Method and device for producing crude synthesis gas by partial oxidation of hydrocarbon-containing gas and liquid

Abstract

The invention relates to a method and a device for producing a crude synthesis gas containing hydrogen and carbon oxides by simultaneous partial oxidation of a hydrocarbon-containing gas input stream and a hydrocarbon-containing liquid input stream containing impurities. The evaporation of the liquid input stream is performed under partial evaporation conditions to obtain a gaseous mixed input stream and a liquid residual stream. The gaseous mixed input stream is impurity-depleted relative to the hydrocarbon-containing liquid input stream and is supplied to partial oxidation, where the depletion is effective to prevent the formation of deposits or carbon deposits by crystallization of dissolved inorganic components, especially in and / or upstream of the POX burner. The liquid residual stream is enriched with impurities relative to a hydrocarbon-containing liquid input stream and discharged from the process.

Description

Field of the Invention

[0001] The present invention relates to a process for producing a crude synthesis gas containing hydrogen and carbon oxides by simultaneous partial oxidation of a hydrocarbon-containing gas input stream and a hydrocarbon-containing liquid input stream. The present invention further relates to an apparatus for producing a crude synthesis gas stream. Background Art

[0002] Synthesis gas is a gas mixture containing hydrogen and carbon oxides which is used for various synthesis reactions. Examples are methanol synthesis, the production of ammonia by the Haber-Bosch process or the Fischer-Tropsch synthesis.

[0003] A commonly used method for producing synthesis gas is the autothermal entrained flow gasification of gaseous, liquid or solid fuels as described in, for example, DE 10 2006 059 149 B4. At the top of the reactor, the ignition and pilot burners are arranged centrally, and three gasification burners are arranged rotationally symmetrically with respect to the reactor axis. Via the gasification burners, coal powder with oxygen and steam as gasifying agents is supplied to the gasification space of the reactor, where the fuel is converted into synthesis gas. The hot gasification gas leaves the gasification space together with the liquid slag and enters the quenching space, into which water is injected to cool the raw gas and slag. The slag is deposited in a water bath and removed via the slag effluent. The quenched raw gas is discharged from the quenching space in a steam saturated state and purified in a subsequent purification stage. Since the fuel reacts directly with the oxidant, the oxidant and the fuel must be supplied coaxially or coannularly.

[0004] US 5,549,877 A1 also describes a method and an apparatus for producing synthesis gas, wherein an oxygen-containing oxidant is supplied at the center of the reactor top and introduced into a reaction space together with a fuel supplied annularly around the oxidant feed, wherein the fuel initially reacts in a substoichiometric amount. A flame is formed that diffuses downward into the reaction space. In the recirculation zone, the material present in the flame flows back upward. Downstream, an additional oxidant stream is supplied to the reaction zone via an annular conduit, thereby forming a more extended flame zone.

[0005] The partial oxidation (POX) of hydrocarbon-containing input materials for the production of synthesis gas is usually carried out at high reactor temperatures in the range of 1000° C. to 1500° C. and pressures of up to 100 bara. The reactor for the non-catalytic partial oxidation (POX reactor) is usually a refractory-lined reactor with a hemispherical or almost hemispherical dome. Here, the partial oxidation burner (POX burner) is usually installed on top of the dome.

[0006] The technical methods and devices for partial oxidation known in the prior art propose various devices for introducing and mixing various streams (i.e., hydrocarbon-containing input materials, usually oxygen-containing oxidants and sometimes moderators). The moderator used is usually carbon dioxide (CO2) or steam, wherein the moderator is introduced into the reactor separately via a separate channel in the burner or mixed with one or more other input streams upstream of the burner. The oxidant used is usually air, oxygen-enriched air or pure oxygen (containing at least 95 mol% oxygen). The hydrocarbon-containing feed stream or input stream is a stream containing hydrocarbons such as methane, higher hydrocarbons or other hydrogen-containing and carbon-containing molecules (e.g., alcohols, such as methanol, ethanol). This can also be a stream derived from an upstream primary reformer, which contains not only carbon monoxide (CO), hydrogen (H2), CO2 and water (H2O), but also hydrocarbons such as methane, ethane, ethylene or higher hydrocarbons such as benzene, toluene or xylene. The mixing of hydrocarbon-containing input materials and oxidants is usually carried out in the reactor close to the injection nozzle.

