Granted Patent
B2
US 12,617,679 · App. 17/420,491 · Granted May 5, 2026
Chemical synthesis plant
Inventors:
Sudip De Sarkar (Kokkedal, DK); Martin Østberg (Tune, DK); Thomas Sandahl Christensen (Kgs. Lyngby, DK); Kim Aasberg-Petersen (Allerød, DK)
Assignee:
HALDOR TOPSØE A/S
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Abstract
A plant, such as a hydrocarbon plant, is provided, which consists of a syngas stage for syngas generation and a synthesis stage where said syngas is synthesized to produce syngas derived product, such as hydrocarbon product. The plant makes effective use of various streams; in particular CO 2 and H 2 . A method for producing a product stream, such as a hydrocarbon product stream is also provided.
Claims (68)
1 . A method for producing a product stream, said method comprising the steps of:
providing a plant, said plant comprising:
a. a syngas stage, said syngas stage comprising an autothermal reforming (ATR) section; and
b. a synthesis stage,
said plant further comprising:
a first feed comprising hydrogen to the syngas stage;
a second feed comprising carbon dioxide to the syngas stage;
a third feed comprising hydrocarbons to the syngas stage, upstream of said ATR section, said third feed being external to the plant; and
a fourth feed comprising oxygen to the ATR section,
wherein said syngas stage is arranged to provide a syngas stream and feed said syngas stream to the synthesis stage,
supplying a first feed comprising hydrogen to the syngas stage;
supplying a second feed comprising carbon dioxide to the syngas stage;
supplying a third feed comprising hydrocarbons to the syngas stage, upstream of said ATR section;
supplying a fourth feed comprising oxygen to the ATR section;
providing a syngas stream in said syngas stage from at least said first, second, third and fourth feeds;
feeding said syngas stream to the synthesis stage; and
converting said syngas stream into at least a product stream and a hydrocarbon-containing off-gas stream in said synthesis stage,
wherein the ratio of moles of carbon in the third feed comprising hydrocarbons to the moles of carbon in CO 2 in the second feed is less than 0.5.
2 . The method according to claim 1 , wherein the ratio of moles of carbon in the third feed comprising hydrocarbons to the moles of carbon in CO 2 in the second feed is less than 0.3.
3 . The method according to claim 1 , further comprising the step of feeding at least a portion of said hydrocarbon-containing off-gas stream to the syngas stage in addition to said third feed comprising hydrocarbons, upstream of said ATR section.
4 . The method according to claim 1 , wherein the syngas stream at the inlet of said synthesis stage has a hydrogen/carbon monoxide ratio in the range 1.00-4.00.
5 . The method according to claim 1 , wherein the ratio of H 2 :CO 2 provided at a plant inlet is between 1.0-9.0.
6 . The method according to claim 5 , wherein the synthesis stage is an FT synthesis stage and the H 2 :CO 2 -ratio at the plant inlet is in the range of 3.0-7.0.
7 . The method according to claim 1 , wherein said syngas stage consists of said autothermal reforming (ATR) section, and wherein first, second, and fourth feeds are fed directly to said ATR section.
8 . The method according to claim 1 , wherein:
the syngas stage additionally comprises a methanation section arranged upstream the ATR section;
a part or all of the first feed is fed to the methanation section;
a part or all of the second feed is fed to the methanation section; and
a part or all of the third feed is fed to the syngas stage, upstream said methanation section or between said methanation section and said ATR section.
9 . The method according to claim 1 , wherein:
the syngas stage additionally comprises a reverse water gas shift (rWGS) section upstream the ATR section wherein a part or all of the first feed is fed to the rWGS section;
a part or all of the second feed is fed to the rWGS section; and
a part or all of the third feed is fed to the syngas stage between said rWGS section and said ATR section.
10 . The method according to claim 1 , wherein:
the syngas stage comprises a reverse water gas shift (rWGS) section arranged in parallel to said ATR section;
at least a portion of the first feed and at least a portion of the second feed are arranged to be fed to the rWGS section and said rWGS section is arranged to convert said at least a portion of the first feed and at least a portion of the second feed to a first syngas stream;
a third feed comprising hydrocarbons and a fourth feed comprising oxygen are arranged to be fed to the ATR section;
said ATR section is arranged to convert said third feed comprising hydrocarbons and said fourth feed comprising oxygen to a second syngas stream; and
the first syngas stream from the rWGS section is arranged to be combined with the second syngas stream from the ATR section; and the combined syngas stream is arranged to be fed to the synthesis stage.
