Thermo-oxidative techniques for multi-feed partial oxidation

Abstract

The present invention relates to the unique operation of a partial oxidation (POx) system by the ability to simultaneously inject feedstocks having widely varying properties, including the simultaneous injection of gaseous, liquid and solid feedstocks into a hot oxygen burner.

Description

Technical Field

[0001] This invention relates to a thermo-oxidative burner (HOB) capable of generating a high-momentum reactive jet suitable for use as a partial oxidation burner. Specifically, the invention allows for unique operation of partial oxidation (POx) systems by enabling the simultaneous injection of feeds with a wide range of properties, including the simultaneous injection of gaseous, liquid, and solid feedstocks into the HOB. Background Technology

[0002] While examples of multi-feed POx burners exist in the literature, their operation typically presents operational and mechanical problems. Therefore, typical POx burners currently in use are designed to use only specific types of feedstocks. For example, a burner might be designed to use natural gas as a feedstock and would not be able to use liquid or solid feedstocks. Another POx burner might be designed to use liquid feedstocks but not gaseous or solid feedstocks. This limitation prevents systems designed for specific feedstocks from being applied to potential operations that would lead to higher product yields or production volumes. Furthermore, this limitation prevents the adaptation of the system to favorable opportunities that might develop over the system's lifespan.

[0003] Units used to produce syngas derived from hydrocarbon feedstocks (such as partial oxidation reactors / systems) typically operate under predetermined conditions based on a set of assumed characteristics. These characteristics generally include the properties of the feedstock and the properties of the syngas products required for downstream conversion into the final product. Examples of feedstock characteristics include physical state (gas / liquid / solid), temperature, composition, and pressure. When there is a change in the characteristics of the feedstock (including inherent properties, such as those listed above, but also extrinsic properties, such as its feed rate), operators are often forced to interrupt operation and / or set up costly alternative methods to accommodate the change. For example, partial oxidation systems designed to operate with gaseous feedstocks often require modifications to the burner and feed system to accommodate feeds with different physical states. This change is often exclusive, making the new configuration incompatible with the previous feedstock.

[0004] An exemplary HOB burner that can be used in a partial oxidation reactor / system is shown in U.S. Patent No. 5,266,024, which is assigned to the applicant and incorporated herein by reference in its entirety.

[0005] While examples of burners capable of partial oxidation using feeds with varying properties exist in the literature, they typically present significant operational or design challenges that render their use impractical for industrial applications. For instance, U.S. Patent 4,946,475 discloses a method in which an oxidizing gas and a slurry (a mixture of liquid and solids) are fed into a converging section to atomize the slurry. An initial droplet / oxidant mixture is then fed into a second “acceleration” section, where the gas is accelerated faster than the droplets—resulting in a second atomization step. The result is a premixture of slurry droplets and oxidizing gas fed into the reactor. A second part of the teaching includes a gaseous feed channel, specifically angled such that the gas will contact the oxidizing feed / droplet mixture at a distance from the burner surface. One disadvantage associated with this disclosure is the potential for backfire to the secondary atomization port. Specifically, a combustible mixture can form within the burner if sufficient fuel evaporates during atomization. In contrast, in this invention, thermal oxidative atomization occurs near the burner outlet, eliminating the need for (or desiring) a secondary acceleration phase and its associated potential risks. Furthermore, while U.S. Patent 4,946,475 discloses slow mixing between the oxidant / droplet mixture and the "fuel" gas using angled ports, this configuration can lead to unstable operation and increased soot production because the hot furnace gas can mix with the fuel gas, causing cracking before it can mix with the oxidant / droplet mixture. In this invention, the close proximity of the thermal oxidative jet and the slurry feed point enhances atomization and mixing between the oxidant (thermal oxygen) and the hydrocarbon feed stream. The close proximity and rapid mixing of the slurry and thermal oxidative feed further enhance evaporation and reaction, while improving flame stability, due to the elevated temperature of the thermal oxidative stream. The high momentum of the thermal oxygen also drives very rapid mixing with any additional feed streams, such as the fuel stream shown in U.S. Patent 4,946,475, to prevent soot formation and improve reaction efficiency.

