Systems and methods for integration of gasification and reforming processes

• US 8,152,874 B2
• Filed: 06/19/2006
• Issued: 04/10/2012
• Est. Priority Date: 06/19/2006
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Briesch, Michael S., Gutierrez, Juan P.
• Primary Examiner(s): Akram, Imran
• Application Number:
  US11/455,524
• Publication Number:
  US 20070289214A1
• Time in Patent Office: 2,122 Days
• Field of Search: 481/271
• US Class Current: 48/127.1
• 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 method of processing fuel comprising:

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

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

providing a reforming reactor separate and distinct from the gasifier which provides heat exchange between the first syngas and a liquid or gaseous hydrocarbon supply different from the first slurry, the reactor having first and second ends;

providing the liquid or gaseous hydrocarbon supply in a second flow through the reforming reactor to transfer sufficient sensible heat generated during the exothermic reaction to convert said liquid or gaseous hydrocarbon supply into a second syngas product in an endothermic gas reforming reaction, wherein provision of sensible heat is accomplished by providing a heat exchanger having an outer chamber in the reforming reactor and receiving the first syngas product into the chamber by receiving the first syngas product through a first opening near the first end of the reactor and providing in the chamber a flow path along a network of thermally conductive heat exchange tubes, which tubes extend between the first and second ends of the reforming reactor, wherein heat is transferred from the first syngas product through the tubes; and

mixing said liquid or gaseous hydrocarbon supply, or the second syngas product, with the first syngas product in the reforming reactor by receiving the hydrocarbon supply or the second syngas product into the outer chamber from openings in the tubes near the first end of the reactor while simultaneously passing the first syngas product from near the first end of the reactor, about the network of tubes, and through an exit opening of the outer chamber near the second end of the reactor, so that gases emitted through the tube openings mix with the first syngas product in the outer chamber to enhance reforming reaction of the gases and a combination of the first syngas product and reformed gases exit the outer chamber through the second opening.

2. A method of generating power comprising:

retrofitting a natural gas combined cycle power plant to incorporate a coal gasifier including;

integrating a gas reforming heat exchange reactor into the plant separate and distinct from the gasifier wherein the reforming reactor has first and second ends, an outer chamber, and a flow path in the outer chamber along a network of thermally conductive heat exchange tubes, which tubes extend between the first and second ends of the reforming reactor;

using the coal gasifier to generate a syngas composition from coal at a first elevated temperature in the gasifier;

providing a light hydrocarbon supply to the gas reforming heat exchange reactor to generate a reformate composition in an endothermic reaction within the heat exchange tubes;

cooling the syngas composition to a second elevated temperature by receiving the syngas composition into the flow path in the outer chamber through a first opening near the first end of the reactor wherein heat is transferred from the syngas composition through the tubes; and

receiving the reformate composition into the outer chamber from openings in the tubes near the first end of the reactor so that a combination of the syngas composition and the reformate composition exit through a second opening of the reactor near the second end of the reactor.

3. The method of claim 2 wherein the reforming reactor receives a continuous flow of the syngas composition to effect a continuous heat exchange, thereby elevating the temperature of the flowing light hydrocarbon supply to sustain an endothermic reaction.