PROCESSES FOR HYDROMETHANATION OF A CARBONACEOUS FEEDSTOCK
First Claim
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1. A process for generating a methane-enriched raw product stream and a syngas raw product stream from one or more carbonaceous feedstocks, the process comprising the steps of:
- (a) supplying a first carbonaceous feedstock, a first oxygen-rich gas stream, and optionally an aqueous stream comprising one or both of water and steam, to a syngas generator;
(b) reacting the first carbonaceous feedstock in the presence of oxygen and optionally the aqueous stream, in the syngas generator to produce a first gas stream at a first temperature and a first pressure, the first gas stream comprising hydrogen, carbon monoxide, heat energy and optionally steam;
(c) introducing the first gas stream into a first heat exchanger unit, optionally with a quench stream comprising one or both of water and steam, to remove heat energy and generate a cooled first gas stream at a second temperature and a second pressure, the cooled first gas stream comprising hydrogen, carbon monoxide and optionally steam;
(d) separating the cooled first gas stream into a hydromethanation gas feed stream and the syngas raw product stream, the syngas raw product stream comprising carbon monoxide, hydrogen and optionally steam;
(e) optionally adding one or both of steam and heat energy to the hydromethanation gas feed stream such that the resulting hydromethanation gas feed stream comprises hydrogen, carbon monoxide and steam at a third temperature and a third pressure;
(f) introducing a second carbonaceous feedstock, a hydromethanation catalyst, the hydromethanation gas feed stream and optionally a second oxygen-rich gas stream, to a hydromethanation reactor;
(g) reacting the second carbonaceous feedstock in the hydromethanation reactor in the presence of carbon monoxide, hydrogen, steam, hydromethanation catalyst and optionally oxygen, at a fourth temperature and a fourth pressure, to produce the methane-enriched raw product stream, wherein the methane-enriched raw product stream comprises methane, carbon monoxide, hydrogen, carbon dioxide, hydrogen sulfide and heat energy; and
(h) withdrawing the methane-enriched product stream from the hydromethanation reactor,wherein;
the reaction in step (g) has a syngas demand, a steam demand and a heat demand;
the amount of carbon monoxide and hydrogen in the hydromethanation gas feed stream (or the superheated hydromethanation gas feed stream if present) is sufficient to at least meet the syngas demand of the reaction in step (g);
if the amount of steam in the hydromethanation gas feed stream from step (d) is insufficient to meet the steam demand of the reaction in step (g), then step (e) is present and steam is added to the hydromethanation gas feed stream in an amount that is sufficient to at least meet the steam demand of the reaction in step (g);
if the second temperature is insufficient to meet the heat demand of the reaction in step (g), then step (e) is present and heat energy is added to the hydromethanation gas feed stream in an amount that is at least sufficient to meet the heat demand of the reaction in step (g).
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Abstract
The present invention relates to processes for preparing gaseous products, and in particular methane and/other value added gases such as hydrogen, via the catalytic hydromethanation of a carbonaceous feedstock in the presence of steam and syngas, wherein a hydromethanation reactor is combined with a syngas generator in a particular combination.
