Gasifier fluidization

• US 10,125,330 B2
• Filed: 09/11/2015
• Issued: 11/13/2018
• Est. Priority Date: 10/26/2011
• Status: Expired due to Fees

• Current Assignee: Res Usa, Llc (Rentech, Inc.)
• Original Assignee: Res Usa, Llc (Rentech, Inc.)
• Inventors: Jiang, Weibin, McComish, Bruce E., Borum, Bryan C., Carryer, Benjamin H., Robertson, Mark K., Elrod, Eric R., Weeks, Sim, Wright, Harold A.
• Primary Examiner(s): Leung, Jennifer A
• Application Number:
  US14/851,633
• Publication Number:
  US 20160002547A1
• Time in Patent Office: 1,159 Days
• Field of Search: None
• CPC Class Codes: B01J 8/18 with fluidised particles combustion apparatus with fluidised bed in general F23C10/00; furnaces with fluidised bed F27B15/00
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/025 containing a partial oxidation step
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/0405 Purification by membrane separation
• CPC Class Codes: C01B 2203/0415 Purification by absorption in liquids
• CPC Class Codes: C01B 2203/043 Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/048 the impurity being an organic compound
• CPC Class Codes: C01B 2203/0485 the impurity being a sulfur compound
• CPC Class Codes: C01B 2203/062 Hydrocarbon production, e.g. Fischer-Tropsch process
• CPC Class Codes: C01B 2203/0877 by direct injection of fluid
• CPC Class Codes: C01B 2203/146 At least two purification steps in series
• CPC Class Codes: C10G 2/00 Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
• CPC Class Codes: C10G 2/30 from carbon monoxide with hydrogen
• CPC Class Codes: C10G 2/34 Apparatus, reactors
• CPC Class Codes: C10G 49/007 in the presence of hydrogen from a special source or of a special composition or having been purified by a special treatment
• CPC Class Codes: C10J 2200/09 Mechanical details of gasifiers not otherwise provided for, e.g. sealing means
• CPC Class Codes: C10J 2300/0909 Drying
• CPC Class Codes: C10J 2300/0916 Biomass
• CPC Class Codes: C10J 2300/093 : Coal
• CPC Class Codes: C10J 2300/0943 : Coke
• CPC Class Codes: C10J 2300/0969 : Carbon dioxide
• CPC Class Codes: C10J 2300/0976 : as steam
• CPC Class Codes: C10J 2300/0993 : Inert particles, e.g. as heat exchange medium in a fluidized or moving bed, heat carriers, sand
• CPC Class Codes: C10J 2300/1606 : Combustion processes
• CPC Class Codes: C10J 2300/1643 : Conversion of synthesis gas to energy
• CPC Class Codes: C10J 2300/1659 : to liquid hydrocarbons Fischer-Tropsch process C10G2/00
• CPC Class Codes: C10J 2300/1671 : with the production of electricity
• CPC Class Codes: C10J 2300/1807 : Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 2300/1815 : for carbon dioxide
• CPC Class Codes: C10J 2300/1823 : for synthesis gas
• CPC Class Codes: C10J 3/48 : Apparatus; Plants
• CPC Class Codes: C10J 3/482 : Gasifiers with stationary fluidised bed
• CPC Class Codes: C10J 3/485 : Entrained flow gasifiers
• CPC Class Codes: C10J 3/50 : Fuel charging devices
• CPC Class Codes: C10J 3/721 : Multistage gasification, e.g. plural parallel or serial gasification stages
• CPC Class Codes: C10K 1/005 : Carbon dioxide
• CPC Class Codes: C10K 1/22 : Apparatus, e.g. dry box purifiers
• CPC Class Codes: C10K 1/32 : with selectively adsorptive solids, e.g. active carbon
• CPC Class Codes: C10K 3/00 : Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
• CPC Class Codes: C10K 3/04 : reducing the carbon monoxide content , e.g. water-gas shift [WGS]

Abstract

A system for the production of synthesis gas, including a gasification apparatus configured to convert at least a portion of a gasifier feed material introduced thereto into a gasification product gas comprising synthesis gas having a molar ratio of hydrogen to carbon monoxide; at least one additional apparatus selected from the group consisting of feed preparation apparatus located upstream of the gasification apparatus, synthesis gas conditioning apparatus, and synthesis gas utilization apparatus; and at least one line fluidly connecting the at least one additional apparatus or an outlet of the gasification apparatus with the at least one vessel of the gasification apparatus, whereby a gas from the at least one additional apparatus or exiting the gasification apparatus may provide at least one non-steam component of a fluidization gas. A method of utilizing the system is also provided.