[0007] In the case of gaseous hydrocarbon-containing input materials (e.g., natural gas, steam cracker exhaust, coke oven gas), the input material is mixed with a hydrogen-rich stream, preheated to, for example, 250°C to 350°C in one or more steps, and sent to a hydrodesulfurization unit to remove sulfur components. Before an optional heating step to further increase the temperature to, for example, 350°C to 550°C, the desulfurized input material can be mixed with a moderator, such as steam or carbon dioxide. The hydrocarbon-containing mixture is then introduced into a burner arranged at the upper end of the partial oxidation reactor. In addition, oxygen is supplied to the burner, and in some cases, a moderator is also supplied. Various streams react in a refractory-lined reactor at a temperature of, for example, 1000°C to 1500°C and a typical pressure of, for example, 30 to 100 bar, to provide a crude synthesis gas comprising hydrogen (H2) and carbon monoxide (CO). The bottom of the reactor can be equipped with an additional catalyst layer to promote the reaction. The gas leaves the reactor and is cooled in a gas cooling unit capable of producing high-pressure steam. The cooled synthesis gas is then freed from acidic gas components in an acidic gas removal unit. Some applications may also include an upstream CO shift stage to increase the hydrogen content. Conventional methods for removing acidic gases include, for example, physical adsorption or chemical adsorption absorption methods or gas scrubbing methods, such as amine scrubbing methods or scrubbing with low-temperature methanol (Rectisol method). In some cases where desulfurization is not performed upstream of the partial oxidation reactor, sulfur components, such as H2S, may also be removed at this stage. The purified synthesis gas is then adjusted to the desired H2 / CO ratio in a synthesis gas conditioning unit. Typical examples of synthesis gas conditioning steps are PSA, TSA, coldboxes or membrane devices known per se from the literature. Other options for changing the composition of the synthesis gas include less complex methods, such as mixing of nearby pure H2 or CO streams. Depending on the conditioning method, different product streams can be produced, such as a CO-rich stream and a H2-rich stream.

[0008] Many chemical syntheses produce by-products or contaminated solvents, which are currently usually not fully recovered, for example by heat recovery of the released CO2. Partial oxidation is an option for converting these waste streams into valuable products, for example into H2, CO or a mixture thereof, so that the carbon present therein can be recycled and converted into new products. However, the amount of by-products available nearby is usually too low to operate a dedicated gasification unit economically. It is therefore desirable to mix different starting materials with the input stream of the POX unit. However, in many cases, this can only be achieved with difficulty due to the type, composition or material state of the waste stream. Therefore, for example, a liquid waste stream containing inorganic elements cannot be injected into the hot gas feed stream of the POX unit because the evaporation residue forms a blockage or corrosion problems occur on the exposed material. Another problem may be that the product is a complex mixture of different organic components that cannot be completely evaporated because they have too low a vapor pressure under given conditions, or are thermally unstable and form carbon deposits at the injection position. Summary of the invention Description of the invention

[0009] It is therefore an object of the present invention to specify a process and an apparatus for producing a raw synthesis gas stream which can process both liquid and gaseous hydrocarbon-containing input streams, but which does not have the above-mentioned disadvantages of the processes and apparatuses of the prior art.

[0010] This object is achieved in a first aspect of the invention by a process having the features of claim 1 and in a further aspect of the invention by a process for producing a raw synthesis gas stream having the features of claim 15. Further embodiments of the invention are apparent from the respective generic dependent claims.

[0011] Oxygen-containing oxidant is understood to mean any oxygen-containing fluid, such as pure oxygen of any desired purity, air or any other fluid capable of supplying oxygen to the carbon-containing reactants.

[0012] Partial evaporation conditions are understood to mean physicochemical / process engineering conditions which allow the liquid phase and the components present therein not to evaporate completely (i.e. to an extent of 100%), but only a first portion of the liquid phase to evaporate while a second portion of the liquid phase remains liquid and is discharged from the process, in one example as a residual stream. A person skilled in the art is able to specify these physicochemical / process engineering conditions on the basis of his general knowledge in the field and / or to determine them by routine experiments.

[0013] Means is understood to mean an article capable of achieving or contributing to the achievement of a purpose. Means for carrying out a particular process step is particularly understood to mean all physical objects that a person skilled in the art would consider to be used for carrying out this process step. For example, a person skilled in the art would consider means for introducing or discharging a material stream to include all conveying and delivery devices that a person skilled in the art would consider necessary or reasonable for carrying out this process step based on their knowledge of the art, i.e., for example, pipes, conduits, pumps, compressors, valves.

[0014] In the present description, steam is to be understood as a synonym for water vapour, unless otherwise specified in individual cases. In contrast, the term "water" relates to liquid water, unless otherwise specified in individual cases.

[0015] Where necessary, and unless otherwise indicated in individual cases, pressures are specified in absolute pressure units, referred to as bara or bar(a) for short, or in gauge pressure units, referred to as barg or bar(g) for short.

[0016] A fluid connection between two regions of a device or an apparatus according to the invention is understood to mean any type of connection that enables a fluid (e.g. a gas stream) to flow from one of the two regions to the other, without regard to intervening regions or components. A direct fluid connection is understood in particular to mean any type of connection that enables a fluid (e.g. a gas stream) to flow directly from one of the two regions to the other, without intervening any further regions or components except for the pure transport operation and the tools required therefor, such as pipeline conduits, valves, pumps, compressors, reservoirs. An example is a pipeline conduit that leads directly from one of the two regions to the other.

