The invention describes a thermally-responsive record material substantially free of aromatic isocyanate. The record material comprises a support having provided thereon a heat-sensitive composition comprising a substantially colorless dye precursor comprising a fluoran; and a developer material selected from the group consisting of 4,4'-diaminodiphenylsulfone and 3,3'-diaminodiphenylsulfone in combination with N-[(butylamino)carbonyl]-4-methylbenzene sulfonamide, which upon being heated react with said dye precursor to develop color, and including a binder material.

A children's coloring pad may incorporate thermochromic pigments that are specially formulated to develop color and clear color by respective applications of cold and hot temperatures. The pad may be used in a similar manner as with respect to finger painting, but without the residual mess.

A security document precursor including, in order: a) at least one transparent biaxially stretched polyester foil; b) one colorless color forming layer containing at least an infrared absorber, a colorless dye-precursor and a polymeric binder; and c) a polymeric support; wherein the polymeric binder is copolymer including at least 90 wt % of a chlorinated ethylene and 1 wt % to 10 wt % of vinyl acetate both based on the total weight of the binder. Methods for making the security document precursor are also disclosed.

A method for preparing a color laser marked article comprising the steps of: a) infrared laser marking a security element including a polymeric support and a color forming layer comprising a color forming compound, an infrared dye and a polymeric binder comprising vinyl acetate and at least 85 wt % of vinyl chloride based on the total weight of the binder; and b) exposing the laser marked security element with light having a wavelength higher than 440 nm. The light exposure of step b) hinders the falsification of an issued security document without significant increase of background density.

A vinyl chloride-based resin latex which froths little when unreacted monomer remaining in the latex are recovered under heat and reduced-pressure conditions, and a thermal transfer image-receiving sheet which has satisfactory water resistance, does not yellow during storage, and gives images having excellent durability and light resistance. The invention provides a vinyl chloride-based resin latex contains a copolymer containing a vinyl chloride and an epoxy-group-containing vinyl or contains vinyl chloride, an epoxy-group-containing vinyl, and a carboxylic acid vinyl ester, wherein a content of the epoxy-group-containing vinyl is 0.1% by weight or more but less than 3% by weight, and wherein the latex contains no surfactant, and has a solid concentration of 25% by weight or more; a process for producing the latex; and a thermal transfer image-receiving sheet obtained using the latex.

Disclosed are a polysiloxane-modified polyhydroxy polyurethane resin characterized by being derived from a reaction between a 5-membered cyclic carbonate polysiloxane compound represented by the below-described formula (1) and an amine compound, and its production process; and a resin composition, thermal recording medium, imitation leather, thermoplastic polyolefin resin skin material, weather strip material, and weather strip, all of which make use of the resin. wherein A means

In an intermediate transfer medium, a substrate, protective layers having a layered structure of two or more layers, and a receiving layer are layered in this order. One layer in the protective layers having the layered structure contains, as a main component, one material or a mixture of two or more materials selected from the group consisting of polyesters having a high polymerization degree, a number-average molecular weight (Mn) of not less than 12,000 and a Tg of not less than 60° C., polycarbonates and polyester urethanes. Another layer in the protective layers having the layered structure contains one or more materials selected from the group consisting of polyvinyl alcohols, polyvinyl butyrals, polyvinyl acetals and polyvinyl pyrrolidones or includes a cationic resin, and the receiving layer contains a side chain-type aralkyl-modified silicone in an amount of 0.5-5% by weight on a base of the total weight of the receiving layer.

Disclosed is a humidity indicator which contains no heavy metal and has good visibility of a color change that occurs when the humidity is increased. The humidity indicator can be produced by applying an aqueous coating comprising a leuco dye, an acidic compound which is in a solid state at ambient temperature, a deliquescent substance and an aqueous resin emulsion onto a substrate such as a resin film, a nonwoven fabric or a paper, and heating and drying the resulting product.

The present invention relates to a thermochromic color-memory composition containing: (I) an electron donating coloring organic compound, (II) an electron accepting compound, and (III) an ester compound represented by the following formula (1) as a reaction medium which controls color reaction of the components (I) and (II): (in the formula, X represents any of a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, and a halogen atom, m represents an integer of from 1 to 3, and n represents an integer of from 1 to 20).

