Patent ID: 7087651

Claim:
A process for converting methane to longer chain hydrocarbons, the process comprising the steps of: (a) mixing a feed gas comprising methane with steam for forming a gas mixture in which the ratio of steam to methane is in the range 1.2 to 2.0; (b) subjecting the gas mixture to reforming for generating carbon monoxide and hydrogen in a catalytic reactor comprising several narrow flow channels between metal sheets, the flow channels being arranged alternately with channels for an exothermic reaction to provide a source of heat, so that the sheets separate the flow channels from the source of heat, the flow channel containing a fluid-permeable catalyst structure with a metal substrate to enhance heat transfer, and each flow channel being of length at 100 mm, causing the gas mixture to flow through the flow channels, wherein the residence time in the flow channels is less than 500 ms but at least 20 ms, and both the average temperature along the flow channels and the exit temperature of the flow channels are in the range 750° C. to 900° C.; (c) subjecting the carbon monoxide and hydrogen from the reforming step to a subsequent Fischer-Tropsch synthesis; (d) separating a gas stream including hydrogen from the resulting longer chain hydrocarbons; and (e) subjecting the hydrogen-including gas stream to combustion in the channels for the exothermic reaction for providing at least part of the heat source for the reforming step.