[0017] "Optionally" or "electively" means that the subsequently described event or circumstance may or may not occur, or the feature may or may not be present. The description includes instances where the event or circumstance occurs and instances where the event or circumstance does not occur. The description also includes instances where the feature is present or not.

[0018] The conditions for non-catalytic partial oxidation (POX) or autothermal, catalytic partial oxidation (autothermal reforming, ATR) are known to the person skilled in the art from the prior art, for example from the literature discussed at the outset. These are physicochemical conditions for achieving a measurable, preferably industrially relevant conversion of a fluid or fluidized carbonaceous input stream into a synthesis gas product. These include the establishment of a suitable partial oxidation temperature of generally about 1000° C. or more as an important parameter. Non-catalytic partial oxidation is characterized in particular in that no catalyst is present in the partial oxidation reactor.

[0019] Those skilled in the art can make necessary adjustments to the conditions of non-catalytic partial oxidation or autothermal reforming based on routine experiments to adapt to their respective operating requirements. Any specific reaction conditions disclosed can be used as a guide, but should not be regarded as limiting the scope of the present invention.

[0020] An object of the present invention is to recover a liquid hydrocarbon stream, such as a liquid hydrocarbon-containing waste stream, in a POX process / POX unit operated with a gaseous input material, such as natural gas, steam cracker exhaust gas, coke oven gas as the main input material. The POX process or POX unit can be operated in the presence of an additional catalyst layer in the POX reactor (autothermal reformer, ATR) or in a non-catalytic manner (non-catalytic POX or gas POX). The present invention describes a method and a device for partially evaporating an incoming liquid input stream and for preventing the formation of deposits or carbon deposits by crystallization of dissolved inorganic components, in particular in and / or upstream of the POX burner. The dissolved inorganic components may include inorganic metal ions or anions such as phosphates, halogen ions, etc., such as Na, K, Mg, Ca, Al, Si, Fe, Co, Cr, Mn, Zn, etc. Organic or inorganic sulfur compounds may also be present. In one example, the major component of the liquid input stream, such as a liquid waste stream, is liquid hydrocarbons, which in one example may also contain functional groups such as alcohols, aldehydes, ketones, acids, or ethers containing heteroatoms such as oxygen, nitrogen, and sulfur.

[0021] In one embodiment of the invention, the gaseous hydrocarbon input stream is preheated to a temperature of about 200°C to 350°C. This is achieved by one or more heat exchangers, for example by heat exchange with steam and / or flue gas heat transfer media. In one example, a hydrogen-rich stream obtained from the produced crude synthesis gas and / or taken from an external source is supplied to the hydrocarbon stream upstream, between or downstream of the heat exchanger. The preheated gaseous hydrocarbon stream is then divided into two substreams: in one example, one substream is sent directly to a hydrodesulfurization unit (HDS), while the other substream is sent to an evaporator unit. In the evaporator unit, the preheated gaseous hydrocarbon stream is contacted with a liquid hydrocarbon input stream and heat of evaporation is provided. In addition, the hydrocarbons in the gaseous hydrocarbon stream reduce the partial pressure of the evaporating components of the liquid waste stream, thereby reducing the tendency of the components in the partially evaporated liquid input stream to interact and undesirable derivative reactions (descendent reactions) (e.g., polymerization or cracking reactions). In an alternative example, the entire gaseous hydrocarbon stream is introduced into the hydrodesulfurization unit and only downstream thereof is divided into two substreams, one of which is sent to the evaporator unit as heat transfer medium and the other is supplied directly to the partial oxidation reactor.

[0022] It is essential for the present invention that the evaporation of the liquid input stream in the evaporation device is carried out under partial evaporation conditions, wherein the partial evaporation conditions are selected so as to discharge a gaseous mixed input stream and a liquid residual stream from the evaporation device, wherein the gaseous mixed input stream is depleted in impurities relative to the hydrocarbon-containing liquid input stream, and wherein the liquid residual stream is enriched in impurities relative to the hydrocarbon-containing liquid input stream. This provides a gaseous mixed input stream that is depleted in impurities relative to the hydrocarbon-containing liquid input stream, thereby effectively preventing the formation of deposits or carbon deposits by crystallization of dissolved inorganic components, in particular in the POX burner and / or upstream thereof. Preferred embodiments of the present invention

[0023] In a second aspect of the invention, the process is characterized in that the second gaseous input substream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and the gaseous mixed input stream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and / or via a separate conduit. This provides greater flexibility for the feeding of the input materials of the POX process. When the gaseous mixed input stream is introduced via a separate conduit, the conduit can be easily replaced and / or cleaned if necessary so as not to damage the POX burner.

[0024] In a third aspect of the invention, the process is characterized in that the first average boiling point and the second average boiling point differ by at least 20° C., preferably by at least 50° C. Studies have shown that for most impurities, this ensures that the impurities remain in the liquid phase and, if evaporated, evaporate only to a small extent. This enables longer, trouble-free operation of the POX process to be ensured.