[0006] U.S. Patent 4,443,230 provides a method in which the feed of a partial oxidizer is arranged coaxially and annularly. The oxidant flow is divided into at least two distinct annular spaces such that when the oxidant flow is reduced (“downgraded”), the velocity through at least one channel can remain sufficiently high to provide atomization and mixing with the slurry feed. A disadvantage of this burner configuration is that the need for multiple channels significantly complicates the control system and potentially places additional operational burdens on the operator. Furthermore, special care must be taken to ensure that the burner channels are not exposed to the thermal reactor environment in the absence of any type of oxidant flow or purge gas flow to avoid burner damage. In this invention, the gas momentum required for atomizing the liquid / slurry is provided by a single oxidizer port, thus avoiding the operational complexity of a multi-channel design. This single oxidizer port atomization is achieved through the very high momentum of the thermal oxygen jet. Even when the burner load is “downgraded” to a lower combustion rate, the momentum of the thermal oxygen jet is high enough to effectively atomize the slurry flow. Therefore, when changing the burner load, the operator does not need to change the downward flow path of the gas or add additional "purge" gas.

[0007] U.S. Patent 4,351,645 discloses a method in which mixing of a hydrocarbon feedstock (including liquid / slurry and / or gaseous hydrocarbons) with an oxidant is achieved by distributing a feed stream across multiple tubes in a bundle surrounded by a second feed stream. More specifically, the document discloses a particular burner design for achieving this. Disadvantages of this invention include the need for uniform distribution of the feedstock across multiple tube bundles to avoid the formation of hot and cold spots in the burner, which can lead to burner damage, reactor damage, and / or poor performance.

[0008] This invention increases the flexibility and operational efficiency of methods for producing hydrocarbon-derived syngas that can be used to produce products such as fuels. More specifically, the high momentum of the reactive jets produced by the HOB of this invention enables a single burner to handle multiple feed streams simultaneously. This overcomes the difficulties shown in previous designs, as perfect feed distribution within the burner is not required before interaction with the mixed jets, thus improving system reliability by avoiding potential burner and reactor damage associated with insufficient feed control or uneven feed distribution leading to hot spots. Summary of the Invention

[0009] In one aspect of the invention, a method for producing syngas is provided. The method includes:

[0010] A carbonaceous feedstock comprising various combinations of gaseous, liquid, and solid components is introduced into a partial oxidation reactor vessel, wherein the feedstock is contacted with a hot oxy-fuel stream generated by a hot oxy-fuel burner, wherein the hot oxy-fuel stream is high-speed and reactive to atomize the carbonaceous feedstock selected from various volume combinations of gaseous, liquid, or solid components, and is supplied to the hot oxy-fuel burner through one or more channels, and the feedstock is partially oxidized in the partial oxidation reactor using the hot oxy-fuel jet with given values ​​of temperature, velocity, and O2 content, wherein the given partial oxidation conditions are temperature in the range of 1100°C to 1650°C, residence time, pressure, specific oxygen consumption, the ratio of oxygen in the hot oxy-fuel jet used in the partial oxidation to the feedstock, and the entrainment rate of the feedstock into the hot oxy-fuel jet, wherein the hot oxy-fuel jet is generated by the reaction of oxygen and fuel in the hot oxy-fuel burner at an HSR in the range of 12 to 3 to produce syngas with given values ​​of temperature, soot content, CH4 content, and tar content. Attached Figure Description

[0011] Figure 1 This is a cross-sectional view of a HOB device that can produce a hot-oxygen flow, which can be used in this invention.

[0012] Figure 2A This is a schematic example of a multi-feed thermo-oxidative POx burner according to one embodiment of the present invention, wherein liquid / slurry is fed together with gaseous feed.

[0013] Figure 2B This is a schematic example of a multi-feed thermo-oxygen POx burner according to one embodiment of the present invention, wherein liquid / slurry is fed together with gaseous feed in different configurations of the HOB.

[0014] Figure 3A This is a schematic example of a multi-feed thermo-oxygen POx burner according to an embodiment of the present invention, wherein multiple gaseous feed streams are supplied to the POx burner in a symmetrical manner.

[0015] Figure 3B This is a schematic example of a multi-feed thermo-oxygen POx burner according to an embodiment of the present invention, wherein multiple gaseous feed streams are supplied to the POx burner in an asymmetrical manner.

