Processes for making syngas-derived products

• US 8,123,827 B2
• Filed: 12/23/2008
• Issued: 02/28/2012
• Est. Priority Date: 12/28/2007
• Status: Active Grant

• Current Assignee: Sure Champion Investments Limited
• Original Assignee: GreatPoint Energy, Inc.
• Inventors: Robinson, Earl T.
• Primary Examiner(s): Vanoy, Timothy
• Application Number:
  US12/342,628
• Publication Number:
  US 20090165381A1
• Time in Patent Office: 1,162 Days
• Field of Search: 423/650, 423/651, 423/652, 252/373, 481/97.R, 518/702, 518/704, 518/712
• US Class Current: 48/197.R
• CPC Class Codes: C10G 2/00 Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
• CPC Class Codes: C10G 2/32 with the use of catalysts
• CPC Class Codes: C10G 2300/807 Steam
• CPC Class Codes: C10J 2300/0903 Feed preparation
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/0943 Coke
• CPC Class Codes: C10J 2300/0986 Catalysts
• CPC Class Codes: C10J 2300/16 Integration of gasification processes with another plant or parts within the plant
• CPC Class Codes: C10J 2300/1659 to liquid hydrocarbons
• CPC Class Codes: C10J 2300/1665 to alcohols, e.g. methanol or ethanol
• CPC Class Codes: C10J 2300/1853 Steam reforming, i.e. injection of steam only
• CPC Class Codes: C10J 2300/1861 Heat exchange between at least two process streams
• CPC Class Codes: C10J 3/00 Production of combustible gases containing carbon monoxide from solid carbonaceous fuels destructive distillation processes C10B
• CPC Class Codes: C10J 3/463 in stationary fluidised beds
• CPC Class Codes: C10K 1/003 of acid contaminants, e.g. acid gas removal
• 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: C10K 3/04 reducing the carbon monoxide content , e.g. water-gas shift [WGS]

Abstract

The present invention provides processes for making syngas-derived products. For example, one aspect of the present invention provides a process for making a syngas-derived product, the process comprising (a) providing a carbonaceous feedstock; (b) converting the carbonaceous feedstock in a syngas formation zone at least in part to a synthesis gas stream comprising hydrogen and carbon monoxide; (c) conveying the synthesis gas stream to a syngas reaction zone; (d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and heat energy, a combustible tail gas mixture, or both; (e) recovering the syngas-derived product; and (f) recovering the heat energy formed from the reaction of the synthesis gas stream, burning the combustible tail gas mixture to form heat energy, or both.

Claims

1. A process of making a syngas-derived product from a carbonaceous feedstock, the process comprising the steps of:

(a) providing a carbonaceous feedstock;

(b)(i) reacting the carbonaceous feedstock in a gasification reactor in the presence of steam and a gasification catalyst under suitable temperature and pressure to form a raw product gas stream comprising a plurality of gases comprising methane, hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and steam;

(b)(ii) removing steam and ammonia from and sweetening the raw product gas stream to form a sweetened gas stream;

(b)(iii) separating carbon monoxide and hydrogen from the sweetened gas stream to provide a synthesis gas stream and a methane gas stream, wherein the synthesis gas stream comprises hydrogen and carbon monoxide;

(c) conveying the synthesis gas stream to a syngas reaction zone;

(d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and heat energy;

(e) recovering the syngas-derived product; and

(f) recovering the heat energy formed from the reaction of the synthesis gas stream.

2. The process of claim 1, wherein the heat energy is used to generate or heat steam.

3. The process of claim 2, wherein the reaction of the synthesis gas further forms a combustible tail gas mixture;

and wherein the combustible tail gas mixture is burned to further heat the steam.

4. The process of claim 3, wherein the steam is driven through a turbine for the generation of electrical power.

5. The process of claim 2, wherein the steam is used in step b(i).

6. A process of making a syngas-derived product from a carbonaceous feedstock, the process comprising the steps of:

(a) providing a carbonaceous feedstock;

(b)(i) reacting the carbonaceous feedstock in a gasification reactor in the presence of steam and a gasification catalyst under suitable temperature and pressure to form a raw product gas stream comprising a plurality of gases comprising methane, hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and steam;

(b)(ii) removing steam and ammonia from and sweetening the raw product gas stream to form a sweetened gas stream;

(b)(iii) separating carbon monoxide and hydrogen from the sweetened gas stream to provide a synthesis gas stream and a methane gas stream, wherein the synthesis gas stream comprises hydrogen and carbon monoxide;

(c) conveying the synthesis gas stream to a syngas reaction zone;

(d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and a combustible tail gas mixture;

(e) recovering the syngas-derived product; and

(f) burning the combustible tail gas mixture to provide heat energy.

7. The process of claim 6, wherein the combustible tail gas mixture is burned to heat steam.

8. The process of claim 7, wherein the steam is driven through a turbine for the generation of electrical power.

9. The process of claim 7, wherein the steam is used in step b(i).

10. A process of making a syngas-derived product from a carbonaceous feedstock, the process comprising the steps of:

(a) providing a carbonaceous feedstock;

(b)(i) reacting the carbonaceous feedstock in a gasification reactor in the presence of steam and a gasification catalyst under suitable temperature and pressure to form a raw product gas stream comprising a plurality of gases comprising methane, hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and steam;

(b)(ii) removing steam and ammonia from and sweetening the raw product gas stream to form a sweetened gas stream;

(b)(iii) reforming the sweetened gas stream to form a synthesis gas stream comprising hydrogen and carbon monoxide;

(c) conveying the synthesis gas stream to a syngas reaction zone;

(d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and heat energy;

(e) recovering the syngas-derived product; and

(f) recovering the heat energy formed from the reaction of the synthesis gas stream.

11. The process of claim 10, wherein the heat energy is used to generate or heat steam.

12. The process of claim 11, wherein the reaction of the synthesis gas further forms a combustible tail gas mixture;

and wherein the combustible tail gas mixture is burned to further heat the steam.

13. The process of claim 12, wherein the steam is driven through a turbine for the generation of electrical power.

14. The process of claim 11, wherein the steam is used in step b(i).

15. A process of making a syngas-derived product from a carbonaceous feedstock, the process comprising the steps of:

(a) providing a carbonaceous feedstock;

(b)(i) reacting the carbonaceous feedstock in a gasification reactor in the presence of steam and a gasification catalyst under suitable temperature and pressure to form a raw product gas stream comprising a plurality of gases comprising methane, hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and steam;

(b)(ii) removing steam and ammonia from and sweetening the raw product gas stream to form a sweetened gas stream;

(b)(iii) reforming the sweetened gas stream to form a synthesis gas stream comprising hydrogen and carbon monoxide;

(c) conveying the synthesis gas stream to a syngas reaction zone;

(d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and a combustible tail gas mixture;

(e) recovering the syngas-derived product; and

(f) burning the combustible tail gas mixture to provide heat energy.

16. The process of claim 15, wherein the combustible tail gas mixture is burned to heat steam.

17. The process of claim 16, wherein the steam is driven through a turbine for the generation of electrical power.

18. The process of claim 16, wherein the steam is used in step b(i).