Method for the gasification of hydrocarbon feedstocks

a hydrocarbon feedstock and gasification technology, applied in the field of gasification of hydrocarbon feedstocks, can solve the problems of high capital cost of coal gasification plants, prohibitively high gas prices, and too low to be used in manufacturing high-value hydrogen-containing materials that are needed for commerce, and achieve the effect of reducing the capital cost and reducing the production of co2

Inactive Publication Date: 2007-11-08
ALCHEMIX CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Benefits of technology

[0028] It is an advantage of the present invention that the solid or liquid hydrocarbons used as the feedstock can be low-value, contaminated hydrocarbons. The method can also have a lower capital cost than conventional gasification.
[0029] For the production of H2, both conventional gasification (discussed above) and the gasification method of the present invention utilize the affinity of carbon to capture O2 as the driving force to dislodge O2 from water and form H2. However, the gasification method of the present invention utilizes a unique chemical pathway as compared to conventional gasification. As is noted above, conventional gasification produces the majority of H2 by stripping the oxygen from H2O with the conversion of CO to CO2 via the water-gas shift reaction (Equation 4). In contrast, the method of the present invention produces a majority of H2 by stripping the oxygen from H2O with an intermediary, metallic iron, derived by reducing FeOx with the energy released during the transition of C to CO, and produces only a minor portion of the overall H2 by strippi

Problems solved by technology

As a result, the syngas derived from solid hydrocarbons by conventional gasification has a H2:CO ratio that is virtually always less than one, which is too low to be used for manufacturing the high-value hydrogen-containing materials that are needed for commerce.
Accordingly, while H2 production by coal gasification is an established commercial technology, it is only economically competitive with steam-methane reformation (SMR) for the production of H2 when natur

Method used

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  • Method for the gasification of hydrocarbon feedstocks

Examples

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example 1

[0265] This example illustrates an embodiment of the process that delivers most of the output energy as electricity (726 MW net), however, still produces 100 mM scfd of H2. This example follows the sequence of unit operations as depicted in FIG. 7 and will be described with reference to FIG. 7.

[0266] All reactors have a 6.5 meter hearth diameter and 8.6 meter barrel diameter. There are two metal oxide reduction reactors (e.g., reactor 604) and both have a 50 minute cycle for reducing FeO to Fe and they are staggered in time. There is one metal oxidation reactor (e.g., reactor 602) that has a 25 minute cycle time for oxidizing Fe to FeO. The plant operates 7884 hours per year (i.e., 90 percent availability).

[0267] At the start of the cycle, two metal oxide reduction reactors (referred to as 604a and 604b) each contain 293 tonnes (metric tons) of an alloy comprised of 40% iron and 60% tin, and 540 tonnes of slag comprised of 65% FeO, 12.4% CaO, 15.4% SiO2 and 7.2% ash (all percentag...

example 2

[0303] Example 2 illustrates an embodiment of the process that also makes 100 mM scfd of H2. Through the recovery of fuel-bound H2 (derived from the hydrocarbon feed), this example focuses on recovering all available H2; consequently, less electricity is produced as compared to Example 1. This example follows the sequence of unit operations as depicted in FIG. 8.

[0304] All reactors have a 4.2 meter hearth diameter and 5.6 meter barrel diameter. These reactors are smaller than the reactors of Example 1 as the total pet coke feed (illustrated below) is less for this Example 2. There are two metal oxide reduction reactors 604 (referred to as 604a and 604b); both have a 50 minute cycle for reducing FeO to Fe, and they are operated in a staggered mode. There is one metal oxidation reactor 602; it has a 25 minute cycle time for oxidizing Fe to FeO. The plant operates 7884 hours per year (i.e., 90 percent availability).

[0305] At the start of the cycle, metal oxide reduction reactor 604 c...

example 3

[0346] This Example 3 is directed to maximizing the amount of electricity produced. It derives from Example 1 (FIG. 7). However, the high CO syngas stream from amine scrubber 623 and the high H2 syngas stream from amine scrubber 622 are combined and sent to turbine unit 642, air compressor and gas-fired turbine. Table 49 summarizes the net electricity generated by this Example 3.

TABLE 49Net Salable ProductNet Electrical922MWEnergy for Sale7,269,048MW · hrs

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Abstract

A method for the gasification of a hydrocarbon-bearing feedstock to produce useful co-products such as high-value hydrocarbon fuels, pure H2, electricity, and/or ammonia. The method advantageously gasifies the carbon in the feedstock to carbon monoxide (CO) without producing large quantities of carbon dioxide (CO2). Supplemental hydrogen (H2) is also produced by reacting steam (H2O) with a metal. The method can advantageously produce two separate syngas streams, one that is CO-rich and one that is H2-rich.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Patent Application No. 60 / 746,748 filed May 8, 2006, which is incorporated herein by reference in its entirety as if set forth in full.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention is directed to a method for the gasification of hydrocarbon feedstocks to produce a syngas that is useful for the production of hydrogen, hydrogen-containing materials, electricity or other energy products. The method advantageously produces such high-value products while reducing the formation of carbon dioxide (CO2) as compared to other gasification methods. [0004] 2. Description of Related Art [0005] Gasification is a well-known process that converts hydrocarbon materials such as coal, petroleum coke, biomass or similar feedstocks into a syngas comprising carbon monoxide (CO) and hydrogen (H2). During gasification, pyrolysis of the hydrocarbon material releases...

Claims

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Application Information

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IPC IPC(8): C10J3/00
CPCC01B3/105Y02E20/18C01B2203/0283C01B2203/0415C01B2203/043C01B2203/045C01B2203/0455C01B2203/0485C01B2203/0495C01B2203/06C01B2203/062C01B2203/068C01B2203/0877C01B2203/0883C01B2203/1247C01B2203/84C01B2203/86C10J3/57C10J3/721C10J2300/0916C10J2300/093C10J2300/0959C10J2300/0983C10J2300/1618C10J2300/1671C10J2300/1693Y02E60/36C10K1/004C10K3/04Y02E20/185Y02E20/16C01B3/348Y02P20/145Y02P30/00
Inventor KINDIG, JAMES KELLY
Owner ALCHEMIX CORP
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