[0025] In a fourth aspect of the invention, the method is characterized in that the at least one impurity fraction contains inorganic or organometallic components. These components are present, for example, in cracker residue fractions and other hydrocarbon-containing, in particular crude oil-derived liquid waste fractions, and thus enable material recovery thereof. The inorganic or organometallic components advantageously have a significant boiling point difference with respect to the hydrocarbons constituting the primary constituents of the at least one impurity fraction, so that the inorganic or organometallic components can be easily removed therefrom by partial evaporation.

[0026] In a fifth aspect of the invention, the method is characterized in that the at least one impurity fraction comprises inorganic components dissolved and / or suspended in the primary constituent fraction. In other words, advantageously, the at least one impurity fraction does not form a separate phase, as this promotes evaporation and mixing with the gaseous hydrocarbon stream.

[0027] In a sixth aspect of the invention, the method is characterized in that the inorganic components are present in ionic form, wherein preferably at least one cation selected from the group consisting of Na, K, Mg, Ca, Al, Si, Fe, Co, Cr, Mn, Zn is present, and / or wherein preferably at least one anion selected from the group consisting of phosphate, sulfate, chloride, nitrate is present. These inorganic components present in ionic form advantageously have a significant boiling point difference with respect to the hydrocarbons constituting the main component of the at least one impurity fraction, so that the inorganic or organometallic components can be easily removed therefrom by partial evaporation.

[0028] In a seventh aspect of the invention, the process is characterized in that the hydrocarbon-containing liquid input stream is mixed with a complexing agent which prevents or reduces crystallization of one or more ionic components. This allows the ionic components to be safely maintained in the liquid phase, thereby facilitating their feeding to the evaporation device as no solid precipitation occurs.

[0029] In an eighth aspect of the invention, the method is characterized in that the liquid residual waste stream is supplied to a metal recovery process. This enables material recovery of the metals present and can prevent or at least reduce the generation of problematic, partly toxic wastes.

[0030] In a ninth aspect of the invention, the process is characterized in that the at least one impurity fraction comprises liquid hydrocarbons containing functional groups containing heteroatoms such as oxygen, nitrogen and sulfur, preferably alcohols, aldehydes, ketones, acids or ethers. Such material fractions are problematic because their condensation and polymerization tendencies are particularly pronounced due to the presence of the listed functional groups, but are effectively reduced by the partial pressure reduction according to the invention.

[0031] In a tenth aspect of the invention, the method is characterized in that the at least one impurity fraction contains polymerizable liquid hydrocarbons. Such material fractions are problematic because their tendency to polymerize is of course particularly pronounced, but is effectively reduced by the partial pressure reduction according to the invention.

[0032] In an eleventh aspect of the present invention, the process is characterized in that the hydrocarbon-containing liquid input stream is mixed with a polymerization inhibitor. This further reduces the polymerization tendency and, as a result, facilitates feeding to the evaporation device because no solid precipitation occurs.

[0033] In a twelfth aspect of the invention, the process is characterized in that the first temperature and partial evaporation conditions are selected so that the liquid residual stream is 1% to 20% by weight, preferably 1% to 10% by weight, and most preferably 1% to 5% by weight of the hydrocarbon-containing liquid input stream. Studies have shown that for most impurities, this ensures that the impurities remain in the liquid phase and, if evaporated, evaporate only to a small extent. This makes it possible to ensure longer, trouble-free operation of the POX process.

[0034] In a thirteenth aspect of the invention, the process is characterized in that the mass flow rate of the heated first gaseous input substream introduced into the evaporation device is selected so that the temperature of the gaseous mixed input stream discharged from the evaporation device does not exceed at most 470° C. Studies have shown that this makes it possible to effectively avoid undesirable cracking or polymerization reactions of compounds derived from the liquid input stream. This makes it possible to ensure longer-term trouble-free operation of the POX process.

[0035] In a fourteenth aspect of the present invention, the method is characterized in that the evaporation device is configured as an evaporation tower comprising the following components: - shells and tubes arranged upright relative to the vertical, - at least one mass transfer zone arranged in the shell tube, which contains at least one mass transfer element selected from the group consisting of separating trays, random packing, structured packing, - an inlet for a first gas input substream for heating, arranged below the at least one mass transfer zone, - an inlet for a liquid input stream arranged above the at least one mass transfer zone, - an outlet for the gaseous mixed input stream arranged above the at least one mass transfer zone, - an outlet for a liquid residual stream arranged below the at least one mass transfer zone, Wherein the evaporation apparatus is further configured to allow mass transfer and direct heat exchange between the heated first gas input substream and the liquid input stream.

[0036] Such a configuration of the evaporation device enables a particularly efficient and space-saving evaporation of a liquid phase containing impurities.

[0037] In a sixteenth aspect of the invention, the device is characterized in that the second gas input substream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and the gaseous mixed input stream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and / or via a separate conduit. The advantages of this aspect of the invention correspond to those discussed in conjunction with the second aspect of the invention.