Claims

1. A system for the production of synthesis gas, the system comprising:

a gasification apparatus configured to convert at least a portion of a gasifier feed material introduced thereto into a gasification product gas comprising synthesis gas having a molar ratio of hydrogen to carbon monoxide, wherein the gasification apparatus comprises at least one vessel configured for fluidization of the contents thereof via introduction thereto of a fluidization gas comprising at least one non-steam component; and

synthesis gas utilization apparatus configured to convert at least a portion of the synthesis gas into a desired product;

wherein the desired product is selected from the group consisting of power, Fischer-Tropsch hydrocarbons, and non-Fischer-Tropsch chemicals;

wherein the synthesis gas utilization apparatus comprises Fischer-Tropsch synthesis apparatus configured to convert at least a portion of the gasification product gas into Fischer-Tropsch hydrocarbons, thus producing a Fischer-Tropsch tailgas, wherein at least one recycle line fluidly connects the Fischer-Tropsch synthesis apparatus with the gasification apparatus, whereby at least a portion of the Fischer-Tropsch tailgas can be utilized as fluidization gas; and

wherein a Fischer-Tropsch wastewater comprising oxygenated components is also produced via the Fischer-Tropsch synthesis apparatus, and wherein the system further comprises a stripper configured to contact at least a portion of the Fischer-Tropsch wastewater with at least a portion of the Fischer-Tropsch tailgas, whereby oxygenates are stripped from the Fischer-Tropsch wastewater by the Fischer-Tropsch tailgas, thus producing an oxygenate-reduced Fischer-Tropsch wastewater and an oxygenate-enriched Fischer-Tropsch tailgas, and wherein the at least one recycle line fluidly connects the stripper with the gasification apparatus, whereby at least a portion of the oxygenate-enriched Fischer-Tropsch tailgas can be utilized as fluidization gas; and

the system optionally comprising at least one additional apparatus selected from the group consisting of feed preparation apparatus located upstream of the gasification apparatus and configured to prepare a carbonaceous material for introduction into the gasification apparatus;

synthesis gas conditioning apparatus configured to produce a conditioned synthesis gas having a molar ratio of hydrogen to carbon monoxide that is different from the molar ratio of hydrogen to carbon monoxide in the gasification product gas, to provide a conditioned synthesis gas having a reduced amount of at least one component relative to the amount of that component in the gasification product gas, or both; and

at least one line fluidly connecting the at least one additional apparatus or an outlet of the gasification apparatus with the at least one vessel of the gasification apparatus, whereby a gas from the at least one additional apparatus or exiting the gasification apparatus may provide the at least one non-steam component of the fluidization gas.

2. The system of claim 1 wherein the at least one vessel is configured for fluidization with a fluidization gas comprising less than about 100, 90, 80, 70, 60, 50, 40, 30, 20, or 10 volume percent steam, or comprising substantially 0 volume percent steam.

3. The system of claim 1 wherein the at least one non-steam component is selected from the group consisting of flue gas, synthesis gas, LP fuel gas, Fischer-Tropsch tailgas, product upgrader tailgas, VSA tailgas, PSA tailgas, exhaust gas, CO₂-rich gas, dryer vent gas, combustion air, oxygenates, VOC'"'"'s, and combinations thereof.

4. The system of claim 1 comprising synthesis gas conditioning apparatus downstream of the gasification apparatus, and a recycle line fluidly connecting the synthesis gas conditioning apparatus with the gasification apparatus, whereby at least a portion of a gas exiting the synthesis gas conditioning apparatus may be utilized as fluidization gas.

5. The system of claim 4 wherein the synthesis gas conditioning apparatus comprises a partial oxidation reactor.

6. The system of claim 5 wherein the partial oxidation reactor is configured for operation at a temperature in the range of from about 900°

C. to about 1500°

C., from about 1000°

C. to about 1300°

C., or from about 1150°

C. to about 1250°

C.

7. The system of claim 5 further comprising air-enrichment apparatus configured to provide oxygen-enriched air or substantially pure oxygen for introduction into the partial oxidation reactor, thus producing an oxygen-reduced product gas, and a recycle line fluidly connecting the air-enrichment apparatus with the at least one vessel, whereby at least a portion of the oxygen-reduced product gas may be utilized as fluidization gas.

8. The system of claim 7 wherein the air-enrichment apparatus is selected from the group consisting of vacuum swing adsorbers and pressure swing adsorbers.

9. The system of claim 4 wherein the synthesis gas conditioning apparatus comprises a carbon-dioxide removal apparatus configured to remove a carbon dioxide-rich fuel gas from at least a portion of the gasification product gas, and a recycle line fluidly connecting the carbon-dioxide removal apparatus with the at least one vessel, whereby at least a portion of the carbon dioxide-rich fuel gas can be utilized as fluidization gas.

10. The system of claim 9 wherein the carbon dioxide removal apparatus comprises a pressure swing adsorption (PSA) unit.

11. The system of claim 1 comprising feed preparation apparatus, and a line fluidly connecting a vent gas outlet of the feed preparation apparatus with the gasification apparatus, whereby at least a portion of a vent gas exiting the feed preparation apparatus can be utilized as fluidization gas.

12. The system of claim 11 wherein the feed preparation apparatus comprises a dryer configured to reduce the moisture content of a relatively wet gasifier feed material to provide a reduced moisture feed material for introduction into the gasification apparatus by contacting the relatively wet gasifier feed material with a drying medium to provide the reduced moisture gasifier feed material and a dryer vent gas comprising volatile organic compounds (VOC'"'"'s).

