Systems and methods for gasifying a feedstock

• US 9,133,405 B2
• Filed: 12/30/2010
• Issued: 09/15/2015
• Est. Priority Date: 12/30/2010
• Status: Active Grant

• Current Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Original Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Inventors: Abughazaleh, John
• Primary Examiner(s): MERKLING, MATTHEW J
• Application Number:
  US12/982,318
• Publication Number:
  US 20120167463A1
• Time in Patent Office: 1,720 Days
• Field of Search: 481/97.R
• US Class Current: 1/1
• CPC Class Codes: C10J 2300/0906 Physical processes, e.g. shredding, comminuting, chopping, sorting
• CPC Class Codes: C10J 2300/0996 Calcium-containing inorganic materials, e.g. lime
• CPC Class Codes: C10J 2300/1631 Ash recycling
• CPC Class Codes: C10J 2300/164 with conversion of synthesis gas
• 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 2300/1656 Conversion of synthesis gas to chemicals
• CPC Class Codes: C10J 2300/1678 with air separation separating gases using rectification of air F25J3/04521
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 3/54 Gasification of granular or pulverulent fuels by the Winkler technique, i.e. by fluidisation
• CPC Class Codes: C10J 3/56 Apparatus; Plants
• CPC Class Codes: C10J 3/86 combined with waste-heat boilers
• CPC Class Codes: C10K 1/003 of acid contaminants, e.g. acid gas removal
• CPC Class Codes: C10K 1/02 Dust removal
• CPC Class Codes: C10K 3/04 reducing the carbon monoxide content , e.g. water-gas shift [WGS]

Abstract

Systems and methods for gasifying a feedstock are provided. The method can include combining one or more feedstocks and one or more solid components in a treatment zone to provide a treated feedstock. At least a portion of the treated feedstock can be introduced to a reaction zone of a gasifier. The one or more solid components can have an average density and an average cross-sectional size that adjusts at least one of an average density of solids within a solids bed of the gasifier and an average cross-sectional size of the solids within the solids bed of the gasifier.

Claims

1. A method for gasifying a feedstock, comprising:

combining one or more feedstocks and one or more solid components in a treatment zone to provide a treated feedstock;

producing a raw syngas-particulate mixture by introducing at least a portion of the treated feedstock to a reaction zone of a gasifier;

producing one or more separated particulates by separating at least a portion of the raw syngas-particulate mixture in a separation zone of the gasifier;

recycling at least a portion of the one or more separated particulates into the reaction zone of the gasifier;

determining whether a property of the recycled one or more separated particulates differs from a design parameter of the gasifier;

if a difference in the property is determined, changing at least one of;

(i) an average density of solids within a solids bed of the gasifier and (i) an average cross-sectional size of the solids within the solids bed of the gasifier by adjusting at least one of an average density and an average cross-sectional size of the one or more solid components being combined with the one or more feedstocks.

2. The method of claim 1, wherein the average density of the one or more solid components ranges from about 2 g/cm3 to about 5 g/cm3.

3. The method of claim 1, wherein the average cross-sectional size of the one or more solid components ranges from about 600 μ

m to about 800 μ

m.

4. The method of claim 1, wherein the average density of the solids within the solids bed of the gasifier ranges from about 3 g/cm3 to about 4 g/cm3.

5. The method of claim 1, wherein the average cross-sectional size of the solids within the solids bed of the gasifier ranges from about 500 μ

m to about 800 μ

m.

6. The method of claim 1, wherein the one or more solid components comprise ash, sand, ceramic materials, furnace fly ash, sieved furnace fly ash, gasifier ash, sieved gasifier ash, crushed limestone, or any combination thereof.

7. The method of claim 1, further comprising introducing one or more oxidants to the gasifier.

8. The method of claim 1, wherein the reaction zone comprises one or more mixing zones and one or more gasification zones.

9. The method of claim 1, wherein the one or more feedstocks comprise a coal based material selected from the group consisting of high-sodium lignite, low-sodium lignite, subbituminous coal, bituminous coal, and anthracite.

10. The method of claim 8, further comprising:

gasifying the treated feedstock to provide a mixture comprising syngas and particulates, wherein the particulates comprise solids produced by gasifying the treated feedstock;

separating the mixture into a first particulate-lean syngas and a first particulate-rich product;

separating the first particulate-lean syngas to provide a second particulate-lean syngas and a second particulate-rich product;

transferring the first particulate-rich product and the second particulate-rich product to the solids bed; and

recycling the particulates from the solids bed to the reaction zone.

11. The method of claim 10, wherein the gasifier is operated at a temperature sufficient not to melt the solid components or the recycled particulates.

12. The method of claim 1, wherein the treated feedstock is heated by the recycled particulates in the reaction zone.

13. The method of claim 1, wherein the average density of the solids within the solids bed of the gasifier ranges from about 3 g/cm3 to about 4 g/cm3, wherein the average cross-sectional size of the one or more solid components ranges from about 20 μ

m to about 800 μ

m, and wherein the one or more solid components comprise sieved gasifier ash, crushed limestone, or a combination thereof.

14. The method of claim 1, further comprising changing a set of properties of the one or more feedstocks during operation of the gasifier and then increasing the efficiency of the gasifier by changing at least one of:

(i) the average density of solids within the solids bed of the gasifier and (i) the average cross-sectional size of the solids within the solids bed of the gasifier.

15. The method of claim 14, wherein the set of properties of the one or more feedstocks is changed by changing a source of the feedstock.