[0038] In a seventeenth aspect of the present invention, the device is characterized in that the evaporation device is configured as an evaporation tower comprising the following components: - shells and tubes arranged upright relative to the vertical, - at least one mass transfer zone arranged in the shell tube, which contains at least one mass transfer element selected from the group consisting of separation trays, random packings, structured packings, - an inlet for a first gas input substream for heating, arranged below the at least one mass transfer zone, - an inlet for a liquid input stream arranged above the at least one mass transfer zone, - an outlet for the gaseous mixed input stream arranged above the at least one mass transfer zone, - an outlet for a liquid residual stream arranged below the at least one mass transfer zone, Wherein the evaporation apparatus is further configured to allow mass transfer and direct heat exchange between the heated first gas input substream and the liquid input stream.

[0039] The advantages of this aspect of the invention correspond to those discussed in conjunction with the fourteenth aspect of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In the attached picture: Figure 1 Showing a process flow diagram / device according to the prior art, Figure 2 A first detailed view showing a process flow diagram / apparatus according to one embodiment of the present invention, Figure 3 A second detailed view of a process flow diagram / apparatus is shown according to one embodiment of the present invention. Exemplary embodiments

[0041] Developments, advantages and possible applications of the invention are also apparent from the following description of exemplary embodiments and the drawings.The invention is formed by all features described and / or depicted individually or in any combination, regardless of how they are combined in the claims or dependent references therein.

[0042] Hereinafter, “not shown” should be understood to mean that an element in the drawing is not shown graphically, but still exists according to the description.

[0043] Figure 1 A process flow diagram / apparatus for producing crude synthesis gas by partial oxidation of hydrocarbon-containing gases and liquids according to the prior art is shown. A hydrocarbon-containing gas input stream, in one example natural gas, is introduced into the process / apparatus via conduit 12 and supplied to a heating stage 10. A hydrogen-containing gas stream can optionally be introduced into the process / apparatus via conduit 14 together with the hydrocarbon-containing gas input stream.

[0044] The hydrocarbonaceous gas input stream, heated in one example to a temperature of 200° C. to 350° C., is discharged from the heating stage 10 via conduit 22 and introduced into the optional desulfurization stage 20. The optional desulfurization stage 20 removes sulfur compounds from the hydrocarbonaceous gas input stream in a manner known per se to the person skilled in the art.

[0045] The hydrocarbonaceous gas input stream depleted of sulfur compounds is discharged from the desulfurization stage 20 via conduit 32 and introduced into the heating stage 30. In the heating stage 30, the hydrocarbonaceous gas input stream depleted of sulfur compounds is further heated and then introduced into the partial oxidation reactor 50 via conduit 34. In one example, the partial oxidation reactor 50 is configured as a POX reactor. In another example, the partial oxidation reactor 50 is configured as an ATR.

[0046] The oxygen-containing oxidant stream oxygen required for the partial oxidation in the partial oxidation reactor 50 is introduced into the process / into the apparatus via conduit 42, heated using the heating stage 40 and introduced into the partial oxidation reactor 50 using conduit 44. In one example, the oxidant stream comprises oxygen of technical purity. In one example, the oxidant stream comprises air. In one example, the oxidant stream comprises oxygen-enriched air.

[0047] Via conduit 36, a moderator stream comprising steam and / or carbon dioxide is introduced into partial oxidation reactor 50 after optional heating (not shown). In one example, a portion of the moderator stream is diverted via conduit 37 and mixed with the oxygen-containing oxidant stream for dilution, mixing, and / or fine temperature control. In another example, a portion of the moderator stream is diverted via conduit 38 and mixed with the hydrocarbon-containing gas input stream for dilution, mixing, and / or fine temperature control.

[0048] The partial oxidation reactor is configured as a non-catalytic partial oxidation reactor (POX reactor) or an autothermal reformer (ATR), wherein the POX reactor or the autothermal reformer comprises at least one partial oxidation burner. The partial oxidation reactor reacts a gas input stream with an oxygen-containing oxidant stream and an optional moderator stream under non-catalytic partial oxidation (POX) or autothermal reforming (ATR) conditions to provide a hot raw synthesis gas stream.

[0049] The hot raw synthesis gas stream is discharged from the partial oxidation reactor via conduit 52 and fed to a gas cooling stage 60. In the gas cooling stage 60, which can be configured, for example, as a heat exchanger or a waste heat boiler, the hot raw synthesis gas is cooled to a temperature allowing subsequent removal of undesired acid gas components.

[0050] Via conduit 62, the cooled raw synthesis gas stream is discharged from the gas cooling stage 60 and supplied to the synthesis gas deacidification stage 70, in which, in particular, acid gas components such as carbon dioxide CO2 and / or gaseous sulfur compounds, in particular hydrogen sulfide H2S, are separated. In one example, the synthesis gas deacidification stage 70 is operated according to a physical adsorptive gas scrubbing process (Rectisol process) with low-temperature methanol as absorbent / scrubbing medium. In another example, the synthesis gas deacidification stage 70 is operated according to a chemical adsorptive gas scrubbing process using an amine-containing absorbent / scrubbing medium. The process conditions of the physical adsorptive / chemical adsorptive gas scrubbing processes themselves are known to those skilled in the art. It is advantageous to obtain acid gas components such as carbon dioxide and / or gaseous sulfur compounds separately in the regeneration of the scrubbing medium and discharge them from the method / the device via separate conduits. In Figure 1 In the example shown in FIG. 7 , carbon dioxide is discharged via conduit 74 and gaseous sulfur compounds are discharged via conduit 76 .

