WO2007009954A1 - Procede de mise en oeuvre d'un processus de synthese d'hydrocarbures - Google Patents

Procede de mise en oeuvre d'un processus de synthese d'hydrocarbures Download PDF

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Publication number
WO2007009954A1
WO2007009954A1 PCT/EP2006/064275 EP2006064275W WO2007009954A1 WO 2007009954 A1 WO2007009954 A1 WO 2007009954A1 EP 2006064275 W EP2006064275 W EP 2006064275W WO 2007009954 A1 WO2007009954 A1 WO 2007009954A1
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Prior art keywords
steady state
conversion
pressure
reactors
hydrocarbons
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PCT/EP2006/064275
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English (en)
Inventor
Robert Martijn Van Hardeveld
Hans Michiel Huisman
Lip Piang Kueh
Thomas Joris Remans
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Shell Internationale Research Maatschappij B.V.
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Publication of WO2007009954A1 publication Critical patent/WO2007009954A1/fr

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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C10G2/32Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40Characteristics of the process deviating from typical ways of processing
    • C10G2300/4031Start up or shut down operations

Definitions

  • the present invention relates to a method to start a catalytic process for producing normally gaseous, normally liquid and optionally solid hydrocarbons from synthesis gas, generally provided from a hydro- carbonaceous feed, for example a Fischer-Tropsch process.
  • the present invention relates to a method to start an integrated, low cost process for the production of hydrocarbons, especially normally liquid hydrocarbons, from natural gas or associated gas, in particular at remote locations as well as at off-shore platforms .
  • the Fischer-Tropsch process can be used for the conversion of hydrocarbonaceous feed stocks into liquid and/or solid hydrocarbons.
  • feed stock e.g. natural gas, associated gas and/or coal-bed methane, peat, biomass, residual oil streams (e.g. tar sands, coal) is converted in a first step into a mixture of hydrogen and carbon monoxide (this mixture is often referred to as synthesis gas or syngas).
  • Fischer-Tropsch reactor systems include fixed bed reactors, especially multi-tubular fixed bed reactors, fluidised bed reactors, such as entrained fluidised bed reactors and fixed fluidised bed reactors, and slurry bed reactors such as three-phase slurry bubble columns and ebulated bed reactors.
  • the Fischer-Tropsch reaction is very exothermic and temperature sensitive, with the result that careful temperature control is required to maintain optimum operation conditions and desired hydrocarbon product selectivity. Indeed, close temperature control and operation throughout the reactor are major objectives.
  • a method to start a steady state process for producing normally gaseous, normally liquid and optionally normally solid hydrocarbons from synthesis gas in at least two conversion reactors comprises the steps of: (i) providing the synthesis gas; and
  • step (ii) catalytically converting the synthesis gas of step (i) at an elevated steady state temperature and a steady state pressure to obtain the normally gaseous, normally liquid and optionally normally solid hydrocarbons; the method comprising using in at least one conversion reactor for a period of at least three days, preferably one week, an initial pressure for the catalytic conversion of the synthesis gas lower than the steady state pressure.
  • reaction temperature By using an initial pressure lower than the steady state pressure, no lowering of reaction temperature, to otherwise compensate for the initial greater activity of the catalyst, is required. A reduction in reaction temperature also influences the quality and selectivity of products provided by the reaction.
  • One such product could be steam. Low quality steam cannot be used to assist in either providing start-up energy or power for - A -
  • a catalyst is made by impregnation, precipitation, drying, calcination, etc. by which method a catalyst is obtained in which the catalytic metal is in the oxidic state.
  • nickel or cobalt such a catalyst is first reduced with hydrogen. See e.g. EP 861,222, EP 533,227 and EP 533,228.
  • the activation (or conditioning) is often done with CO or CO/H2 mixtures.
  • Activation is usually done with a period up till one or two days. During activation with hydrogen no product is formed. When CO/H2 mixtures are used, some hydrocarbon will be made, usually less than 25% of the steady state production. After activation a highly active catalyst is obtained. Using the steady state (or design) conditions (GHSV, pressure, CO-conversion) a reaction temperature is needed which is relatively low. It is observed in this respect that a major design parameter of a plant is the overall capacity. Based on a certain feed a specific amount of product is to be made. In order to get the desired amount of product to be made a selection is made with respect to GHSV, pressure, CO-conversion, temperature, etc.. Based on these figures a specific reactor size, distillation equipment, pump size, etc.
