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Two-Train Catalytic Gasification Systems

  • US 20090324458A1
  • Filed: 06/26/2009
  • Published: 12/31/2009
  • Est. Priority Date: 06/27/2008
  • Status: Abandoned Application
First Claim
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1. A gasification system to generate a plurality of gases from a catalyzed carbonaceous feedstock, the system comprising:

  • (a) a first and a second gasifying reactor unit, wherein each gasifying reactor unit independently comprises;

    (A1) a reaction chamber in which a catalyzed carbonaceous feedstock and steam are converted to (i) a plurality of gaseous products comprising methane, hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide and unreacted steam, (ii) unreacted carbonaceous fines and (iii) a solid char product comprising entrained catalyst;

    (A2) a feed inlet to supply the catalyzed carbonaceous feedstock into the reaction chamber;

    (A3) a steam inlet to supply steam into the reaction chamber;

    (A4) a hot gas outlet to exhaust a hot first gas stream out of the reaction chamber, the hot first gas stream comprising the plurality of gaseous products;

    (A5) a char outlet to withdraw the solid char product from the reaction chamber; and

    (A6) a fines remover unit to remove at least a substantial portion of the unreacted carbonaceous fines that may be entrained in the hot first gas stream;

    (b) (1) a single catalyst loading unit to supply the catalyzed carbonaceous feedstock to the feed inlets of both the first and second gasifying reactor units, or(2) a first and a second catalyst loading unit to supply the catalyzed carbonaceous feedstock to the feed inlets of the first and second gasifying reactor units,wherein each catalyst loading unit independently comprises,(B1) a loading tank to receive one or more carbonaceous particulates and to load a catalyst onto the particulates to form the catalyzed carbonaceous feedstock; and

    (B2) a dryer to thermally treat the catalyzed carbonaceous feedstock to reduce moisture content;

    (c) (1) when only the single catalyst loading unit is present, a single carbonaceous material processing unit to supply the carbonaceous particulates to the loading tank of the single catalyst loading unit, or(2) when the first and second catalyst loading units are present, (i) a single carbonaceous material processing unit to supply the carbonaceous particulates to the loading tanks of both the first and second catalyst loading units, or (ii) a first and a second carbonaceous material processing unit to supply the carbonaceous particulates to the loading tanks of the first and second catalyst loading units,wherein each carbonaceous material processing unit independently comprises;

    (C1) a receiver to receive and store a carbonaceous material; and

    (C2) a grinder to grind the carbonaceous material into the carbonaceous particulates, the grinder in communication with the receiver;

    (d) (1) a single heat exchanger unit to remove heat energy from the hot first gas streams from both the first and second gasifying reactor units to generate steam and produce a single cooled first gas stream, or(2) a first and a second heat exchanger unit to remove heat energy from the hot first gas stream from the first and second gasifying reactor units to generate steam, a first cooled first gas stream and a second cooled first gas stream;

    (e) (1) when only the single heat exchanger unit is present, a single acid gas remover unit to remove at least a substantial portion of the carbon dioxide and at least a substantial portion of the hydrogen sulfide from the single cooled first gas stream, to produce a single acid gas-depleted gas stream comprising at least a substantial portion of the methane, at least a substantial portion of the hydrogen and, optionally, at least a portion of the carbon monoxide from the single cooled first gas stream, or(2) when the first and second heat exchanger units are present, (i) a single acid gas remover unit to remove at least a substantial portion of the carbon dioxide and at least a substantial portion of the hydrogen sulfide from the first cooled first gas stream and the second cooled first gas stream, to produce a single acid gas-depleted gas stream comprising at least a substantial portion of the methane, at least a substantial portion of the hydrogen and, optionally, at least a portion of the carbon monoxide from both of the first and second cooled first gas streams, or (ii) a first and a second acid gas remover unit to remove at least a substantial portion of the carbon dioxide and at least a substantial portion of the hydrogen sulfide from the first and second cooled first gas stream to produce a first acid gas-depleted gas stream and a second acid gas-depleted gas stream, wherein the first and second acid gas-depleted gas streams together comprise at least a substantial portion of the methane, at least a substantial portion of the hydrogen and, optionally, at least a portion of the carbon monoxide from the first and second cooled first gas streams;

    (f) (1) when only the single acid gas-depleted stream is present, a single methane removal unit to separate and recover at least a substantial portion of the methane from the single acid gas-depleted gas stream to produce a single methane-depleted gas stream and a single methane product stream, wherein the single methane product stream comprises at least a substantial portion of the methane from the single acid gas-depleted gas stream, or(2) when the first and second acid gas-depleted gas streams are present, (i) a single methane removal unit to separate and recover at least a substantial portion of the methane from the first and second acid gas-depleted gas streams to produce a single methane-depleted gas stream and a single methane product stream, or (ii) a first and a second methane removal unit to separate and recover at least a substantial portion of the methane from the first and second acid gas-depleted gas streams to produce a first methane-depleted gas stream and a first methane product stream, and a second methane-depleted gas stream and a second methane product stream, wherein the first and second methane product streams together comprise at least a substantial portion of the methane from the first and second acid gas-depleted gas streams; and

    (g) (1) a single steam source to supply steam to the steam inlets of the first and second gasifying reactor units, or(2) a first and a second steam source to supply steam to the steam inlets of the first and second gasifying reactor units.

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