[0051] exist Figure 1 In the example shown in , the raw synthesis gas stream freed of acid gas components is discharged from the synthesis gas deacidification stage 70 via conduit 72 and then supplied to a synthesis gas conditioning stage 80. The synthesis gas conditioning stage is an example of a further physicochemical conditioning step depending on the type of intended further use of the synthesis gas. Examples of further conditioning steps are temperature increase or decrease, pressure increase or decrease, change of chemical composition, for example by removing secondary components or impurities, for example by adsorption processes, for example by pressure swing adsorption (PSA). Depending on the type of conditioning step performed, this provides one or more synthesis gas products discharged from the synthesis gas conditioning stage 80 as indicated by the dashed arrows.

[0052] Figure 2 A first detailed view of a process flow diagram / apparatus according to one embodiment of the invention is shown. Unless otherwise indicated in the individual context, the same reference numerals in the figures correspond to the same process steps / apparatus parts and the same process conditions. Figure 1 Other process steps / apparatus components not shown correspond to Figure 1 Those in .

[0053] Different from Figure 1 ,exist Figure 2In the example of the present invention shown in , the heated hydrocarbon-containing gas input stream in conduit 22 is divided into a first heated gas input substream and a second heated gas input substream. The first heated gas input substream is introduced into the evaporation device 90 via conduit 22, and is in close contact with the liquid input stream introduced into the evaporation device 90 via conduit 92. The first heated gas input substream provides heat of evaporation. In addition, the hydrocarbons in the first heated gas input substream reduce the partial pressure of the evaporation components of the liquid input stream, thereby reducing the interaction tendency of the partially evaporated liquid input stream. Partial evaporation conditions are selected here to discharge a gaseous mixed input stream from the evaporation device via conduit 24, and to discharge a liquid residual stream from the evaporation device via conduit 94, wherein the gaseous mixed input stream is depleted of impurities relative to the hydrocarbon-containing liquid input stream, and wherein the liquid residual stream is enriched in impurities relative to the hydrocarbon-containing liquid input stream.

[0054] The gaseous mixed input stream is discharged from the evaporation device 90 via conduit 24. The second heated gaseous input substream bypasses the evaporation device 90 via conduit 99 and is mixed with the gaseous mixed input stream in conduit 24. The resulting combined gaseous mixed input stream is supplied to the optional desulfurization stage 20 via conduit 24. The other process steps / plant components correspond to the combined Figure 1 Those described.

[0055] exist Figure 2 In an alternative example not shown in the drawing, the entire gaseous hydrocarbon stream is introduced into the desulfurization stage 20 and divided into two substreams only downstream thereof, one substream being sent to the evaporation device 90 as heat transfer medium and the other substream being supplied directly to the partial oxidation reactor 50 .

[0056] Figure 3 A second detailed view of a process flow diagram / apparatus according to one embodiment of the present invention and an example of the configuration of an evaporation apparatus 90 therein is shown. Unless otherwise indicated in the individual context, the same reference numerals in the drawings correspond to the same process steps / apparatus parts and the same process conditions. Figure 1 Other process steps / apparatus components not shown correspond to Figure 1 Those in .

[0057] The liquid feed stream for partial evaporation is introduced into the evaporation device 90 at its upper part via conduit 92 and trickles downward through the internals ( Figure 3 ), such as bubble cap trays, sieve plates, structured packings, random packings or any desired combination of two or more of the listed elements.

[0058] The first heated gaseous input substream is introduced into the evaporation device 90 at its lower end and passes through the evaporation device countercurrently with the liquid input stream. This involves intensive mass transfer and heat exchange between the two fluid streams, and a portion of the liquid input stream evaporates to obtain a gaseous mixed input stream. The partial evaporation conditions are selected here to discharge the gaseous mixed input stream from the evaporation device via conduit 24 and to discharge a liquid residual stream from the evaporation device via conduit 94, wherein the gaseous mixed input stream is depleted in impurities relative to the hydrocarbon-containing liquid input stream, and wherein the liquid residual stream is enriched in impurities relative to the hydrocarbon-containing liquid input stream.

[0059] The gaseous mixed input stream is discharged from the evaporation device 90 via conduit 24. The second heated gaseous input substream bypasses the evaporation device 90 via conduit 99 and is mixed with the gaseous mixed input stream in conduit 24. The resulting combined gaseous mixed input stream is supplied to the optional desulfurization stage 20 via conduit 24. The other process steps / plant components correspond to the combined Figure 1 Those described.