  • the temperature is a parameter that can be varied fairly easily. Thus, given a certain capacity, a pressure is selected to carry out the reaction, and the temperature is used to control the reaction. In this way the process is carried out at constant pressure.
  • the method of using an initial pressure lower than the steady state pressure is preferably used in all the conversion reactors to which the invention applies .
  • the method could be applied to each conversion reactor in a simultaneous manner. This arrangement may be suitable where the catalyst in the conversion reactor (s) is pre-activated, and does not require activation in situ.
  • each conversion reactor to which the invention applies is started at a different time.
  • the method is therefore applied sequentially to each relevant conversion reactor.
  • each conversion reactor undergoes catalyst activation in situ.
  • This arrangement is particularly suitable where start up resources are only able or only suitable for providing catalyst activation of one or two conversion reactors at a time.
  • a conversion reactor takes a number of weeks from its start up before it reaches a steady state. Such period can be between 1 and 12 weeks, preferably in the range 1-8 weeks or longer, more usually 2-5 weeks especially 3-4 weeks.
  • the lower initial pressure used in the at least one conversion reactor is increased to the steady state pressure once the process for producing normally gaseous, normally liquid and optionally normally solid hydrocarbons has reached a steady state in said at least one conversion reactor.
  • steady state is a term well known in the art, and relates to a constant or regular, relative to the matter involved, value or position over a period of time. Minor variation in all chemical reactions is common even for a steady state process, but a steady state process is well known in the art wherein the expected output or result is relatively predictable over time. Such conditions may or may not also be optimal, or to provide optimum results. Occasionally the "steady state” is also called the “design state” or indicated as “line out conditions”. It is the intention to use the plant for a prolongued period of time (e.g. at least 6 months, preferably at least 1 year, more preferably at least two or three years. It is closely related to the "name plate capacity" of the plant. Another definition of "steady state” relates to the overall and individual conditions, including pressures and temperatures, of the hydrocarbon synthesis plant design. Such conditions are fundamental conditions set for the plant, and their selection would be known to a person skilled in the art.
  • steady state is similarly used herein in relation to pressure and temperature and catalyst activity.
  • pressure is usually related to that at the top of the reactor.
  • fresh or new catalyst when first used can have as much as 70% or higher greater activity of the expected or design or steady state activity. This heightened activity naturally reduces as the catalyst is used from the start up.
  • the initial catalyst activity can be in the range 120- 170%, preferably in the range 135-140%, of the steady state catalyst activity.
  • the H2/CO ratio of the syngas is suitably around the same as the H2/CO ratio of the syngas in the steady state condition.
  • the value may be e.g. 10% higher or lower, preferably 5%, but is preferably the same.
  • At least two of the conversion reactors involved in the method of the present invention could have a product recycle system or arrangement, more preferably a common gas recycle.
  • a common recycle preferably all the conversion reactors to which the method applies have the same pressure, such that the lower initial pressure used is increased to the steady state pressure once the process for producing the hydrocarbons has reached a steady state in all the conversion reactors started at the lower initial pressure .
  • the lower initial pressure used in at least one conversion reactor could be any suitable amount lower than the steady state pressure which suits other start up conditions, or the reactor conditions and/or products being provided by such reactor.
  • the present invention is particularly suitable for integrated processes.
  • One other usual product of the Fischer-Tropsch reaction is the provision of steam, and one effect of the present invention is to provide in minimal time steam of sufficient quality for use in other parts of the process, or ancillary or other connected processes, units or apparatus, such as an air separation unit (ASU) .
  • ASUs are often powered by steam generators, which generally require steam of sufficient quality, generally pressure, as a power source.
