Systems and methods for integration of gasification and reforming processes

• US 20070289214A1
• Filed: 06/19/2006
• Published: 12/20/2007
• Est. Priority Date: 06/19/2006
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Power Generation, Inc.
• Inventors: Gutierrez, Juan P., Briesch, Michael S.
• Granted Patent: US 8,152,874 B2
• Time in Patent Office: Days
• US Class Current: 48/61
• CPC Class Codes: B01J 2208/00212 Plates; Jackets; Cylinders
• CPC Class Codes: B01J 2208/00309 with two or more reactions in heat exchange with each other, such as an endothermic reaction in heat exchange with an exothermic reaction
• CPC Class Codes: B01J 2219/00006 Large-scale industrial plants
• CPC Class Codes: B01J 8/067 Heating or cooling the reactor B01J8/062 takes precedence
• CPC Class Codes: C01B 2203/06 Integration with other chemical processes
• CPC Class Codes: C01B 2203/0838 by heat exchange with exothermic reactions, other than by combustion of fuel
• CPC Class Codes: C01B 2203/0894 Generation of steam
• CPC Class Codes: C01B 2203/1058 Nickel catalysts
• CPC Class Codes: C01B 2203/1223 Methanol
• CPC Class Codes: C01B 2203/1229 Ethanol
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 3/323 Catalytic reaction of gaseous or liquid organic compounds other than hydrocarbons with gasifying agents
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: C10J 2300/165 integrated with a gas turbine or gas motor gas turbine plants provided with a gas producer F02C3/28; engines using solid fuels F02B43/08
• CPC Class Codes: C10J 2300/1675 making use of a steam turbine
• CPC Class Codes: C10J 2300/1687 with steam generation
• CPC Class Codes: C10J 3/463 in stationary fluidised beds
• CPC Class Codes: C10J 3/466 Entrained flow processes
• 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: F01K 23/067 the combustion heat coming from a gasification or pyrolysis process, e.g. coal gasification gas turbines with fuel gasifiers F02C3/28
• CPC Class Codes: Y02E 20/16 : Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 20/18 : Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]

Abstract

A system and method for producing multiple syngas products. In one embodiment (FIG. 5) a syngas producing system (200) includes a gasifier (210) and a hydrocarbon steam reformer (226). The gasifier (210) is configured to react a solid or liquid carbonaceous material (212) and provide a first syngas product (222). The reformer (226) is coupled to receive sensible heat from the first syngas product (222) and drive an endothermic reaction in which a second syngas product (238) is produced from a liquid or gaseous hydrocarbon supply (150). In a method of processing fuel, a solid or liquid carbonaceous material (212) is provided to a gasifier (210) in the form of a slurry, which is converted into a first syngas product (222) in an exothermic reaction. A liquid or gaseous hydrocarbon supply (150) receives sufficient sensible heat generated during the exothermic reaction to convert the liquid or gaseous hydrocarbon supply (150) into a second syngas product (238).

Claims

1. A syngas producing system, comprising:

a gasifier configured to react a solid or liquid carbonaceous material received at an input thereof and provide a first syngas product through an output port thereof; and

a hydrocarbon steam reformer coupled to receive sensible heat from the first syngas product and drive an endothermic reaction in which a second syngas product is produced from a liquid or gaseous hydrocarbon supply.

2. The system of claim 1 wherein the gasifier is of the type which converts coal to syngas.

3. The system of claim 1 wherein the reformer is of the type which converts natural gas to syngas.

4. The system of claim 1 wherein the reformer is of the type which converts methanol or ethanol to syngas.

5. The system of claim 1 wherein the steam reformer comprises a heat exchanging reactor which transfers the sensible heat to the liquid or gaseous hydrocarbon supply.

6. The system of claim 4 wherein the reactor mixes the first syngas product with the liquid or gaseous hydrocarbon supply so that the first syngas product and the second syngas product are mixed together.