[0060] In order to avoid unwanted liquid outflow, a demisting device can be installed on the top of the evaporation device 90 in one example. In another example, the gas inlet of the evaporation device can be in the form of a dip tube, which is immersed in a Figure 3 The liquid hydrocarbon reservoir is shown in the lower part of the evaporation device.

[0061] In order to adjust the flow conditions during mass transfer and heat exchange in the evaporation device, in one example, Figure 3 In the manner shown in , part of the liquid hydrocarbon reservoir collected in the lower part of the evaporation device can be discharged via conduit 96 and pump 97 and recycled to the upper part of the evaporation device, preferably above the internals of the enlarged surface area, via conduit 98. The remaining part of the liquid hydrocarbon reservoir collected in the lower part of the evaporation device is discharged from the evaporation device via conduit 94 and, in one example, is supplied to further processing or recovery of the components present, such as recovery of metal components.

[0062] It is possible to make changes to the above-described embodiments of the present disclosure without departing from the scope of the present disclosure as defined by the appended claims. Expressions used to describe and claim the present disclosure, such as "comprises," "comprising," "containing," "having," "is," should be understood to be non-exhaustive, i.e., they allow for the presence of items, components, or elements that are not explicitly described. References to the singular should be understood to refer to the plural as well, absent an explicit indication to the contrary in a particular case. List of Reference Symbols [1] Method / Apparatus

[10] Heating stage

[12] Pipe

[14] Pipe

[20] Desulfurization stage

[22] Pipe

[24] Pipe

[30] Heating stage

[32] Pipe

[34] Pipe

[36] Catheter

[37] Catheter

[38] duct

[40] Heating stage

[42] duct

[44] duct

[50] Partial oxidation reactor (POX, ATR)

[52] duct

[60] Gas cooling stage

[62] duct

[70] Syngas deacidification stage

[72] duct

[74] duct

[76] duct

[80] Syngas conditioning stage

[90] Evaporation stage

[92] duct

[94] duct

[96] Catheter

[97] Pump

[98] Catheter

[99] Catheter.

Claims

1. A process for producing a crude synthesis gas containing hydrogen and carbon oxides by simultaneous partial oxidation of a hydrocarbon-containing gas input stream and a hydrocarbon-containing liquid input stream, comprising the steps of: (a) providing a hydrocarbon-containing gas input stream, preferably natural gas, and heating the hydrocarbon-containing gas input stream; (b) providing a hydrocarbon-containing liquid input stream comprising hydrocarbons as a major component fraction and at least one impurity fraction comprising impurities, wherein the major component fraction has a first average boiling point and wherein the at least one impurity fraction has a second average boiling point, wherein the second average boiling point is higher than the first average boiling point; (c) dividing the heated hydrocarbon-containing gas input stream into a first gas input substream and a second gas input substream; (d) introducing the heated first gaseous input substream and the liquid input stream into an evaporation unit, contacting the heated first gaseous input substream and the liquid input stream in the evaporation unit under partial evaporation conditions, wherein the partial evaporation conditions are selected to discharge from the evaporation unit a gaseous mixed input stream and a liquid residual stream, wherein the gaseous mixed input stream is depleted in impurities relative to the hydrocarbon-containing liquid input stream, and wherein the liquid residual stream is enriched in impurities relative to the hydrocarbon-containing liquid input stream; (e) introducing the gaseous mixed input stream and the second gaseous input substream into a partial oxidation reactor configured as a non-catalytic partial oxidation reactor (POX reactor) or an autothermal reformer (ATR), wherein the POX reactor or the autothermal reformer comprises at least one partial oxidation burner, reacting the gaseous mixed input stream and the second gaseous input substream with an oxygen-containing oxidant stream and optionally a moderator stream comprising steam and / or carbon dioxide in the partial oxidation reactor under non-catalytic partial oxidation (POX) or autothermal reforming (ATR) conditions to provide a crude synthesis gas stream; (f) discharging the raw synthesis gas stream from the partial oxidation reactor and supplying the raw synthesis gas stream to at least one further purification, treatment, conditioning and / or processing step.

2. The method according to claim 1, characterized in that The second gaseous input substream is introduced into the partial oxidation reactor via the at least one partial oxidation burner, and the gaseous mixed input stream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and / or via a separate conduit.

3. The method according to any one of the preceding claims, characterized in that The first average boiling point and the second average boiling point differ by at least 20°C, preferably by at least 50°C.

4. The method according to any one of the preceding claims, characterized in that The at least one impurity fraction comprises inorganic or organometallic components.

5. The method according to claim 4, characterized in that The at least one impurity fraction comprises inorganic components dissolved and / or suspended in the main component fraction.

6. The method according to claim 5, characterized in that The inorganic components are present in ionic form, wherein preferably at least one cation selected from Na, K, Mg, Ca, Al, Si, Fe, Co, Cr, Mn, Zn is present, and / or wherein preferably at least one anion selected from phosphate, sulfate, chloride, nitrate is present.