  • the lower initial pressure used in at least one conversion reactor could be 5-50% lower than the steady state pressure, preferably 10-40% lower.
  • the method starts with using in at least one conversion reactor an initial temperature for the catalytic conversion of the synthesis gas lower than the steady state temperature.
  • the initial lower temperature could then be raised above the steady state temperature for a period, in order to compensate for the lower initial pressure in terms of producing desired types and proportions of hydrocarbon products as soon as possible.
  • the temperature could then be adjusted to the steady state temperature once the process for producing hydrocarbons in the conversion reactor reaches a steady state, preferably in co- ordination with the increase of the pressure in such conversion reactor from the initial lower pressure to the steady state pressure.
  • any initial temperature used could in the range >0-30 0 C lower than the steady state temperature, preferably 5-15 0 C lower, and the subsequent raise in temperature could be in the range >0-50 0 C above the steady state temperature, preferably 5-15 0 C above.
  • the temperature regime used in each conversion reactor to which the method of the present invention applies is wholly or substantially the same or similar.
  • the or each conversion reactor to which the invention applies has the same space time yield (STY, hydrocarbon produced/1 catalyst/hour, hydrocarbon including C ] _H—hydrocarbons inclusive olefin, oxygenates etc., but excluding CO2.
  • the STY is usually between 50 and 300, especially 100-150 (fixed bed) or 50- 100, especially 60-90 (slurry, hydrocarbon/1 gasified slurry/hour) .
  • the synthesis gas can be provided by any suitable means, process or arrangement. This includes partial oxidation and/or reforming of a hydrocarbonaceous feedstock as is known in the art.
  • the catalytic conversion of synthesis gas in step (ii) provides steam
  • the present invention includes the provision of using the steam obtained in step (ii) for generating power in the provision of the synthesis gas for step (i), once the temperature in the at least one conversion reactor using an initial lower pressure is approximately the same as or above the steady state temperature .
  • the process to which the present start up invention applies could involve a number of conversion reactors.
  • an initial pressure for step (ii) lower than the steady state pressure is used in at least two but not all of the conversion reactors, optionally between 25-75% of the reactors, preferably between 40-60% of the reactors, and the method to start with an initial pressure for step (ii) lower than the steady state pressure is not used in the remaining conversion reactors.
  • the start up of at least one of the remaining conversion reactors for step (ii) could involve using the steady state pressure, and an admixture stream of the synthesis gas of step (i) and one or more inert gases.
  • the one or more inert gases could be, or could be part of, one or more selected from the group comprising: methane, nitrogen, ethane, propane, offgas, carbon dioxide, and post-conversion reactor syngas; preferably methane, offgas and/or post-conversion reactor syngas .
  • the amount of inert gas(es) in the admixture stream could be in the range >0-99%, more suitably 5-50%, more suitably 20-40%, and more suitably 30-40%, of the combination of the inert gas(es) and the synthesis gas of step (i) .
  • the admixture stream could be used in more than one of the remainder conversion reactors, preferably all. Each remainder conversion reactor using such an admixture stream could be started simultaneously, or sequentially. Preferably, the remainder conversion reactors using an admixture stream are started after the conversion reactors to which the start up method of the present invention applies, and are started up simultaneously.
  • the amount of inert gas(es) in the admixture stream could be reduced, either incrementally, continuously, or a combination of both, to zero.
  • the use of the admixture stream allows the conversion reactor to be started directly at a steady state temperature and steady state pressure, as the use of inert gas provides a lower partial pressure of the syngas and a lower possible water pressure.
  • step (ii) in at least one conversion reactor, catalytically converting the synthesis gas of step (i) at elevated steady state temperature and a first pressure to obtain the normally liquid, normally gaseous, and optionally normally solid hydrocarbons;
  • the present invention also provides a process for producing normally gaseous, normally liquid and optionally normally solid hydrocarbons from a hydrocarbonaceous feed using the method hereindescribed, as well as hydrocarbons whenever provided by such a process.