[0016] Figure 4 This is a schematic example of a multi-feed thermo-oxygen POx burner according to an embodiment of the present invention, wherein multiple gaseous feed streams are supplied to the POx burner together with liquid / slurry feed streams.

[0017] Figure 5 This is a graph showing reactor temperatures in pilot-scale reactors operating under different ratios of liquid and gaseous feedstocks.

[0018] Figure 6 This is a graph showing methane escape from a natural gas-feed burner alone, compared to a multi-feed burner operating on natural gas. Detailed Implementation

[0019] This invention can be used in any application where combustible materials are partially or completely oxidized. It is particularly useful in operations that convert hydrocarbon feedstocks (such as natural gas or biomass-derived bio-oils) into useful hydrocarbon products (such as, but not limited to, liquid fuels). The product stream produced by this invention is high-temperature syngas (i.e., a mixture of hydrogen, carbon monoxide, carbon dioxide, methane, water, and a small amount of sulfur), which includes components that can be sold and used after purification, as well as products (e.g., diesel, ethanol, methanol, etc.) that can be used as reactants to produce other ultimately useful products that can then be sold and used.

[0020] A key aspect of this invention is the use of a high-speed reactive jet to drive the atomization and mixing of various feedstocks without employing complex burner designs as shown in the prior art. Specifically, the jet's mixing power is high enough that even after mixing / atomizing the first feedstock stream, sufficient mixing power remains to mix second or more feedstock streams of different types. A second aspect of the invention is the ability to independently vary the jet's mixing power based on the feedstock mixture used at any given time. These aspects are described in more detail below.

[0021] The basic part of the present invention is Figure 1 The HOB 100 shown is a specially designed burner for producing a high-temperature, high-momentum jet containing oxygen. The jet is generated by burning a small amount of fuel 10 with a large amount of oxygen 20 in the combustion chamber of burner 100. The resulting gas mixture has an oxygen concentration in the range of 65% to 90% (along with some H2O and / or CO2, depending on the fuel used) at a temperature in the range of 1000°C to 2500°C. The “hot oxygen” mixture is then accelerated through nozzle 30 to a velocity in the range of 500 m / s to 800 m / s. The overall effect is a highly reactive jet 40 with excellent mixing and shearing capabilities. For example, the jet is able to atomize liquids while entraining surrounding gases. The high O2 content and high temperature make the jet extremely reactive, forcing all liquids, gases, and solids to be drawn into the jet for rapid reaction to produce the desired effect on the process.

[0022] A key benefit of using HOBs for the vaporization of liquid feedstocks is their ability to produce very fine droplets compared to conventional atomizers. The use of hot oxygen increases gas momentum compared to ambient or “cold oxygen” streams. This increased momentum results in a reduction in the average droplet size after atomization. This combined effect of smaller droplets and higher local temperatures improves carbon conversion even with relatively short residence times. This type of HOB is utilized in U.S. Patents 5,266,024, 6,450,108, and 6,565,010, assigned to the applicant and incorporated herein by reference in their entirety. The use of this type of HOB is an excellent way to achieve atomization and combustion of liquids, viscous liquids, slurries, and sludge. Naturally, HOBs can be associated with reactors where entrainment and vaporization of gaseous / liquid / solid feedstock combinations can occur to form syngas.

[0023] In an exemplary embodiment of the invention, the HOB can be designed to atomize liquid feedstock while still having residual capacity to ensure adequate entrainment of gaseous feedstock. This is schematically illustrated in Figure 2. The HOB 200, designed to atomize and react the liquid / slurry feed, is arranged within a gaseous feedstock injector 60. When the liquid enters the throat of the HOB 200, it is atomized to form a cloud of droplets surrounded by hot oxygen. The jet of hot oxygen / atomized liquid can then preferentially entrain the gaseous feedstock before mixing with the gas in the thermal reactor. Because the hot oxygen jet dominates the mixing, the arrangement between the hot oxygen jet and the gaseous feedstock is very flexible. Figure 2 shows the gaseous feedstock injector 60 arranged symmetrically with respect to the HOB 200, but it can be reconfigured so that the feedstock can be introduced in a variety of other ways, such as biasing the HOB position to one side of the feedstock injector, distributing it to several separate injectors, or positioning the feedstock jet completely separate from the HOB 200. Furthermore, due to the high entrainment capacity of the hot oxygen jet, multiple gaseous feedstock injectors can be utilized in conjunction with the HOB. For example, it may include an additional gaseous injector for use during preheating and to continue to be used as an additional process gas feedstock in addition to the main design feedstock during normal operation. Figure 2A The annular channel surrounding the thermo-oxidative generator can also be used to transport solid feedstocks, preferably those that have already been at least partially fluidized by adding a small amount of carrier gas. Preferably, the solid feedstock is positioned as close as possible to the thermo-oxidative nozzle to avoid solid short-circuiting in the reaction zone.