13. The system of claim 12 wherein the drying medium comprises superheated steam.

14. The system of claim 1 wherein the system further comprises a steam stripper configured to contact at least a portion of the Fischer-Tropsch wastewater with steam whereby oxygenates are stripped from the Fischer-Tropsch wastewater by the steam, thus producing an oxygenate-reduced Fischer-Tropsch wastewater and an oxygenate-enriched steam, and wherein the at least one recycle line fluidly connects the steam stripper with the gasification apparatus, whereby at least a portion of the oxygenate-enriched steam can be utilized as fluidization gas.

15. The system of claim 1 wherein the system further comprises a carbon dioxide removal apparatus configured to separate a carbon dioxide-rich gas from the Fischer-Tropsch tailgas, thus providing a carbon dioxide-reduced Fischer-Tropsch tailgas, and wherein the at least one recycle line fluidly connects the carbon dioxide removal apparatus with the gasification apparatus, whereby at least a portion of the carbon dioxide-rich gas can be utilized as fluidization gas.

16. The system of claim 15 further comprising a recycle line whereby the carbon dioxide-reduced Fischer-Tropsch tailgas can be introduced into a synthesis gas conditioning apparatus upstream of the Fischer-Tropsch synthesis apparatus, a recycle line whereby the carbon dioxide-reduced Fischer-Tropsch tailgas can be introduced into the Fischer-Tropsch synthesis apparatus, or both.

17. The system of claim 15 wherein the carbon dioxide removal apparatus comprises a membrane designed for hydrogen recovery, configured to provide a low BTU carbon dioxide-enriched fuel gas.

18. The system of claim 1 further comprising product upgrading apparatus configured to convert at least a portion of the Fischer-Tropsch hydrocarbons to more desirable hydrocarbons, wherein the product upgrading apparatus is configured to produce a product upgrading tailgas, and wherein at least one recycle line fluidly connects the product upgrading apparatus with the gasification apparatus whereby at least a portion of the product upgrading tailgas can be utilized as fluidization gas.

19. The system of claim 18 comprising synthesis gas conditioning apparatus downstream of the gasification apparatus, and further comprising hydrogen recovery apparatus configured to separate hydrogen from a portion of the conditioned synthesis gas, and a line fluidly connecting the hydrogen separation apparatus with the product upgrading apparatus, whereby separated hydrogen can be utilized therein.

20. The system of claim 1 wherein the synthesis gas utilization apparatus produces a hydrocarbon containing purge gas, and wherein the synthesis gas utilization apparatus is fluidly connected with the gasification apparatus whereby at least a portion of the hydrocarbon-containing purge gas can be utilized as fluidization gas.

21. The system of claim 1 wherein the system further comprises at least one unit selected from the group consisting of pressure swing adsorbers, vacuum swing adsorbers and product upgraders, and wherein the at least one recycle line fluidly connects the at least one unit with the gasification apparatus, whereby a tailgas produced in the at least one unit can be utilized as fluidization gas.

22. The system of claim 1 wherein the gasification apparatus is a dual fluidized bed gasifier comprising a fluidized bed pyrolyzer fluidly connected with a fluidized bed combustor such that a circulation stream comprising a heat transfer material can be continuously circulated between the fluidized bed pyrolyzer, in which the temperature of the circulation stream is reduced via endothermal pyrolysis, and the fluidized bed combustor, in which the temperature of the circulation stream is increased, wherein the fluidized bed combustor is operable to increase the temperature of the circulation stream via combustion of at least char introduced thereto with the circulation stream, and wherein the gasification apparatus optionally further comprises a gasifier seal pot, a combustor seal pot, or both, and wherein the at least one vessel is selected from the pyrolyzer, the combustor, the combustor seal pot, and the gasifier seal pot.

23. The system of claim 22 wherein the combustor is configured to produce a combustor flue gas, and wherein the at least one recycle line fluidly connects the combustor with the at least one vessel whereby at least a portion of the combustor flue gas may be utilized as fluidization gas.

24. The system of claim 23 comprising feed preparation apparatus, wherein the feed preparation apparatus comprises a feed bin configured for storage of gasifier feed material, and wherein the system further comprises a recycle line configured for introducing at least a portion of the combustor flue gas into the feed bin, whereby direct contact of the at least a portion of the combustor flue gas with the gasifier feed material provides a dried gasifier feed material for introduction into the gasifier, and a feed bin vent gas, and wherein the at least one recycle line fluidly connects a dryer vent gas outlet line with the gasification apparatus whereby at least a portion of a dryer vent gas can be utilized as fluidization gas.

25. The system of claim 22 wherein the at least one vessel is selected from the group consisting of the fluidized bed pyrolyzer, the gasifier seal pot, and the combustor seal pot, and wherein the combustor is configured to increase the temperature of the circulation stream via combustion of at least char in the circulation stream by contact with hot combustion air, and wherein the at least one recycle line fluidly connects a combustion air inlet line with the at least one vessel, whereby at least a portion of the hot combustion air can be utilized as fluidization gas.