  • the catalysts used in step (ii) for the catalytic conversion of the mixture comprising hydrogen and carbon monoxide into hydrocarbons are known in the art and are usually referred to as Fischer-Tropsch catalysts. Catalysts for use in the
  • Fischer-Tropsch hydrocarbon synthesis process frequently comprise, as the catalytically active component, a metal from Group VIII of the previous IUPAC version of the Periodic Table of Elements such as that described in the 68 th Edition of the Handbook of Chemistry and Physics (CPC Press).
  • a metal from Group VIII of the previous IUPAC version of the Periodic Table of Elements such as that described in the 68 th Edition of the Handbook of Chemistry and Physics (CPC Press).
  • Particular catalytically active metals include ruthenium, iron, cobalt and nickel. Cobalt is a preferred catalytically active metal.
  • the hydrocarbonaceous feed suitably is methane, natural gas, associated gas or a mixture of C]__4 hydrocarbons.
  • the feed comprises mainly, i.e. more than 90 v/v%, especially more than 94%, C]__4 hydrocarbons, especially comprises at least 60 v/v percent methane, preferably at least 75 percent, more preferably 90 percent.
  • Very suitably natural gas or associated gas is used.
  • any sulphur in the feedstock is removed.
  • hydrocarbons or mixtures thereof are liquid or solid at temperatures between 5 and 30 0 C (1 bar), especially at about 20 0 C (1 bar), and usually are paraffinic of nature, while up to 30 wt%, preferably up to 15 wt%, of either olefins or oxygenated compounds may be present.
  • normally gaseous hydrocarbons normally liquid hydrocarbons and optionally normally solid hydrocarbons are obtained. It is often preferred to obtain a large fraction of normally solid hydrocarbons.
  • These solid hydrocarbons may be obtained up to 85 wt% based on total hydrocarbons, usually between 50 and 75 wt%.
  • the partial oxidation of gaseous feedstocks can take place according to various established processes. These processes include the Shell Gasification Process. A comprehensive survey of this process can be found in the Oil and Gas Journal, September 6, 1971, pp 86-90.
  • the oxygen containing gas for the partial oxidation can be air (containing about 21 vol. percent of oxygen), oxygen enriched air, suitably containing up to 70 percent, or substantially pure air, containing typically at least 95 vol.%, usually at least 98 vol.%, oxygen.
  • Oxygen or oxygen enriched air may be produced via cryogenic techniques, but could also be produced by a membrane based process, e.g. the process as described in WO 93/06041.
  • a gas turbine can provide the power for driving at least one air compressor or separator of the air compression/separating unit. If necessary, an additional compressing unit may be used between the separation process and step (i), and the gas turbine in that case may also provide at the (re) start power for this compressor.
  • the compressor may also be started at a later point in time, e.g. after a full start, using steam generated in steps (i) and/or (ii).
  • carbon dioxide and/or steam may be introduced into the partial oxidation process. Preferably up to 15% volume based on the amount of syngas, preferably up to 8% volume, more preferable up to 4% volume, of either carbon dioxide or steam is added to the feed.
  • Water produced in the hydrocarbon synthesis may be used to generate the steam.
  • carbon dioxide from the effluent gasses of the expanding/combustion step may be used.
  • the H2/CO ratio of the syngas is suitably between 1.5 and 2.3, preferably between 1.8 and 2.1.
  • additional amounts of hydrogen may be made by steam methane reforming, preferably in combination with the water shift reaction. Any carbon monoxide and carbon dioxide produced together with the hydrogen may be used in the hydrocarbon synthesis reaction or recycled to increase the carbon efficiency. Additional hydrogen manufacture may be an option.
  • the gaseous mixture comprising predominantly hydrogen, carbon monoxide and optionally nitrogen, is contacted with a suitable catalyst in the catalytic conversion stage, in which the hydrocarbons are formed.
  • At least 70 v/v% of the syngas is contacted with the catalyst, preferably at least 80%, more preferably at least 90%, still more preferably all the syngas.
  • the catalytically active metal is preferably supported on a porous carrier.
  • the porous carrier may be selected from any of the suitable refractory metal oxides or silicates or combinations thereof known in the art. Particular examples of preferred porous carriers include silica, alumina, titania, zirconia, ceria, gallia and mixtures thereof, especially silica and titania.
  • the amount of catalytically active metal on the carrier is preferably in the range of from 3 to 300 pbw per 100 pbw of carrier material, more preferably from 10 to 80 pbw, especially from 20 to 60 pbw.
  • the catalytically active metal and the promoter may be deposited on the carrier material by any suitable treatment, such as impregnation, kneading and extrusion.