7. The method according to claim 6, characterized in that The hydrocarbon-containing liquid input stream is mixed with a complexing agent that prevents or reduces crystallization of one or more ionic components.

8. The method according to claim 4 or 6, characterized in that: The liquid residue stream is supplied to a metal recovery process.

9. The method according to any one of the preceding claims, characterized in that The at least one impurity fraction comprises liquid hydrocarbons containing functional groups containing heteroatoms such as oxygen, nitrogen and sulfur, preferably alcohols, aldehydes, ketones, acids or ethers.

10. The method according to any one of the preceding claims, characterized in that The at least one impurity fraction comprises polymerizable liquid hydrocarbons.

11. The method according to claim 10, characterized in that The hydrocarbon-containing liquid input stream is mixed with a polymerization inhibitor.

12. The method according to any one of the preceding claims, characterized in that The first temperature and the partial vaporization conditions are selected so that the liquid residual stream is from 1 wt % to 20 wt %, preferably from 1 wt % to 10 wt %, most preferably from 1 wt % to 5 wt % of the hydrocarbon-containing liquid input stream.

13. A method according to any one of the preceding claims, characterised in that The mass flow rate of the heated first gaseous input substream introduced into the evaporation device is selected such that the temperature of the gaseous mixed input stream exiting the evaporation device does not exceed at most 470°C.

14. A method according to any one of the preceding claims, characterised in that The evaporation device is configured as an evaporation tower comprising the following components: - shells and tubes arranged upright relative to the vertical, - at least one mass transfer zone arranged in the shell tube, which contains at least one mass transfer element selected from the group consisting of separation trays, random packings, structured packings, - an inlet for a first gas input substream for heating, arranged below the at least one mass transfer zone, - an inlet for a liquid input stream arranged above the at least one mass transfer zone, - an outlet for the gaseous mixed input stream arranged above the at least one mass transfer zone, - an outlet for the liquid residual stream arranged below the at least one mass transfer zone, wherein the evaporation device is further configured to allow mass transfer and direct heat exchange between the heated first gaseous input substream and the liquid input stream.

15. An apparatus for producing a crude synthesis gas containing hydrogen and carbon oxides by simultaneous partial oxidation of a hydrocarbon-containing gas input stream and a hydrocarbon-containing liquid input stream, comprising the following components fluidly connected to one another: (a) means for providing a hydrocarbon-containing gas input stream, preferably natural gas, and means for heating said hydrocarbon-containing gas input stream; (b) means for providing a hydrocarbon-containing liquid input stream comprising hydrocarbons as a major component fraction and at least one impurity fraction comprising impurities, wherein the major component fraction has a first average boiling point and wherein the at least one impurity fraction has a second average boiling point, wherein the second average boiling point is higher than the first average boiling point; (c) means for dividing the heated hydrocarbon-containing gas input stream into a first gas input substream and a second gas input substream; (d) an evaporation apparatus adapted to contact the heated first gas input substream and the liquid input stream in the evaporation apparatus under partial evaporation conditions, wherein the partial evaporation conditions are selected to discharge a gaseous mixed input stream and a liquid residual stream from the evaporation apparatus, wherein the gaseous mixed input stream is depleted in impurities relative to the hydrocarbon-containing liquid input stream, and wherein the liquid residual stream is enriched in impurities relative to the hydrocarbon-containing liquid input stream, means for introducing the heated first gas input substream and the liquid input stream into the evaporation apparatus; (e) a partial oxidation reactor configured as a non-catalytic partial oxidation reactor (POX reactor) or an autothermal reformer (ATR), wherein said POX reactor or said autothermal reformer comprises at least one partial oxidation burner, means for introducing said gaseous mixed input stream and a second gaseous input substream into said partial oxidation reactor; (f) means for discharging the raw synthesis gas stream from the partial oxidation reactor and means for supplying the raw synthesis gas stream to at least one further purification, treatment, conditioning and / or processing step.

16. The apparatus according to claim 15 is configured so that the second gas input sub-stream is introduced into the partial oxidation reactor via the at least one partial oxidation burner, and the gaseous mixed input stream is introduced into the partial oxidation reactor via the at least one partial oxidation burner and / or via a separate conduit.

17. The device according to claim 15 or 16, wherein the evaporation device is configured as an evaporation tower comprising the following components: - shells and tubes arranged upright relative to the vertical, - at least one mass transfer zone arranged in the shell tube, which contains at least one mass transfer element selected from the group consisting of separation trays, random packings, structured packings, - an inlet for a first gas input substream for heating, arranged below the at least one mass transfer zone, - an inlet for a liquid input stream arranged above the at least one mass transfer zone, - an outlet for the gaseous mixed input stream arranged above the at least one mass transfer zone, - an outlet for the liquid residual stream arranged below the at least one mass transfer zone, wherein the evaporation device is further configured to allow mass transfer and direct heat exchange between the heated first gaseous input substream and the liquid input stream.

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