IP Library Granted Patent US 12,180,130
Granted Patent B2
US 12,180,130 · App. 17/401,778 · Granted Dec 31, 2024

Methods, systems, and catalysts for the direct conversion of syngas to high-octane hydrocarbons

Inventors: Daniel Ruddy (Arvada, CO); Jesse Evan Hensley (Arvada, CO); Joshua A. Schaidle (Arvada, CO); Connor Patrick Nash (Lakewood, CO); Anh The To (Denver, CO)
Assignee: Alliance for Sustainable Energy, LLC
C07C1/22B01J8/04B01J21/04B01J21/066B01J21/08B01J23/72B01J23/80B01J29/7007B01J35/19C07C29/154C07C41/09B01J2208/025B01J2208/027C07C2521/04C07C2521/06C07C2521/08C07C2523/06C07C2523/72
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Quick Facts
Patent No.
US 12,180,130
App. No.
17/401,778
Granted
Dec 31, 2024
Kind
B2
Abstract

The present disclosure relates to a method that includes converting a gas stream that contains hydrogen (H 2 ) and carbon monoxide (CO) to a second mixture that contains a hydrocarbon, for example, a hydrocarbon having between 3 and 15 carbon atoms, where the converting is performed using a first catalyst configured to convert H 2 and CO to methanol, a second catalyst configured to convert methanol to dimethyl ether (DME), and a third catalyst configured to convert DME to the hydrocarbon.

Claims (14)

1. A method comprising:

converting a gas stream comprising hydrogen (H 2 ) and carbon monoxide (CO) to a mixture comprising a hydrocarbon having between 3 and 15 carbon atoms, wherein:

the converting is performed using a first catalyst configured to convert H 2 and CO to methanol, a second catalyst configured to convert methanol to dimethyl ether (DME), and a third catalyst configured to convert DME to the hydrocarbon;

the first catalyst and the second catalyst are physically mixed in a first catalyst bed and the third catalyst is positioned in a second catalyst bed;

the first catalyst bed and second catalyst bed are contained in a single stacked packed-bed reactor in series;

the first catalyst comprises copper-zinc oxide-alumina (CZA);

the second catalyst comprises gamma alumina (A); and

the third catalyst comprises copper modified BEA zeolite (Cu/BEA).

2. The method of claim 1 , wherein the Cu/BEA catalyst comprises a beta zeolite having a silica to alumina ratio between about 20:1 and about 300:1.

3. The method of claim 2 , wherein the copper in the third catalyst is present at a concentration between about 1 wt % and about 20 wt %, relative to the total weight of the third catalyst.

4. The method of claim 1 , wherein the first catalyst and the second catalyst are present at a ratio between about 1:1 and about 8:1.

5. The method of claim 4 , wherein the second catalyst and the third catalyst are present at a ratio between about 0.1:1 and about 5:2.

6. The method of claim 1 , wherein the gas stream further comprises carbon dioxide (CO 2 ).

7. The method of claim 6 , wherein the gas stream has a concentration of carbon dioxide greater than or equal to 10 mol %.

Assignments (3)
CHANGE OF NAME Recorded Dec 16, 2025
From: ALLIANCE FOR SUSTAINABLE ENERGY, LLC
To: ALLIANCE FOR ENERGY INNOVATION, LLC
Reel/Frame 073993/0276 →
CONFIRMATORY LICENSE Recorded Mar 30, 2022
From: NATIONAL RENEWABLE ENERGY LABORATORY
To: UNITED STATES DEPARTMENT OF ENERGY
Reel/Frame 059447/0884 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 1, 2021
From: RUDDY, DANIEL; HENSLEY, JESSE EVAN; SCHAIDLE, JOSHUA A.; NASH, CONNOR PATRICK; TO, ANH THE
To: ALLIANCE FOR SUSTAINABLE ENERGY, LLC
Reel/Frame 057351/0876 →