Hybrid topcoat formulations comprising a water soluble polymer and a water dispersible polymer provide improved adhesion to underlying surfaces. Paper products coated with these formulations, such as thermal paper, achieve high stain resistance and improved adhesion of UV cured silicone release layers.

A thermal dye image receiver element has a substrate comprising a voided compliant layer and metalized layer. Disposed on the metalized layer is an opacifying layer that includes an opacifying agent and a dye receiving layer. This thermal dye image receiver element can be a duplex element with image receiving layers on both sides of the substrate, and it can be used in association with a thermal donor element to provide a thermal image on either or opposing sides of the receiver element. The metalized layer provides increased specular reflectance under resulting thermal dye images.

A method for enabling D2T2 printing onto non-D2T2 printable substrates uses a diffusible primer material provided on a dye-sheet or ribbon. The primer comprises a polymer, a release agent and a plasticizer. The release agent and the plasticizer are diffused into the substrate, while the polymer remains on the dye-sheet or ribbon. Printing of the primer onto the PC substrate is controlled via a computer image program corresponding to a colored image. This computer image program also controls the printing of the colored image at the primed locations. Accordingly, image-wise treatment of a plastic material via the primer selectively renders the PC substrate surface D2T2 printable at the point of personalization, providing for a 100% PC full card body having the colored image.

The present invention relates to a web substrate comprising an activatable colorant and at least one deformed region. A first activated color region is produced in the web substrate upon exposure to a first external stimulus and a second activated color region is produced within the first activated color region upon exposure to a second external stimulus. The second activated color region coincides with the deformed region.

A security document precursor including, in order, at least: a) a transparent biaxially stretched polyethylene terephthalate foil; b) a colorless color forming layer containing at least an infrared absorber, a color forming component and a polymeric binder; and c) a polymeric support; wherein the colorless color forming layer contains at least one component forming a compound having a melting temperature of less than 20° C. upon laser marking the colorless color forming layer with an infrared laser. Methods for securing a security document using the security document precursor are also disclosed.

The invention provides a phenolsulfonic acid aryl ester represented by formula (1) wherein each symbol is as defined in the description. The phenolsulfonic acid aryl ester is useful as a developer to provide a thermal recording material with good color-developing sensitivity, image density when printed at a low application energy (i.e., high start-up sensitivity), and heat and plasticizer resistance. The invention also provides a thermal recording material using the developer.

The present invention provides a thermosensitive multiple recording sheet characterized in that a second base material having light transmission properties is attached to the side of a first thermosensitive recording layer of a first thermosensitive recording sheet comprising a first base material and the first thermosensitive recording layer formed on one surface of the first base material, through a temporary adhesive layer, the second base material is composed of an information disclosing portion and an information non-disclosing portion, a shielding layer is formed at the position corresponding to the information non-disclosing portion on the second base material, and an ultraviolet curable resin layer are formed as an outermost layer of the sheet.

Provided is a thermal recording material that is excellent in water resistance and prevention of print head wear, less prone to discoloration in the non-printing area, and stably producible. The thermal recording material comprises a protective layer formed by applying a coating liquid for forming the protective layer, the coating liquid being prepared by mixing an acetoacetyl-modified polyvinyl alcohol and calcium glyoxylate particles with a maximum diameter less than 500 μm and an average diameter of 125 μm or less.

To provide a thermosensitive recording material, which contains: a support; a thermosensitive recording layer provided on one surface of the support; and a back layer provided on the other surface of the support, wherein the support has a surface formed of a resin, and wherein the back layer contains a combination of a core-shell acrylic resin and an oxazoline resin, or a reaction product thereof, or both thereof.

A method of increasing the solubility and/or dispersibility of a perylene dye in a liquid medium. The method comprises binding the perylene dye to a polymer which is soluble in the liquid medium. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.

The invention describes a thermally-responsive record material substantially free of aromatic isocyanate. The record material comprises a support having provided thereon a heat-sensitive composition comprising a substantially colorless dye precursor comprising a fluoran; and a developer material selected from the group consisting of 4,4'-diaminodiphenylsulfone and 3,3'-diaminodiphenylsulfone, which upon being heated react with said dye precursor to develop color, and including a binder material. Optionally, a modifier compound is included in the heat-sensitive composition. The modifier compound can be selected from the group consisting of a fatty acid amide, preferably a saturated fatty acid amide such as an alkyl amide, a bis methylene alkyl amide, or a bis ethylene alkyl amide, or any of 1,2-diphenoxy ethane, dimethyl diphenoxy ethane, and dimethyl phthalate.