11 . A plant, said plant comprising:
a. a syngas stage, said syngas stage comprising an autothermal reforming (ATR) section; and
b. a synthesis stage,
said plant comprising:
a first feed comprising hydrogen to the syngas stage;
a second feed comprising carbon dioxide to the syngas stage;
a third feed comprising hydrocarbons to the syngas stage, upstream of said ATR section, said third feed being external to the plant; and
a fourth feed comprising oxygen to the ATR section,
wherein said syngas stage is arranged to provide a syngas stream and feed said syngas stream to the synthesis stage, and
wherein:
the syngas stage additionally comprises a methanation section arranged upstream the ATR section;
a part or all of the first feed is fed to the methanation section;
a part or all of the second feed is fed to the methanation section;
a part or all of the third feed is fed to the syngas stage, upstream said methanation section or between said methanation section and said ATR section,
the synthesis stage has a product outlet and three different hydrocarbon-containing off-gas outlets, a first hydrocarbon-containing off-gas outlet being a first hydrocarbon-containing off-gas feed to the ATR section, a second hydrocarbon-containing off-gas outlet being a second hydrocarbon-containing off-gas feed to the methanation section, and a third hydrocarbon-containing off-gas outlet being a third hydrocarbon-containing off-gas feed to the methanation section.
12 . The method according to claim 1 , wherein said third feed comprising hydrocarbons is fed to the syngas stage, directly upstream of said ATR section.
13 . The method according to claim 1 , further comprising a fifth steam feed to the syngas stage.
14 . The method according to claim 1 , wherein said third feed comprising hydrocarbons is a natural gas feed.
15 . The method according to claim 1 , wherein the synthesis stage is a Fischer-Tropsch (F-T) stage arranged to convert said syngas stream into at least a hydrocarbon product stream and a hydrocarbon-containing off-gas stream in the form of an F-T tail gas stream.
16 . The method according to claim 1 , wherein the synthesis stage comprises a methanol synthesis stage arranged to provide at least a methanol product stream.
17 . The method according to claim 1 , further comprising an electrolyser arranged to convert water or steam into at least a hydrogen-containing stream and an oxygen-containing stream, and wherein at least a part of said hydrogen-containing stream from the electrolyser is fed to the syngas stage as said first feed and/or wherein at least a part of said oxygen-containing stream from the electrolyser is fed to the syngas stage as said fourth feed.
18 . The method according to claim 1 , further comprising providing a sixth feed comprising hydrogen to the syngas stream, upstream the synthesis stage.
19 . The method according to claim 1 , wherein:
the syngas stage further comprises a methanation section arranged upstream the ATR section; and
the synthesis stage has a product outlet and three different hydrocarbon-containing off-gas outlets, a first hydrocarbon-containing off-gas outlet being a first hydrocarbon-containing off-gas feed to the ATR section, a second hydrocarbon-containing off-gas outlet being a second hydrocarbon-containing off-gas feed to the methanation section, and a third hydrocarbon-containing off-gas outlet being a third hydrocarbon-containing off-gas feed to the methanation section,
the process further comprising:
feeding the first hydrocarbon-containing off-gas feed from the first hydrocarbon-containing off-gas outlet to the ATR section;
feeding the second hydrocarbon-containing off-gas feed from the second hydrocarbon-containing off-gas outlet to the methanation section; and
feeding the third hydrocarbon-containing off-gas feed from the third hydrocarbon-containing off-gas outlet to the methanation section.
Assignments (2)
CHANGE OF NAME
Recorded Jul 16, 2026
From: HALDOR TOPSØE A/S
To: TOPSOE A/S
Reel/Frame 076014/0782 →
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Sep 22, 2021
From: DE SARKAR, SUDIP; ØSTBERG, MARTIN; CHRISTENSEN, THOMAS S.; AASBERG-PETERSEN, KIM
To: HALDOR TOPSØE A/S
Reel/Frame 057555/0549 →
Priority Claims (1)
DK PA 2019 00434
· Apr 8, 2019
· national
Continuity (1)
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Danish Search Report for Danish Application No. PA 2019 01145 dated Mar. 12, 2020 (7 pages).
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Danish Search Report for Danish Application No. PA 2019 01432 dated Mar. 27, 2020 (10 pages).
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Danish Search Report issued in corresponding Danish Patent Application No. PA201901435 dated Apr. 24, 2020. (9 pages).
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Danish Search Report issued in corresponding Patent Application No. PA 2019 01324 dated May 27, 2020, 8 pages.
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Danish Search Report issued in corresponding Patent Application No. PA 2019 01434 dated May 27, 2020 (8 pages).
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European Search Report for European Application No. 20 21 6617 dated May 10, 2021. (9 pages).
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European Search Report issued in corresponding Application No. EP 19 21 3432 dated May 8, 2020.
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European Search Report issued in corresponding Application No. EP 20 20 1817 dated Mar. 17, 2021.
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Extended European Search Report mailed on Jul. 8, 2021, by the European Patent Office for European Application No. (2115595534).
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