[0024] As described above, the configuration shown in Figure 2 can be used for gaseous and / or solid feedstocks without the need for simultaneous use of liquid / slurry feed. However, since the high momentum of the thermal oxidant jet is ideal for atomizing liquids and slurries, these feedstocks can be used in the burner shown in Figure 2 simply by initiating a flow of liquid / slurry feed. The liquid or slurry injector should be arranged close to the thermal oxidant nozzle to maximize atomization potential and produce the smallest possible droplets. Those skilled in atomization will recognize that various methods of introducing liquids into high-momentum gaseous streams also apply here, adding another element of flexibility to HOB design. For example, Figure 2 depicts a configuration where the thermal oxidant burner is in the center and other feedstocks are introduced around the burner. However, those skilled in the art will appreciate that a configuration where the feed port is in the center and a first annular space surrounding the feed port can also be used for the thermal oxidant burner. Figure 4 The feed through the central port of this structure can be solid, liquid / slurry. Gaseous feed can also be supplied through the central port, but is preferably fed outside the hot oxygen ring (i.e., between the hot oxygen ring and the furnace wall).

[0025] Therefore, as Figure 2A As shown and as described above, HOBs can be designed to atomize liquid / slurry only, entrain gaseous feed only, entrain fluidized solid feed only, or process any combination of gaseous, solid, and liquid feeds simultaneously.

[0026] Because the jet formation occurs within the HOB, it is unaffected by external operating conditions. It also operates independently, meaning that jet properties, such as temperature, composition, and momentum, can be adjusted to accommodate changes in external operating conditions. This operational flexibility allows the operator to modify the reactive jet properties during operation. For example, if the HOB is designed for a gaseous feedstock with an internal stoichiometry (HSR) between 3 and 12, preferably between 6 and 9, it may be desirable to increase the burner momentum when a liquid feed is included. One way to achieve this is by increasing the thermal oxidative temperature by lowering the HSR. This adjustment is described in U.S. Patent Application No. 2023-0183063 A1, assigned to the applicant and incorporated herein by reference in its entirety. As used herein, “HSR” or “thermal oxidative stoichiometry” refers to the ratio of the number of moles of oxygen contained in the oxidant fed to the burner to the number of moles of oxygen required for complete combustion of the fuel fed to the burner. As used herein, “Total Stoichiometry” and “TSR” refer to the ratio of the number of moles of oxygen contained in the oxidizer fed into the burner to the number of moles of oxygen required for the complete combustion of all the fuel fed into the burner plus auxiliary fuel plus all the combustible feed fed into the reactor.

[0027] According to one aspect of the invention, and referring back to the previous one. Figure 2AThe HOB 200 has fuel 10 and O2 20 feeds, as discussed above. The HOB 200 can handle multiple individual feeds or combinations of feeds. For example, the total feed can be at or within the outlet of the HOB nozzle 210, consisting of: gaseous, liquid, slurry, or solid feeds only; or combinations of liquid / gas, liquid / solid, solid / gas, or liquid, as well as solid and gaseous feeds. Feeds in different physical states (solid, liquid, gas) can be fed separately to the burner, for example, through different flow channels, or can be combined before being fed to the burner. For scenarios using solid and liquid feeds, it is preferred, but not necessary, to combine the two streams into a single "slurry" stream before feeding into the HOB. For scenarios with gaseous and solid feeds, the solids can be fed as a fluidized stream or slurry, where the liquid phase may or may not be a hydrocarbon feed. The maximum size of the solid particles is defined based on the solids conversion rate in the POx reactor and the final burner channel size. Typically, any finely ground hydrocarbon-containing solid feedstock can be combined with hydrocarbon-containing liquid and / or gaseous feedstocks. For scenarios utilizing both liquid and gaseous feedstocks, it is preferable to feed them separately into the burner.

