps of: e. removing excess heat energy developed during the reacting step (b) ; f. removing excess heat energy developed during the reacting step (c); and g. using the excess heat energy from steps (e) and (f) to compress additional air in combination with step (a). 11. A process to convert normal gaseous hydrocarbons into heavier hydrocarbons, which are liquid or solid at standard temperature and pressure, the process comprising the steps of: (a) reacting air and gaseous hydrocarbons in a reactor to produce a gas containing quantities of H2. and CO and N2; from the air; (b) reacting the produced gas in step (a) over a Fischer-Tropsch catalyst to produce heavier hydrocarbon products; (c) separating the heavier hydrocarbon products and water from gaseous light hydrocarbon products and unreacted H2, CO, and N2; (d) combusting the residue gas from step (c) in a gas turbine; (e) extracting a portion of the air from a compressor section of the gas turbine of step (d) to react with gaseous hydrocarbons in step (a); and (f) reacting the remaining air left from step (e) along with the residue gas in step (d). 12. The process of claim 11, wherein step (a) comprises the step of reacting an enriched air with gaseous light hydrocarbons in the reactor. 13. The process of claim 11, further comprising the step of introducing CO2 into the reactor in step (a) to adjust the ratio of H2 to CO. 14. The process of claim 11, further comprising the step of introducing steam into the reactor in step (a) to adjust the ratio of H2 to CO. 15. The process of claim 11, further comprising the step of compressing the gaseous light hydrocarbon products and unreacted H2, CO, and N2 from step (c) to at least partially compensate for the pressure drop associated with steps (b) and (c). 16. The process of claim 11, wherein the step of further compressing the gaseous light hydrocarbon products and unreacted H2, CO, and N2 comprises compressing the gaseous light hydrocarbons and unreacted H2, CO and N2 to a level substantially equal to the pressure of the air extracted in step (e). 17. The process of claim 11, wherein the step (a) comprises reacting compressed air and gaseous hydrocarbons in an autothermal reformer. 18. The process of claim 11, wherein the step (a) comprises the step of reacting air and gaseous hydrocarbons in a non-catalytic partial oxidation reactor. 19. The process of claim 11, further comprising the steps of: collecting moisture produced in steps (a) and (b); and delivering the collected moisture to an expansion-turbine section of the gas turbine referenced in step (d). 20. The process of claim 11, wherein step (a) comprises reacting air and natural gas in a reactor to produce a gas containing quantities of H2, CO and N2. 21. The method of claim 11 wherein the combusting of step (d) is conducted in the presence of a combustion-promoting catalyst. 22. A system for converting normal gaseous hydrocarbons into heavier hydrocarbons, which are liquid or solid at standard temperature and pressure, the system comprising: a gas turbine having a compressor section, an expansion section, an air intake, and an exhaust; a synthesis gas production unit having an autothermal reformer coupled to the compressor section of gas turbine for receiving compressed air therefrom and having a feedstack inlet for receiving the normal gaseous hydrocarbons and an outlet for delivering synthesis gas; a Fischer-Tropsch synthesis unit having an inlet coupled to the outlet of the synthesis gas production unit for receiving synthesis gas therefrom and having a first outlet for delivering a residue gas and a second outlet for delivering the heavier hydrocarbons; a combustor associated with the gas turbine and having a combustor inlet and combustor outlet, the combustor inlet coupled to the first outlet of the synthesis unit for receiving residue gas and the combustor outlet coupled to the expansion section of the gas turbine, the combustor inlet also coupled to a portion of the compressor section for receiving compressed air therefrom; and wherein the combustor is operable to burn residue gas and compressed air and supply a resultant product to the expansion section of the gas turbine to at least drive the compressor section. 23. The system of claim 22 further comprising a boosting compressor coupled to the combustor inlet and first outlet of the synthesis unit, the boosting compressor operable to boost a pressure of the residue gas delivered by the synthesis unit prior to the residue gas entering the combustor. 24. The system of claim 22 further comprising a booster compressor coupled to the outlet of the synthesis gas unit and the inlet of the synthesis unit for boosting a pressure of the synthesis gas prior to delivery to the synthesis unit. 25. The system of claim 22 wherein the gas turbine further comprises an energy off-take for removing excess power beyond what is required to drive the compressor section. 26. The system of claim 22 wherein the gas turbine further comprises a combustion-promoting catalyst for facilitating combustion of gases therein. 27. The system of claim 22 further comprising: a supplemental gas turbine having a compressor section, an expansion section, an air intake, and an exhaust, for providing additional compressed air to the synthesis gas production unit; wherein the synthesis gas production unit further comprises a heat exchanger; and a conduit for delivering excess heat energy from the heat exchanger of the synthesis gas production unit to the supplemental gas turbine to power the supplemental gas turbine. 28. The system of claim 22 further comprising: a supplemental gas turbine having a compressor section, an expansion section, an air intake, and an  exhaust, for providing additional compressed air ":o the synthesis gas production unit; wherein the synthesis unit further comprises a heat exchanger coupled to a reactor for removing excess heat from the reactor; and a conduit for delivering excess heat energy from the heat exchanger of the synthesis unit to the supplemental gas turbine to power the supplemental gas turbine. 29. The system of claim 22 further comprising: a supplemental gas turbine having a compressor section, an expansion section, an air intake, and an exhaust, for providing additional compressed air to the synthesis gas production unit; wherein the synthesis unit further comprises a heat exchanger coupled to a reactor for removing excess heat from the reactor; wherein the synthesis gas production unit further comprises a heat exchanger; and a plurality of conduits for delivering excess heat energy from the heat exchanger of the synthesis unit and from the heat exchanger of the synthesis gas production unit to the supplemental gas turbine to power the supplemental gas turbine.