Disclosed is a thermal transfer image-receiving sheet which excels in adhesiveness to a receiving layer and solvent resistance, and a manufacturing method thereof. In the thermal transfer image-receiving sheet, which includes a porous layer, a barrier layer, a receiving layer which are stacked in this order on a substrate, the porous layer includes a binder resin and hollow particles, and the barrier layer includes (i) (A) a first acrylic resin and (B) one or more kinds of resins selected from the group consisting of polyester resins, polyvinyl pyrrolidone type resins, polyester type urethane resin, and a second acrylic resin which differs from the first acrylic resin; or (ii) a polyvinyl pyrrolidone type resin.

Methods and systems for producing a synthetic fuel are disclosed. In some embodiments, the methods and systems include the following: thermally reforming methane and carbon dioxide to generate a syngas including a first quantity of carbon monoxide and a first quantity of hydrogen; oxidizing the quantity of first carbon monoxide with a metal to produce metal oxide and carbon thereby separating oxygen from the carbon monoxide; gasifying the carbon using steam to produce a second quantity of carbon monoxide and a second quantity of hydrogen; reacting the metal oxide with methane to produce metal oxide, carbon dioxide, and a third quantity of hydrogen; and synthesizing the first quantity of carbon monoxide, the first quantity of hydrogen, the second quantity of hydrogen, and the third quantity of hydrogen to form the synthetic fuel.

A process for the production of methane comprising reacting at least part of a feed gas containing carbon monoxide and hydrogen in an internally cooled methanation reactor containing a nickel comprising methanation catalyst to produce a product gas containing methane, cooling the internally cooled methanation reactor with water, wherein the water enters the internally cooled methanation reactor at a temperature in the range from 20-120° C. below its boiling temperature.

The invention discloses an improved multistage fischer tropsch process scheme for the production of hydrocarbon fuels comprising feeding gaseous phase syngas and liquid stream hydrocarbons in a counter current manner such as herein described into the reaction vessel at a number of stages containing reaction catalysts; wherein fresh syngas enters into the stage where the product liquid stream leaves and the fresh liquid stream enters into the stage where the unreacted syngas leaves; wherein further the temperature of each stage can be controlled independently. More particularly the invention relates to improving the heat release in different reactors, product selectivity and reactor productivity of FT reactors.

A method for producing ethanol by which ethanol can be synthesized from less fermentable biomass materials such as plant-derived materials and rice straws and industrial waste biomass materials such as wooden building materials and pulp and which can therefore broaden the range of raw materials for the production of ethanol. Specifically, a method for producing ethanol including reacting a raw material gas obtained by a thermochemical gasification reaction of biomass in the presence of a catalyst containing rhodium, at least one transition metal, and at least one element selected from lithium, magnesium and zinc.

The invention relates to a so-called zero emission ‘AST-CNR/ITM system’ modular plant for removal of pollutants from flue gases produced by industrial processes. The plant comprises prefabricated modular elements with programmed and automatic operation, easy to mount and assemble on site without undergoing expensive plant stoppage. Each module or ‘reaction tower’ comprises a plurality of sections vertically arranged on top of one another, which carry out the following functions: Removal of particulate matter with treatment and removal of chemical pollutants, such as heavy metals, chlorides, fluorides Treatment and removal of SOx Treatment and removal of NOx Capture of CO2 Production of hydrogen Production of methanol. The various sections may be combined according to the requirements of the plant and of the flue gases to be treated.

The present invention relates to a novel process for the production of methanol. The process comprises the heterolytic cleavage of hydrogen by a frustrated Lewis pair comprising a Lewis acid and a Lewis base; and the hydrogenation of CO2 with the heterolytically cleaved hydrogen to form methanol.

A system and method for reducing the CO2 in a gaseous stream between 33% up to and even in excess of 90%, by reducing CO2. A gaseous stream that includes substantial amounts of CO2 is provided to a reaction chamber along with H2O (steam) and a carbon source such as charcoal, coke or other carbonaceous material. Carbon is provided to the chamber at a ratio (C/CO2) of between about 0.100 to 0.850, and between about 0.200 to 0.900 of H2O to the provided CO2. The CO2, H2O and carbon are heated to between about 1500° F. and about 3000° F. at about one atmosphere to produce syngas (i.e. carbon monoxide (CO) and hydrogen (H2)) and reduces the amount of CO2. The Syngas may then be cleaned and provided to a Fischer-Tropsch synthesis reactor or a Bio-catalytic synthesis reactor to produce a fuel, such as Methanol, Ethanol, Diesel and Jet Fuel.