176 Citations
17 Claims
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1. A process for generating a methane-enriched raw product stream and a syngas raw product stream from one or more carbonaceous feedstocks, the process comprising the steps of:
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(a) supplying a first carbonaceous feedstock, a first oxygen-rich gas stream, and optionally an aqueous stream comprising one or both of water and steam, to a syngas generator; (b) reacting the first carbonaceous feedstock in the presence of oxygen and optionally the aqueous stream, in the syngas generator to produce a first gas stream at a first temperature and a first pressure, the first gas stream comprising hydrogen, carbon monoxide, heat energy and optionally steam; (c) introducing the first gas stream into a first heat exchanger unit, optionally with a quench stream comprising one or both of water and steam, to remove heat energy and generate a cooled first gas stream at a second temperature and a second pressure, the cooled first gas stream comprising hydrogen, carbon monoxide and optionally steam; (d) separating the cooled first gas stream into a hydromethanation gas feed stream and the syngas raw product stream, the syngas raw product stream comprising carbon monoxide, hydrogen and optionally steam; (e) optionally adding one or both of steam and heat energy to the hydromethanation gas feed stream such that the resulting hydromethanation gas feed stream comprises hydrogen, carbon monoxide and steam at a third temperature and a third pressure; (f) introducing a second carbonaceous feedstock, a hydromethanation catalyst, the hydromethanation gas feed stream and optionally a second oxygen-rich gas stream, to a hydromethanation reactor; (g) reacting the second carbonaceous feedstock in the hydromethanation reactor in the presence of carbon monoxide, hydrogen, steam, hydromethanation catalyst and optionally oxygen, at a fourth temperature and a fourth pressure, to produce the methane-enriched raw product stream, wherein the methane-enriched raw product stream comprises methane, carbon monoxide, hydrogen, carbon dioxide, hydrogen sulfide and heat energy; and (h) withdrawing the methane-enriched product stream from the hydromethanation reactor, wherein; the reaction in step (g) has a syngas demand, a steam demand and a heat demand; the amount of carbon monoxide and hydrogen in the hydromethanation gas feed stream (or the superheated hydromethanation gas feed stream if present) is sufficient to at least meet the syngas demand of the reaction in step (g); if the amount of steam in the hydromethanation gas feed stream from step (d) is insufficient to meet the steam demand of the reaction in step (g), then step (e) is present and steam is added to the hydromethanation gas feed stream in an amount that is sufficient to at least meet the steam demand of the reaction in step (g); if the second temperature is insufficient to meet the heat demand of the reaction in step (g), then step (e) is present and heat energy is added to the hydromethanation gas feed stream in an amount that is at least sufficient to meet the heat demand of the reaction in step (g). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17)
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16. A gasifier apparatus for generating a methane-enriched raw product stream and a syngas raw product stream from one or more carbonaceous feedstocks, the gasifier apparatus comprising:
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(a) a syngas generator configured (1) to receive a first carbonaceous feedstock, a first oxygen-rich gas stream and, optionally an aqueous stream comprising one or both of water and steam;
(2) to contain a reaction of the first carbonaceous feedstock in the presence of oxygen and optionally the aqueous stream, that produces a first gas stream comprising hydrogen, carbon monoxide and optionally steam, at a first temperature and a first pressure, and (3) to exhaust the first gas stream;(b) a cooling zone configured to (1) receive the first gas stream and, optionally, a quench stream comprising one or both of steam and water, and (2) generate a cooled first gas stream comprising hydrogen, carbon monoxide and, optionally, steam at a second temperature and a second pressure; (c) a separation zone configured to (1) receive the cooled first gas stream, and (2) separate the cooled first gas stream into a hydromethanation gas feed stream and the syngas raw product stream, the syngas raw product stream comprising carbon monoxide, hydrogen and optionally steam; (d) an optional superheater zone configured to (1) receive the hydromethanation gas feed stream from the separation zone, (2) optionally receive a steam feed stream, and (3) generate a superheated hydromethanation gas feed stream comprising carbon monoxide, hydrogen and steam at a third temperature and a third pressure; and (e) a hydromethanation reactor configured (1) to receive a second carbonaceous feedstock, a hydromethanation catalyst, the hydromethanation gas feed stream and, optionally, a second oxygen-rich gas stream, the second carbonaceous feedstock comprising a carbon content;
(2) to contain a reaction of the second carbonaceous feedstock in the presence of carbon monoxide, hydrogen, steam, hydromethanation catalyst and optionally oxygen, at a fourth temperature and a fourth pressure, that produces a methane-enriched raw product stream, the methane-enriched raw product stream comprising methane, carbon monoxide, hydrogen and carbon dioxide; and
(3) to exhaust the methane-enriched raw product stream.
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Specification