7. A method of processing fuel comprising:

providing a solid or liquid carbonaceous material in the form of a slurry to a gasifier;

converting the slurry into a first syngas product in an exothermic reaction; and

providing a liquid or gaseous hydrocarbon supply with sufficient sensible heat generated during the exothermic reaction to convert said liquid or gaseous hydrocarbon supply into a second syngas product.

8. The method of claim 7 wherein the step of providing sensible heat is accomplished with a heat exchanger comprising a chamber for receiving the first syngas product and a flow path configured to circulate said liquid or gaseous hydrocarbon supply about the first syngas product in order to receive thermal energy therefrom.

9. The method of claim 8 including the step of directing the flow path to mix said liquid or gaseous hydrocarbon supply, or the second syngas product, with the first syngas product.

10. A method of generating power comprising the steps of:

generating a first syngas composition;

providing first and second power generating cycles;

applying sensible heat present in the first syngas composition to drive an endothermic reaction yielding a second syngas composition; and

combusting at least the first composition in the first generating cycle.

11. The method of claim 10 further including the step of transfering a portion of the sensible heat present in the first syngas composition to the second cycle.

12. The method of claim 10 wherein the step of combusting includes combusting at least some of the second syngas composition in the first generating cycle.

13. A method of generating power, comprising:

providing a first syngas composition at a first elevated temperature;

providing a light hydrocarbon supply to a reactor; and

cooling the first syngas composition to a second elevated temperature by transferring sensible heat therein to the reactor to reform the light hydrocarbon supply in an endothermic reaction.

14. The method of claim 13 wherein the reactor receives a continuous flow of the first syngas composition to effect a continuous heat exchange, thereby elevating the temperature of the flowing light hydrocarbon supply to sustain an endothermic reaction.

15. A heat exchanger comprising:

a chamber having first and second spaced-apart regions with an inlet positioned in the first region to receive a first relatively hot gas at a first temperature, and an outlet positioned in the second region; and

a network of one or more thermally conductive heat exchange tubes positioned within the chamber and extending between the first and second regions, said network including (i) an inlet positioned in the second region for receiving a second relatively cool gas capable of undergoing an endothermic reaction at a temperature at or lower than the first temperature; and

(ii) an outlet configuration for emitting the second gas from the tubes.

16. The heat exchanger of claim 15 wherein the outlet configuration is positioned to place the second gas in the first region for mixing with the relatively hot gas.

17. The heat exchanger of claim 15 wherein the outlet configuration is positioned to emit the second gas outside the chamber without mixing with the first gas.

18. The heat exchanger of claim 15 further including a catalyst placed within the one or more tubes to reduce required activation energy in order for the second gas to undergo the endothermic reaction.

19. The heat exchanger of claim 18 wherein the catalyst comprises Ni or MgAl₂O₄.

20. The heat exchanger of claim 15 wherein the outlet configuration includes a series of openings among portions of several tubes.

21. The heat exchanger of claim 15 wherein the chamber has first and second opposing end portions with each of the first and second spaced-apart regions positioned in a different end portion.

22. A method of performing an endothermic reaction, comprising the steps of:

providing a chamber having first and second spaced-apart regions with a first inlet positioned in the first region and a first outlet positioned in the second region;

passing a first gas at a relatively hot first temperature through the first inlet;

providing a network of thermally conductive heat exchange tubes within the chamber, extending between the first and second regions, the network including a second inlet positioned in the second region to receive different gas into the network and a second outlet positioned in the first region to emit the different gas from the network; and

flowing a second, relatively cool gas, capable of undergoing an endothermic reaction at a temperature at or lower than the first temperature, into the second inlet, heating the second gas as it passes through the network, and emitting the second gas through the second outlet.

23. The method of claim 22 wherein, upon emitting the second gas through the second outlet, the second gas mixes with the first gas.

24. The method of claim 22 wherein, in the process of passing the second gas through the network and mixing the second gas with the first gas, the second gas undergoes the endothermic reaction to form a product and mixes with the first gas.

25. The method of claim 22 further including the step of flowing the product and the first gas through the first outlet.