  • the loaded carrier is typically subjected to calcination at a temperature of generally from 350 to 750 0 C, preferably a temperature in the range of from 450 to 550 0 C.
  • the effect of the calcination treatment is to remove crystal water, to decompose volatile decomposition products and to convert organic and inorganic compounds to their respective oxides.
  • the resulting catalyst may be activated by contacting the catalyst with hydrogen or a hydrogen-containing gas, typically at temperatures of about 200 to 350 0 C.
  • a Fischer-Tropsch catalyst which yields substantial quantities of paraffins, more preferably substantially unbranched paraffins.
  • a part may boil above the boiling point range of the so-called middle distillates, to normally solid hydrocarbons.
  • a most suitable catalyst for this purpose is a cobalt- containing Fischer-Tropsch catalyst.
  • middle distillates is a reference to hydrocarbon mixtures of which the boiling point range corresponds substantially to that of kerosene and gas oil fractions obtained in a conventional atmospheric distillation of crude mineral oil.
  • the boiling point range of middle distillates generally lies within the range of about 150 to about 360 0 C.
  • the amount of catalytically active metal present in the hydrocracking catalyst may vary within wide limits and is typically in the range of from about 0.05 to about 5 parts by weight per 100 parts by weight of the carrier material .
  • Suitable conditions for the catalytic hydrocracking are known in the art.
  • the hydrocracking is effected at a temperature in the range of from about 175 to 400 0 C.
  • Typical hydrogen partial pressures applied in the hydrocracking process are in the range of from 10 to 250 bar.
  • the process may be operated in a single pass mode ("once through") or in a recycle mode.
  • Slurry bed reactors, ebulliating bed reactors and fixed bed reactors may be used, the fixed bed reactor being the preferred option .
  • the product of the hydrocarbon synthesis and consequent hydrocracking suitably comprises mainly normally liquid hydrocarbons, beside water and normally gaseous hydrocarbons.
  • the off gas of the hydrocarbon synthesis may comprise normally gaseous hydrocarbons produced in the synthesis process, nitrogen, unconverted methane and other feedstock hydrocarbons, unconverted carbon monoxide, carbon dioxide, hydrogen and water.
  • the normally gaseous hydrocarbons are suitably C]__5 hydrocarbons, preferably
  • hydrocarbons are gaseous at temperatures of 5-30 0 C (1 bar), especially at 20 0 C (1 bar).
  • oxygenated compounds e.g. methanol, dimethyl ether
  • the off gas may be utilized for the production of electrical power, in an expanding/combustion process such as in a gas turbine described herein, or recycled to the process.
  • the energy generated in the process may be used for own use or for export to local customers. Part of an energy could be used for the compression of the oxygen containing gas .
  • the process as just described may be combined with all possible embodiments as described in this specification.
  • Steam generated by any start-up gas turbine and/or steam generated in step (i) may also be used to preheat the reactor to be used in step (ii) and/or may be used to create fluidization in the case that a fluidized bed reactor or slurry bubble column is used in step (ii).
  • a Fischer- Tropsch plant there are usually several so-called steam- system. Examples are a high pressure steam system, a medium pressure steam system and a low pressure steam system.
  • a large steam system in a Fischer-Tropsch plant is the medium pressure steam system. All Fischer-Tropsch steam (generated in the syngas conversion reactors) is fed to the medium pressure system. A main use of this steam is to drive the compressors in the air separation unit. These compressors, and also other units using the medium pressure steam, are designed for use at a certain pressure. Therefore, in order to be used for the medium pressure steam system, the Fischer-Tropsch steam must have the design steam pressure. For that reason it is important that the Fischer-Tropsch reaction is done at a certain temperature.
  • the invention is especially useful for fixed bed Fischer-Tropsch reactions, more especially using cobalt catalysts.
  • the term "normally” (unless otherwise defined) relates to STP-condition (0 0 C, 1 bar).
  • a process for producing hydrocarbons from syngas prepared from natural gas in two slurry bed reactors using an iron-based catalyst was prepared.
  • the steady state temperature in the conversion reactors was set for 220 0 C, and the design of the plant was for a steady state pressure at the head of the reactors of 30 bar.
  • the initial temperature of the conversion reactors was 210 0 C, and the initial pressure was 20 bar.
  • the initial pressure for the catalytic conversion of the synthesis gas was lower than the steady state pressure.