A method is described for optimizing the operation of a reaction section for the synthesis of hydrocarbons from a feed comprising synthesis gas, operated in the presence of a catalyst comprising cobalt, said method comprising the following steps: a) determining the theoretical partial pressure of CO in the reaction section;b) optionally, adjusting the partial pressure of CO determined in step a) to a value of 4 bar or higher;c) determining a new value for the theoretical partial pressure of CO in the reaction section.

A biomass gasification gas purification system includes a dust collector for removing dust in biomass gasification gas (containing tar components) acquired by gasifying biomass by a biomass gasification furnace, a desulfurizer for removing sulfur oxide components in the dust-removed biomass gasification gas, a pre-reforming reactor for reforming tar components in the desulfurized biomass gasification gas, a steam feed unit for feeding steam to an upstream side of the pre-reforming reactor, and a natural-gas feed unit for feeding natural gas on an upstream side of the desulfurizer.

The invention relates to a process for increasing the carbon monoxide content of a feed gas mixture comprising carbon dioxide, hydrogen and carbon monoxide via a catalytic reversed water gas shift reaction, comprising the steps of (1) heating the feed gas mixture having an initial feed temperature of at most 350° C. in a first zone to a temperature within a reaction temperature range in the presence of a first catalyst; and (2) contacting the heated feed gas in a second zone within the reaction temperature range with a second catalyst. This process shows relatively high conversion of carbon dioxide, and virtually no methane or coke is being formed, allowing stable operation.

A method for producing a gas comprising at least 80 vol % carbon monoxide from a Fischer-Tropsch off-gas comprises: (1) feeding Fischer-Tropsch off-gas through a column comprising an adsorbent bed at high pressure and discharging effluent; (2) reducing the pressure in the column and the bed slightly; (3) rinsing the column and the adsorbent bed with methane or a mixture of methane and carbon dioxide; (4) reducing the pressure of the column and adsorbent bed to a low pressure; (5) rinsing the column and adsorbent bed with a mixture of hydrogen and nitrogen; (6) pressurizing the column and adsorbent bed to a high pressure using a mixture of hydrogen and nitrogen. The product stream obtained in step (3) comprising at least 80 vol % carbon monoxide can be sent as feed to a Fischer-Tropsch reaction. In an embodiment, a gas comprising at least 80 vol % hydrogen is also produced.

A methanol synthesis process includes reacting a process gas containing hydrogen, carbon dioxide and carbon monoxide over a catalyst including shaped units formed from a reduced and passivated catalyst powder the powder including copper in the range 10-80% by weight, zinc oxide in the range 20-90% by weight, alumina in the range 5-60% by weight and optionally one or more oxidic promoter compounds selected from compounds of Mg, Cr, Mn, V, Ti, Zr, Ta, Mo, W, Si and rare earths in the range 0.01-10% by weight, to form a product gas, and condensing methanol, water and oxygenate by-products therefrom, wherein the total oxygenate by-product level in the condensate is below 500 ppm.

The invention relates to a catalyst and process for making syngas mixtures including hydrogen, carbon monoxide and carbon dioxide. The process comprises contacting a gaseous feed mixture containing carbon dioxide and hydrogen with the catalyst, where the catalyst comprises Mn oxide and an auxiliary metal oxide selected from the group consisting of La, Ca, K, W, Cu, Al and mixtures or combinations thereof. The process enables hydrogenation of carbon dioxide into carbon monoxide with high selectivity, and good catalyst stability over time and under variations in processing conditions. The process can be applied separately, but can also be integrated with other processes, both up-stream and/or down-stream including methane reforming or other synthesis processes for making products like alkanes, aldehydes, or alcohols.

Iron/carbon (Fe/C) nanocomposite catalysts are prepared for Fischer-Tropsch synthesis reaction. A preparation method includes steps of mixing iron hydrate salts and a mesoporous carbon support to form a mixture, infiltrating the iron hydrate salts into the carbon support through melt infiltration of the mixture near a melting point of the iron hydrate salts, forming iron-carbide particles infiltrated into the carbon support through calcination of the iron hydrate salts infiltrated into the carbon support under a first atmosphere, and vacuum-drying the iron-carbide particles after passivation using ethanol. Using such catalysts, liquid hydrocarbons are produced.