[0028] Examples of suitable raw feedstocks and their sources include:

[0029] Natural gas, which comes from any of its commercial sources;

[0030] A gaseous stream generated by a gasification reactor in which solid hydrocarbon materials (such as biomass) or solid fuels (such as coal or lignin) are gasified at a sufficiently high temperature in a gaseous stream that typically contains air, steam and / or oxygen, such that at least a portion of the solid material is converted into a gaseous raw stream.

[0031] Product streams and by-product streams produced by petrochemical refineries or chemical plants are more typically gaseous, but may also be liquid and / or solid.

[0032] Coke oven gas, which is the waste gas stream generated in a reactor that heat-treats coal to produce coke;

[0033] Cracking gas is a hydrocarbon-containing gaseous stream generated in a reactor to thermally treat solid carbonaceous materials such as fossil fuels or biomass to liquefy and partially oxidize the solid materials.

[0034] Other possible feed streams include oils such as pyrolysis oil, and liquid hydrocarbons.

[0035] Gaseous feed streams typically exhibit temperatures between approximately 33℉ and 1800℉. Solid feed streams are typically fed at temperatures below where solids might begin to “soften” or become viscous. In a representative example, the feed of high-density polyethylene plastic material can be kept below 180℉ to avoid sticking and feed problems. Liquid feeds can be fed at temperatures up to their boiling points. Liquid feeds can also be fed at any lower temperature, where the liquid feed can be pumped to the HOB.

[0036] A particularly unique and useful operational feature of multi-feed hob (HOB) is its ability to operate using any ratio of feedstock in a single burner. A hob can operate with 100% gaseous feedstock, then convert to 75% gaseous feedstock and 25% liquid feedstock, and then convert to 100% liquid feedstock. This is... Figure 5 As shown in the figure, this graph shares data from pilot-scale experimental testing. A single HOB was used to vaporize NG and bio-oil. The horizontal axis shows the proportion of bio-oil, expressed as a percentage of the combined bio-oil and NG feedstocks processed. The vertical axis is the operating temperature of the POx reactor. The narrow temperature range shown indicates the ability of a single HOB to very efficiently vaporize NG itself, bio-oil itself, and any combination of NG and bio-oil.

[0037] refer to Figure 2B This shows an alternative configuration of HOB 200, in which liquid or slurry feedstock 70 is introduced concentrically and is positioned inside the hot oxidizing feedstock, wherein at nozzle 210, atomized feedstock entrained with gaseous feedstock 50 is guided to the outlet of nozzle 210 in the partial oxidation reactor.

[0038] In another exemplary implementation and reference Figure 3A Multiple gaseous feedstocks (i.e., multiple gaseous feedstocks with the same or different compositions) 50 and 80 are symmetrically fed through parallel conduits 60 and 90, respectively, and are guided to the nozzle of the HOB 300 and entrained in the partial oxidation reactor. For example... Figure 3B As shown, these multiple gaseous feed streams 50 and 80, wherein stream 50 is directly introduced into the partial oxidation reactor, while stream 80 is guided parallel to HOB 300 to the nozzle of HOB 300, where the two are combined in the partial oxidation reactor.

[0039] Figure 4 Another exemplary embodiment is shown, in which multiple gaseous feedstocks 50, 80 are mixed with liquid / slurry feedstock 70, wherein the slurry feedstock stream 70 is arranged concentrically with HOB 400 and respectively on the outer periphery of gaseous feedstocks 80 and 50, such that the liquid / slurry feedstock 70 is atomized, and gaseous feedstocks 80 and 50 are entrained in the hot oxygen stream flowing from the HOB nozzle into a partial oxidation reactor, in which the mixture is reformed into syngas.

[0040] It is equally important to note that HOBs designed to simultaneously vaporize multiple feeds (such as...) Figure 3A and Figure 3B (As shown) will still maintain the same ability to gasify a single feed as a burner designed for a single feed. This is in Figure 6 The figure shows the variation of CH4 slip data (a common measure of gasification efficiency) with operating temperature collected during two separate experimental test events. Solid data points are from tests using a HOB designed to gasify both gaseous and liquid feedstocks. Hollow data points are from several tests using a HOB designed to gasify only gaseous feedstocks. For all tests, the gaseous feedstock was natural gas. Liquid feedstocks were not used in these tests. It is clear that there is no significant difference in CH4 slip for either burner type, indicating identical gasification performance.

