Catalytic steam gasification of petroleum coke to methane
First Claim
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1. A process for converting petroleum coke to methane, comprisingcombining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
- introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles with said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
recovering methane from said raw product gas; and
controlling the concentration of catalyst in said aqueous medium based on the amount of ash in said petroleum coke.
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Abstract
The present invention provides a catalytic steam gasification process for gasifying petroleum coke. The solids composition within the gasification reactor of the disclosed invention is maintained by controlling the catalyst composition of the feed. The process utilizes sour water from the raw gasification product gases to recover and recycle catalyst. Fine particles generated in the handling of coke are advantageously utilized to increase the efficiency of the process.
234 Citations
20 Claims
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1. A process for converting petroleum coke to methane, comprising
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry; -
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst; reacting said dry solid particles with said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; recovering methane from said raw product gas; and controlling the concentration of catalyst in said aqueous medium based on the amount of ash in said petroleum coke. - View Dependent Claims (2, 3, 4, 5, 6, 15, 18)
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7. A process for converting petroleum coke to methane, comprising:
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combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry; introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst; reacting said dry solid particles and said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;recovering methane from said raw product gas; contacting said solid purge with said sour water to dissolve said incorporated catalyst to form a dilute aqueous catalyst solution, and returning said dilute aqueous catalyst solution to said feed slurry. - View Dependent Claims (8, 9, 10, 16, 19)
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11. A process for gasifying petroleum coke comprising:
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crushing petroleum coke to produce petroleum coke particles having a mesh size larger than about 325 mesh on the U.S. Standard Sieve Scale and a stream of petroleum coke fines; combining said petroleum coke particles and at least part of said petroleum coke fines with a catalyst having steam gasification activity in an aqueous medium to form a feed slurry; introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst; reacting said dry solid particles and said net steam in a gasification reactor. - View Dependent Claims (12, 13)
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14. A process for converting petroleum coke to methane, comprising:
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introducing dry petroleum coke, catalyst having steam gasification activity, and superheated steam to a gasification reactor; reacting said coke, catalyst, and steam to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith; cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
contacting said solid purge with said sour water in a slurry vessel;recovering ammonia vapor from said slurry vessel; and recovering methane from said raw product gas. - View Dependent Claims (17, 20)
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Specification