A fuel processing system for converting a logistical fuel and air into a liquid product comprising methanol. One such system comprises a fuel injection system configured to combine a logistical fuel and ambient air to produce a logistical fuel and air mixture, a synthesis gas production system configured to convert the logistical fuel and air mixture to synthesis gas, and a methanol synthesis system configured to convert the synthesis gas to a crude methanol liquid. Related methods are additionally disclosed.

A gasification-liquefaction disposal method, system and equipment for MSW are disclosed. The method involves the MSW pretreatment of dehydrating and separating, thus reducing water and inorganic substance content of the waste. Then, the MSW is introduced into a plasma gasifier (23) by a carbon dioxide air-sealed feeding device (13) and gasified therein to obtain hydrogen-rich syngas. The hydrogen-rich syngas is then cooled, deacidified, dedusted and separated to obtain carbon dioxide. Then, the hydrogen-rich syngas is catalyzed to produce methanol product in a methanol synthesis reactor (52). The separated carbon dioxide is sent back to a carbonation reaction chamber (2007) of a gasification system to perform carbonation reaction with calcium oxide, thereby releasing heat to provide assistant heat energy for gasification and avoiding greenhouse gas from being discharged into environment. Exhaust gas is returned to the plasma gasifier (23) for remelting treatment, thus forming a closed-loop circulation production system and realizing the disposal of the MSW with zero discharge and no pollution, thereby avoiding dioxin pollution and converting the MSW to chemical raw materials and fuel needed by mankind. The method, system and equipment are suitable for harmless and recycling disposal of MSW, industrial high polymer waste, composting waste and waste in waste sorting sites.

There is provided a method for upgrading hydrocarbon compounds, in which hydrocarbon compounds synthesized in a Fisher-Tropsch synthesis reaction are fractionally distillated, and the fractionally distillated hydrocarbon compounds are hydrotreated to produce liquid fuel products. The method includes fractionally distilling heavy hydrocarbon compounds synthesized in the Fisher-Tropsch synthesis reaction as a liquid into a first middle distillate and a wax fraction, and fractionally distilling light hydrocarbon compounds synthesized in the Fisher-Tropsch synthesis reaction as a gas into a second middle distillate and a light gas fraction.

In a synthesis gas methanation process, at least one first fraction of synthesis gas to treat is fed, together with steam, to a shift reactor where a shift reaction occurs; the gas flow produced in the shift reactor is then fed to a first methanation reactor where a methanation reaction occurs and then to further second methanation reactors in series, where further methanation reactions, performed with the addition of fresh synthesis gas which has not been subjected to the shift reaction.

A process for sulfiding a cobalt-molybdenum bulk catalyst precursor to form a bulk sulfided alcohol synthesis catalyst. The process steps include contacting an oxidic bulk cobalt-molybdenum catalyst precursor with an amount of a sulfur-containing compound which is in the range of about 1 to about 10 moles of sulfur per mole of metals, at one or more temperatures at or in excess of about 300° C. in a medium which is substantially devoid of added hydrogen, so as to form a sulfided bulk cobalt-molybdenum catalyst product. Also described are processes for forming the catalyst precursor, processes for producing an alcohol using the catalyst product and the catalyst product itself.

The invention provides for a method of forming methanol by combining a mixture of methane, water and carbon dioxide under reaction conditions sufficient to form a mixture of hydrogen and carbon monoxide. Hydrogen and carbon monoxide are reacted under conditions sufficient to form methanol. The molar ratio of hydrogen to carbon monoxide is at least two moles of hydrogen to one mole of carbon monoxide and the overall molar ratio between methane, water and carbon dioxide is about 3:2:1. Methane, carbon dioxide and water are bi-reformed over a catalyst. The catalyst includes a single metal, a metal oxide, a mixed catalyst of a metal and a metal oxide or a mixed catalyst of at least two metal oxides.