[0041] One aspect of the invention is the ability to optimize the composition of the product gas by selecting feedstocks in the mixture. For example, it is known that the gasification of many solid feedstocks produces syngas with a low H2:CO ratio. Adding a feedstock with a high H:CO ratio (such as natural gas) to the feedstock fed into the reactor results in an increase in the H2:CO ratio.

[0042] To demonstrate the capabilities of thermo-oxidation technology as described above, a set of example cases has been defined and explored. A proprietary model developed by Linde was used to estimate the HOT performance in the partial oxidation system to predict syngas generation and / or reforming performance. This model combines the effects of thermo-oxidation jet properties on feedstock atomization and mixing with the reactivity of the jet and feedstock materials to predict the properties of the syngas leaving the system. The model has been validated against a wide dataset including feedstocks such as natural gas, coke oven gas, and biomass-derived syngas, operating at temperatures ranging from 1100°C to 1650°C and operating pressures from 0 bar to 28 bar.

[0043] The example scenarios demonstrate how HOBs can be used to enhance the normal operation of devices designed to use biomass feedstocks. Five scenarios are included for evaluation, each representing a combination of gaseous feedstock (biomass-derived syngas) and liquid methanol. The use of representative gaseous biomass-derived syngas and liquid methanol is chosen to illustrate the benefits of multi-feed HOBs. Other configurations and feedstocks as described above are acceptable and can be utilized in a similar manner to those illustrated in these examples.

[0044] Table 1 summarizes five scenarios. Scenario 1 represents the baseline scenario, where syngas represents gaseous biomass-derived syngas as the primary and sole feedstock. Scenario 2 shows how H2 and CO production is affected when the unit is forced to downgrade its operation due to biomass gasification issues. Scenario 3 shows that the addition of a liquid feedstock (in this case, methanol) can be used to restore H2 and CO production to design levels. Scenario 4 shows how H2 and CO production can be increased relative to Scenario 1 by adding a liquid feedstock during normal operation. Scenario 5 shows how syngas production can be maintained when the biomass gasification system is completely shut down and unusable. The values ​​of operational flexibility shown through these examples will be readily apparent to those familiar with the operation of chemical plants utilizing biomass gasifiers.

[0045] Because biomass feedstock and methanol have different properties, the syngas produced by the HOB system will differ in some aspects. For example, comparing the H2:CO ratio in Case 1 and Case 5 shows that for this representative biomass-derived syngas, the H2:CO ratio is 1.16, while for methanol, the H2:CO ratio is 1.5. Similarly, O2 and fuel usage, as well as operating temperature, will also differ. The example assumes that the operation is optimized to maximize H2+CO production, as indicated by the amount of CH4 escape in the regulated syngas. These differences are operational and will not require costly downtime or mechanical changes to accommodate, provided the unit is designed for the possible operating range. Table 1: Example Operation Details

[0046]

[0047] The momentum of the hot oxygen feed stream and the feed should be high enough to achieve the required mixing level of oxygen with all feed streams. The momentum flux ratio of the hot oxygen feed stream to the feed stream should be at least 3.0.

[0048] The composition of the hot oxidizing flow depends on the conditions under which it is generated, but preferably it contains at least 50% by volume of O2, and more preferably at least 65% by volume of O2. The formation of a high-speed hot oxidizing flow can be performed according to the description in U.S. Patent No. 5,266,024.

[0049] Typical values ​​for the properties of a thermo-oxygen jet are usually within the following range:

[0050] Temperature: 2000℉ to 4700℉

[0051] Speed: 500 ft / s to 4500 ft / s, preferably 1950 ft / s to 2625 ft / s

[0052] O2 content: 50% to 90%

[0053] O2 flow rate is 1 kg / s to 50 kg / s

[0054] Typical values ​​for partial oxidation conditions are usually within the following range:

[0055] Temperature in the POx reactor: 2550℉, but as low as 2400℉ to 2100℉ and as high as 2650℉ to 3200℉.

