Method and system for producing synthesis gas, gasification reactor, and gasification system

• US 20060260191A1
• Filed: 05/02/2006
• Published: 11/23/2006
• Est. Priority Date: 05/02/2005
• Status: Active Grant

• Current Assignee: Air Products and Chemicals Incorporated (Linde Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Van Der Ploeg, Henrik Jan, Von Kossak-Glowczewski, Thomas Paul, Van Den Berg, Robert Erwin, Van Dongen, Franciscus Gerardus, Zuideveld, Pieter Lammert
• Granted Patent: US 8,685,119 B2
• Time in Patent Office: Days
• US Class Current: 48/197.R
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/0956 Air or oxygen enriched air
• CPC Class Codes: C10J 2300/0959 Oxygen
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 3/466 Entrained flow processes
• CPC Class Codes: C10J 3/84 with means for removing dust or tar from the gas
• CPC Class Codes: C10J 3/845 Quench rings
• CPC Class Codes: C10K 1/101 with water only
• CPC Class Codes: F28C 3/06 the heat-exchange media being a liquid and a gas or vapour temperators for cooling steam F22

Abstract

A method and system for producing synthesis gas comprising CO, CO₂, and H₂ from a carbonaceous stream using an oxygen containing stream. A stream containing a carbonaceous material, and a stream containing oxygen are injected into a gasification reactor, where the carbonaceous stream is partially oxidised to obtain a raw synthesis gas. The raw synthesis gas is removed from the gasification reactor and directed into a quenching section wherein a liquid, preferably water, is injected in the form of a mist.

Claims

1. A method of producing synthesis gas comprising CO, CO₂, and H₂ from a carbonaceous stream using an oxygen containing stream, the method comprising the steps of:

(a) injecting a carbonaceous stream and an oxygen containing stream into a gasification reactor;

(b) at least partially oxidising the carbonaceous stream in the gasification reactor, thereby obtaining a raw synthesis gas;

(c) removing the raw synthesis gas obtained in step (b) from the gasification reactor into a quenching section; and

(d) injecting a liquid into the quenching section in the form of a mist.

2. The method of claim 1, wherein the liquid injected in step (d) is water.

3. The method of claim 1, wherein the injected liquid has a temperature of above about 150°

C.

4. The method of claim 1, wherein the injected liquid has a temperature within a range from about 200°

C. to about 230°

C.

5. The method of claim 1, wherein the raw synthesis gas is in the quenching section at a pressure, and wherein the injected liquid has a temperature of at most 50°

C. below a bubble point of the liquid at the pressure of the raw synthesis gas.

6. The method according to claim 1, wherein the mist comprises droplets having a diameter within a range from about μ

m 50 to about 200°

μ

m.

7. The method of claim 1, wherein the mist is injected with a velocity within a range from about 30 m/s to about 100 m/s.

8. The method of claim 1, wherein the mist is injected with a velocity within a range from about 40 m/s to about 60 m/s.

9. The method of claim 1, wherein the raw synthesis gas is in the quenching section at a pressure, and wherein the mist is injected with an injection pressure within a range from about 20 bar to about 60 bar above the pressure of the raw synthesis gas.

10. The method of claim 1, wherein the mist is injected in an amount that is selected such that the raw synthesis gas leaving the quenching section comprises at least about 40 vol. % H₂O.

11. The method of claim 1, wherein the mist is injected in an amount that is selected such that the raw synthesis gas leaving the quenching section comprises at least about 45 vol. % H₂O.

12. The method of claim 10, wherein the raw synthesis gas leaving the quenching section comprises up to about 60 vol. % H₂O.

13. The method of claim 11, wherein the raw synthesis gas leaving the quenching section comprises up to about 60 vol. % H₂O.

14. The method of claim 10, wherein the raw synthesis gas leaving the quenching section comprises up to about 55 vol. % H₂O.

15. The method of claim 11, wherein the raw synthesis gas leaving the quenching section comprises up to about 55 vol. % H₂O.

16. The method of claim 1, wherein the mist is injected in a direction away from the gasification reactor.

17. The method of claim 16, wherein the quenching section extends about a longitudinal axis, and wherein the mist is injected under an angle within a range from about 30°

to about 60°

with respect to a plane perpendicular to the longitudinal axis of the quenching section.

18. The method of claim 1, wherein the injected mist is at least partially surrounded by a shielding fluid.

19. The method of claim 18, wherein the shielding fluid is selected from a group consisting of an inert gas including one or more of N₂ and CO₂, synthesis gas, steam and a combination thereof.

20. The method of claim 1, wherein the raw synthesis gas is first cooled to a temperature below a solidification temperature of the non-gaseous components in the raw synthesis gas by injecting a fluid having a reduced temperature into the raw synthesis gas before performing step (d).

21. The method of claim 20, wherein the fluid comprises liquid water in the form of a mist.

22. The method of claim 1, wherein an upwardly moving flow of raw synthesis gas is first cooled to a temperature below the solidification temperature of the non-gaseous components by injecting a fluid having a reduced temperature into the flow of raw synthesis gas upstream of performing step (d), wherein the flow is subsequently deflected at a more elevated position relative to said injection to a downwardly moving flow of synthesis gas and wherein the injection of the liquid in step (d) is performed into the downwardly moving flow of synthesis gas.