A process for improving the hydrogen content of a synthesis gas stream to a synthesis loop, comprising the steps of: (a) removing a purge stream comprising hydrogen and hydrocarbons from a synthesis loop; (b) separating hydrogen from the purge stream; (c) passing the purge stream to a reformer and reacting with steam and oxygen to produce a stream comprising hydrogen and carbon monoxide; (d) subjecting the reformed reaction product stream to a shift reaction to produce a stream comprising carbon dioxide and hydrogen; (e) subjecting the product stream from the shift reaction to separation to separate hydrogen from carbon dioxide; (f) supplying the separated hydrogen to the synthesis loop; and (g) removing the carbon dioxide.

The present invention provides a process for producing a hydrocarbon oil by performing a Fischer-Tropsch synthesis reaction using a reactor for a Fischer-Tropsch synthesis including a reaction apparatus having a slurry containing catalyst particles and a gaseous phase located above the slurry to obtain a hydrocarbon oil, wherein the Fischer-Tropsch reaction is performed while controlling a temperature of the slurry so that a difference T2−T1 between the average temperature T1 of the slurry and a temperature T2 at the liquid level of the slurry in contact with the gaseous phase is 5 to 30° C.

Catalyst compositions comprising molybdenum, sulfur and an alkali metal ion supported on a nanofibrous, mesoporous carbon molecular sieve are useful for converting syngas to higher alcohols. The compositions are produced via impregnation and may enhance selectivity to ethanol in particular.

A method for producing synthetic hydrocarbons from at least one carbonaceous material is provided. The method includes evaluating the resources of the carbonaceous material available on a determined territory; determining from the resources a total production capacity of synthetic hydrocarbons; determining from the total production capacity, a number of elementary production units required for obtaining the total production capacity, each elementary production unit having an elementary production capacity between a 100 and a 1,000 barrels a day of synthetic hydrocarbons; building the number of elementary production units on the territory; transporting the carbonaceous material from the territory as far as the elementary production units; producing the synthetic hydrocarbons in the elementary production units from the transported carbonaceous material.

A method and an apparatus is disclosed that uses a gas lift tubing arrangement to produce synthetic hydrocarbon related products. Using the Fischer Tropsch process as an example, the tubing is packed with a suitable catalyst and then hydrogen and carbon monoxide are injected into the top of the tubing in a fashion similar to a gas lift process. As the gases travel past the catalyst, synthetic hydrocarbons are formed and heat is rejected. The synthetic hydrocarbons and water flow out of the bottom of the tubing and travel up the annulus to the surface. In some embodiments, this process is carried out in a producing well or a in producing riser. In a producing well or a producing riser, the production from the well which flows up the annulus cools the synthetic hydrocarbon derived products. In additional and alternate embodiments, this process can be used in non-flowing wells.

A method and an apparatus is disclosed that uses a gas lift tubing arrangement to produce synthetic hydrocarbon related products. Using the Fischer Tropsch process as an example, the tubing is packed with a suitable catalyst and then hydrogen and carbon monoxide are injected into the top of the tubing in a fashion similar to a gas lift process. As the gases travel past the catalyst, synthetic hydrocarbons are formed and heat is rejected. The synthetic hydrocarbons and water flow out of the bottom of the tubing and travel up the annulus to the surface. In some embodiments, this process is carried out in a producing well or a in producing riser. In a producing well or a producing riser, the production from the well which flows up the annulus cools the synthetic hydrocarbon derived products. In additional and alternate embodiments, this process can be used in non-flowing wells.

Systems and methods for producing a synthetic natural gas are provided. A syngas can be separated into a first syngas, a second syngas, and a third syngas. The first syngas can be methanated to produce a first effluent. The first effluent can be mixed with the second syngas to produce a first mixed effluent. The first mixed effluent can be methanated to produce a second effluent. The second mixed effluent can be methanated to produce a third effluent. The third effluent can be cooled to produce a first cooled effluent. The first cooled effluent can be cooled to produce a synthetic natural gas.

The present invention relates generally to processes for hydromethanating a carbonaceous feedstock in a hydromethanation reactor to a methane product stream and a char by-product, and more specifically to removal of the char by-product from the hydromethanation reactor.

Disclosed is a process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising: flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst; transferring heat from the process microchannels to a heat exchanger; and removing the product from the microchannel reactor; the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour; the selectivity to methane in the product being less than about 25%. Also disclosed is a supported catalyst comprising Co, and a microchannel reactor comprising at least one process microchannel and at least one adjacent heat exchange zone.