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  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
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  • Organic Chemistry (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

Abstract

L'invention se rapporte à un procédé de mise en en oeuvre d'un processus stationnaire de production d'hydrocarbures normalement gazeux, normalement liquides et éventuellement normalement solides à partir d'un gaz de synthèse obtenu dans au moins deux réacteurs de conversion, ledit procédé consistant à (I) fournir le gaz de synthèse ; et (ii) à convertir catalytiquement le gaz de synthèse obtenu à l'étape (I) à une température d'équilibre élevée et à une pression stationnaire pour obtenir les hydrocarbures normalement gazeux, normalement liquides et éventuellement normalement solides ; le procédé consiste également à utiliser au moins un réacteur de conversion à une pression initiale pour procéder à la conversion catalytique du gaz de synthèse, ladite pression étant inférieure à la pression stationnaire.
PCT/EP2006/064275 2005-07-20 2006-07-14 Procede de mise en oeuvre d'un processus de synthese d'hydrocarbures WO2007009954A1 (fr)

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EP05254507 2005-07-20
EP05254507.6 2005-07-20

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US8344168B2 (en) 2006-06-14 2013-01-01 Generics (Uk) Limited Process for the preparation of fluticasone propionate
WO2014037201A1 (fr) * 2012-09-05 2014-03-13 Haldor Topsøe A/S Procédé pour le démarrage d'un procédé de conversion de gaz en carburant liquide
CN110494533A (zh) * 2017-02-10 2019-11-22 英国石油有限公司 费-托法的启动程序
CN113548945A (zh) * 2021-07-29 2021-10-26 中国石油天然气股份有限公司 一种催化剂低温活性利用的工艺

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US8344168B2 (en) 2006-06-14 2013-01-01 Generics (Uk) Limited Process for the preparation of fluticasone propionate
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CN110494533A (zh) * 2017-02-10 2019-11-22 英国石油有限公司 费-托法的启动程序
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JP2020507655A (ja) * 2017-02-10 2020-03-12 ビーピー ピー・エル・シー・ フィッシャー―トロプシュプロセスのための始動プロセス
US10954450B2 (en) * 2017-02-10 2021-03-23 Bp P.L.C. Start-up procedure for a Fischer-Tropsch process
CN113548945A (zh) * 2021-07-29 2021-10-26 中国石油天然气股份有限公司 一种催化剂低温活性利用的工艺

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