[0056] Residence time in the POx reactor: 2 to 10 seconds

[0057] Pressure in the POx reactor: atmospheric pressure to 600 psig – but can be higher as required by the process. The pressure is typically set based on downstream processing requirements or limitations of the biomass gasifier feed system.

[0058] The specific oxygen consumption in partial oxidation will vary based on the composition of the feedstock (which can vary widely) and is highly temperature-dependent.

[0059] The ratio of oxygen to feed in the thermal oxygen jet used in partial oxidation: this depends on the HSR, which is described below.

[0060] Entrainment rate of feedstock entering the thermo-oxygen jet: This depends on both the properties of the HOB (Hot Oxygen Booster) and the properties of the feedstock flow entrained into the jet. For example, less dense feedstocks (feedstocks operating at higher temperatures or lower pressures) will be entrained more slowly than denser feedstocks.

[0061] Typical values ​​for the conditions used in a thermal oxygen generator to produce a thermal oxygen flow are usually within the following range:

[0062] The HSR in the oxidizing generator is preferably 3 to 6, but can be as high as 20.

[0063] The temperature of the oxygen fed into the thermal oxygen generator is: ambient temperature -400℉.

[0064] Typical characteristics of syngas produced by POx reactors are generally within the following range:

[0065] Temperature: 2550℉, but as low as 2100℉ and as high as 3200℉.

[0066] Ash content: 0 gm / Nm3 to 0.02 gm / Nm3

[0067] CH4 content: 0% to 1%, preferably as low as possible, but reactor T will limit the extent to which it can be reduced. Operation typically ends at around 0.5%.

[0068] Tar content: 0 gm / Nm3 - No tar can be tolerated, as it will eventually deposit on downstream equipment and cause it to stop operating.

[0069] Although the invention has been described in detail with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications may be made and equivalents may be employed without departing from the scope of the appended claims.

Claims

1. A method for generating syngas in a partial oxidation reactor operated with a thermal-oxygen burner, the method comprising: A carbonaceous feedstock comprising various combinations of gaseous, liquid, and solid components is introduced into a partial oxidation reactor vessel. The feedstock is contacted with a hot oxy-fuel stream generated by a hot oxy-fuel burner, which is high-speed and reactive to atomize the carbonaceous feedstock, selected from various volume combinations of gaseous, liquid, or solid components, and supplied to the hot oxy-fuel burner through one or more channels. The feedstock is partially oxidized in the partial oxidation reactor using the hot oxy-fuel jet with given values ​​for its temperature, velocity, and O2 content under given partial oxidation conditions, which are temperature in the range of 1100°C to 1650°C, residence time, pressure, specific oxygen consumption, the ratio of oxygen in the hot oxy-fuel jet used in the partial oxidation to the feed, and the entrainment rate of the feedstock into the hot oxy-fuel jet. The hot oxy-fuel jet is generated by the reaction of oxygen and fuel in the hot oxy-fuel burner at an HSR in the range of 3 to 12 to produce syngas with given values ​​for temperature, soot content, CH4 content, and tar content.

2. The method according to claim 1, wherein the raw material is a combination of a liquid raw material component and a gaseous raw material component, wherein the liquid raw material component is selected from the group consisting of pyrolysis oil, ethanol, plastic-derived oil, heavy petroleum products and slurry, and the gaseous raw material component is selected from the group consisting of natural gas, biogas, crude syngas derived from biomass gasification and hydrocarbon-containing gases produced from petroleum products, wherein the ratio of liquid to gas varies from 0% by volume to 100% by volume.

3. The method according to claim 2, wherein the raw material comprises a solid raw material component selected from the group consisting of coal, biomass, municipal solid waste and agricultural waste.

4. The method according to claim 1, wherein the thermo-oxygen jet has a velocity in the range of 500 m / s to 800 m / s.

5. The method of claim 1, wherein the thermal oxygen jet has an oxygen concentration in the range of 65% to 90% by volume.

6. The method of claim 1, wherein the oxy-thermal burner operates at an oxygen flow rate between 1 kg / s and 50 kg / s.

7. The method of claim 1, wherein the reactor vessel operates at a pressure between 1 bar and 50 bar.

8. The method of claim 1, wherein the syngas is further processed to produce chemicals such as ammonia, methanol, or synthetic fuels.

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