23. The method of claim 22, wherein the fluid comprises liquid water in the form of a mist.

24. The method according to claim 1, further comprising a step of shift converting of the raw synthesis gas leaving the quenching section, whereby at least a part of any water present is reacted with CO to produce CO₂ and H₂ thereby obtaining a shift converted synthesis gas stream.

25. The method of claim 24, wherein before shift converting the raw synthesis gas, the raw synthesis gas is heated in a heat exchanger against the shift converted synthesis gas stream.

26. The method of claim 24, wherein the mist is heated before injecting it in step (d) by indirect heat exchange against the shift converted synthesis gas stream.

27. The method of claim 21, performed in a gasification reactor comprising:

a pressure shell for maintaining a pressure higher than atmospheric pressure;

a slag bath located in a lower part of the pressure shell;

a quenching section comprising a tubular formed part positioned within the pressure shell, open at its lower end and its upper end and having a smaller diameter than the pressure shell thereby defining an annular space around the tubular part; and

a gasifier wall arranged inside the pressure shell defining a gasification chamber wherein during operation a synthesis gas comprising Co, CO₂, and H₂ from a carbonaceous stream can be formed using an oxygen containing stream, a lower open part of the gasifier wall being in fluid communication with the slag bath and an open upper end of the gasifier wall being in fluid communication with the quench zone;

wherein;

the lower open end of the quenching section is fluidly connected to the upper end of the gasifier wall and the open upper end of the gasifier wall is in fluid communication with the annular space;

an injector is present at the lower end of the tubular part for injecting a fluid cooling medium;

an injector is present in the annular space to inject a liquid in the form of a mist; and

an outlet for the synthesis gas is present in the wall of the pressure shell fluidly connected to said annular space.

28. The method of claim 21, performed in a gasification system comprising a gasification reactor and a quench vessel wherein the gasification reactor comprises:

a pressure shell for maintaining a pressure higher than atmospheric pressure;

a slag bath located in a lower part of the pressure shell;

a quench vessel comprising a quenching section;

a gasifier wall arranged inside the pressure shell defining a gasification chamber wherein during operation a synthesis gas comprising CO, CO₂, and H₂ from a carbonaceous stream can be formed using an oxygen containing stream, a lower open part of the gasifier wall being in fluid communication with the slag bath and an open upper end of the gasifier wall being in fluid communication with a vertically extending tubular part, which tubular part is open at its lower end and its upper end, the upper end being in fluid communication with a synthesis gas inlet of the quench vessel and wherein the tubular part is provided an injector to add a fluid cooling medium at its lower end;

wherein;

the quench vessel is provided at its top end with a synthesis gas inlet, with an injector to inject a liquid in the form of a mist into the synthesis gas and with an outlet for the synthesis gas.

29. A gasification reactor comprising:

a pressure shell for maintaining a pressure higher than atmospheric pressure;

a slag bath located in a lower part of the pressure shell;

a quench zone comprising a tubular formed part positioned within the pressure shell, open at its lower end and its upper end and having a smaller diameter than the pressure shell thereby defining an annular space around the tubular part; and

a gasifier wall arranged inside the pressure shell defining a gasification chamber wherein during operation a synthesis gas comprising CO, CO₂, and H₂ from a carbonaceous stream can be formed using an oxygen containing stream, a lower open part of the gasifier wall being in fluid communication with the slag bath and an open upper end of the gasifier wall being in fluid communication with the quench zone;

wherein;

the lower open end of the quench zone is fluidly connected to the upper end of the gasifier wall and the open upper end of the gasifier wall is in fluid communication with the annular space;

an injector is present at the lower end of the tubular part for injecting a fluid cooling medium;

an injector is present in the annular space to inject a liquid in the form of a mist; and

an outlet for the synthesis gas is present in the wall of the pressure shell fluidly connected to said annular space.

30. A gasification system comprising a gasification reactor and a quench vessel wherein the gasification reactor comprises:

a pressure shell for maintaining a pressure higher than atmospheric pressure;

a slag bath located in a lower part of the pressure shell;

a quench vessel;

a gasifier wall arranged inside the pressure shell defining a gasification chamber wherein during operation a synthesis gas comprising Co, CO₂, and H₂ from a carbonaceous stream can be formed using an oxygen containing stream, a lower open part of the gasifier wall being in fluid communication with the slag bath and an open upper end of the gasifier wall being in fluid communication with a vertically extending tubular part, which tubular part is open at its lower end and its upper end, the upper end being in fluid communication with a synthesis gas inlet of the quench vessel and wherein the tubular part is provided with an injector to add a fluid cooling medium at its lower end;

wherein;

the quench vessel is provided at its top end with a synthesis gas inlet, with an injector to inject a liquid in the form of a mist into the synthesis gas and with an outlet for the synthesis gas.

31. A system for producing a synthesis gas comprising Co, CO₂, and H₂, the system comprising:

a gasification reactor having an inlet for an oxygen containing stream, an inlet for a carbonaceous material containing stream, and, an outlet for raw synthesis gas produced in the gasification reactor;

a quenching section connected to the outlet of the gasification reactor for the raw synthesis gas;

wherein the quenching section comprises at least one first injector adapted for injecting a liquid in the quenching section in the form of a mist.

32. The system of claim 31, wherein the liquid comprises water.

33. The system of claim 31, wherein the first injector during operation injects the mist in a direction away from the gasification reactor.

34. The system of claim 31, wherein the quenching section comprises a second injector adapted for injecting a shielding fluid at least partially surrounding the mist injected by the at least one first injector.