Our extensive portfolio of patents, issued by various national jurisdictions, provides strong protection for the ZF technologies described elsewhere on this site. Numerous applications for additional patents are pending. U.S. and international patents include the following:
REACTOR WITH JET IMPINGEMENT HEAT TRANSFER – US Patents 8,976,783 and 8,257,658
The reactor geometry that uniquely creates the flow pattern providing 2.0-2.5 times the heat transfer coefficient of packed beds at the same pressure drop
Benefits
- 20-40% higher space velocity (throughput)
- Higher outlet temperature – increased feedstock conversion, lower initial CO2/CO
- Eliminates tube hotspot upstream of the outlet (without side wall or terraced wall firing)
- Improved temperature and compositional uniformity to permit reforming at <2.0 S/C without coking
STRUCTURED PACKING FOR A RECTOR – US Patent 8,235,361
Embodiment of the reactor geometry providing the above ideal flow pattern with good durability and manufacturability
Benefits
- Excellent durability (almost stress free)
- Inexpensive, high-speed manufacturability
REACTOR PACKING – US Patents 8,932,536 and 9,403,147
The features necessary for a structured packing to maintain contact with the tube wall as the tube diameter creeps
Benefits
- Consistent heat transfer and pressure drop throughout 10-year tube life
- Lower bypass or “wall effect” than large particles in a small diameter tube
ENGINEERED PACKING FOR HEAT EXCHANGE AND SYSTEMS AND METHODS CONSTRUCTING THE SAME – US Patent 9,677,828
Alternative method of fabricating a structured packing reactor
Benefits
- Potentially less expensive manufacturing method
STEAM METHANE REFORMING SYSTEM – US Patent 9,592,487
Apparatus of bayonet steam reforming reactors in multiple radiant zones combined with a single convective zone for heat recovery
Benefits
- Independent scheduling of down time for multiple radiant zone furnaces with a single common convective zone
- Feasibility and economy-of-scale for larger steam methane reforming units
- Standardized heat recovery sections
BAYONET CATALYTIC REACTOR
Reactor structure necessary for effective heat recovery for bayonet reactors using structured packings
Benefits
- Increased heat recovery
- Reduced firing rate and GHG emissions
- Reduced steam export
- Reduced CAPEX for process gas boiler and mixed feed preheat
SUPPORT STRUCTURE FOR STRUCTURED CATALYST PACKINGS – US 2021/0220798
Improved catalytic reactor design
Benefits
- Elimination of welding for less expensive reactor fabrication
- Simplified adjustment of reactor to fit tubes of different diameters without retooling
- Enable adjustment of application-specific pressure drop and heat transfer coefficient
Patents pending
AMMONIA PRODUCTION METHOD – US 62/965,637
Steam reforming in bayonet reactors and/or with recuperative burners to eliminate steam export
Benefits
- More energy efficient drivers for compressors than low temperature steam turbines
METHANOL PRODUCTION METHOD – US 2020/62965637
Steam reforming in bayonet reactors and/or with recuperative burners to eliminate steam export
Benefits
- Freedom to use more energy efficient drivers for compressors than low temperature steam turbines
HIGH PRESSURE AND TEMPERATURE STEAM REFORMING REACTOR – US 63/068,170
Redesign of bayonet catalytic reactors with structured packings for steam reforming
Benefits
- Steam reforming at up to 65 bar above 900o C
- Reduced product compression costs
STEAM REFORMING WITH CARBON CAPTURE – US 63/066,467
Recirculation of PSA tail gas to reformer feed for carbon capture from syngas. Use of hydrogen product and hydrogen and inerts separated from tail gas for fuel.
Benefits
- Inexpensive pre-combustion carbon capture
- Approximately 99.7% avoidance of CO2 emissions (if compressor driven by green electricity)
- Up to 5% lower CO2 avoidance using grid electricity, depending on the grid’s footprint
GREEN METHANOL PRODUCTION – US 63/113,844
Adjust ratio of H2/CO in the syngas to 2.2 by passing excess hydrogen through a membrane for use as fuel. Inerts are purged from synthesis tail gas as fuel with optional carbon separation to the feedstock with little or no carbon entering the combustion system
Benefits
- Carbon conversion to product approaches 100%
- Carbon capture and sequestration not necessary
- Avoid air separation unit
AMMONIA PRODUCTION METHOD WITH CARBON CAPTURE – US 63/226,857
Recirculation of PSA tail gas to reformer feed for carbon capture from syngas. Use of hydrogen product and hydrogen and inerts separated from tail gas for fuel. Use of flue gas as the nitrogen feed to the synthesis reactor.
Benefits
- Very high avoidance of CO2 emissions by inexpensive pre-combustion carbon capture
- Avoidance of air separation unit, nitrogen plant, and secondary reformer
GAS-TO-LIQUIDS PROCESS – 63/229,373
Adjust ratio of H2/CO in the syngas to 2.0 by passing excess hydrogen through a membrane for hydro-finishing and use as fuel. Inerts are purged from Fischer-Tropsch tail gas as fuel with optional carbon separation to the feedstock with little or no carbon entering the combustion system.
Benefits
- Carbon conversion to product approaches 100%
- Carbon capture and sequestration not necessary
- Avoid air separation unit