AU2007245732B2

AU2007245732B2 - Gasification reactor and its use

Info

Publication number: AU2007245732B2
Application number: AU2007245732A
Authority: AU
Inventors: Robert Erwin Van Den Berg; Franciscus Gerardus Van Dongen; Thomas Paul Von Kossak-Glowczewski; Pieter Lammert Zuideveld
Original assignee: Air Products and Chemicals Inc
Current assignee: Air Products and Chemicals Inc
Priority date: 2006-05-01
Filing date: 2007-04-20
Publication date: 2010-07-01
Anticipated expiration: 2027-04-20
Also published as: AU2007245732A1; WO2007125047A1; EP2016160A1; JP2009535471A

Description

WO 2007/125047 PCT/EP2007/053871 GASIFICATION REACTOR AND ITS USE Field of the Invention The present invention relates to an improved gasification reactor for preparing synthesis gas comprising CO, CO 2 and H 2 from a carbonaceous stream using an oxygen containing stream. The invention is also 5 directed to a system for preparing such a synthesis gas and to a process, which may be performed in said reactor and in said system. Background of the invention Methods for producing synthesis gas are well known 10 from practice. An example of a method for producing synthesis gas is described in EP-A-400740. Generally, a carbonaceous stream such as coal, brown coal, peat, wood, coke, soot, or other gaseous, liquid or solid fuel or mixture thereof, is partially combusted in a gasification 15 reactor using an oxygen containing gas such as substantially pure oxygen or (optionally oxygen enriched) air or the like, thereby obtaining a.o. synthesis gas (CO and H 2 ), CO 2 and a slag. The slag formed during the partial combustion drops down and is drained through an 20 outlet located at or near the reactor bottom. The hot product gas in the reactor of EP-A-400740 flows upwardly. This hot product gas, i.e. raw synthesis gas, usually contains sticky particles that lose their stickiness upon cooling. These sticky particles in the 25 raw synthesis gas may cause problems downstream of the gasification reactor where the raw synthesis gas is further processed. This because undesirable deposits of the sticky particles on, for example, walls, valves or outlets may adversely affect the process. Moreover such 30 deposits are hard to remove.

WO 2007/125047 PCT/EP2007/053871 -2 Therefore, the raw synthesis gas is quenched in a quench section. In such a quench section a quench gas is injected into the upwardly moving raw synthesis gas in order to cool it. 5 EP-A-662506 describes a process to cool synthesis gas by injecting downwardly a cooling gas into said hot synthesis gas at the interface of a combustion chamber and a tubular part fluidly connected to the top of the combustion chamber. 10 A similar reactor as in EP-A-400740 is described in WO-A-2004/005438 of the same applicant. This publication describes a gasification combustion chamber and a tubular part fluidly connected to an open upper end of said combustion chamber. Both combustion chamber and tubular 15 part are located in a pressure shell defining an annular space between said pressure shell and the combustion chamber and tubular part respectively. According to this publication measures are required to avoid dust laden raw synthesis gas as prepared in the combustion chamber to 20 enter the annular space. This publication also describes a syngas cooler having three heat exchanging surfaces located one above the other as present in a separate pressure vessel. US-A-5803937 describes a gasification reactor and a 25 syngas cooler within one pressure vessel. In this reactor a tubular part fluidly connected to an open upper end of a combustion chamber, both located within a pressure shell. At the upper end of the tubular part the gas is deflected 1800 to flow downwardly through the annular 30 space between tubular part and the wall of the pressure shell. In said annular space heat exchanging surfaces are present to cool the hot gas. The afore discussed gasification reactors have in common that the synthesis gas as produced flows 35 substantially upwards and the slag flows substantially -3 downwards relative to the gasification burners as present in said reactors. Thus, all these reactors have an outlet for slag, which is separate from the outlet for synthesis gas. This in contrast to a class of gasification reactors as for example described in EP-A-926441 where both slag and synthesis gas flow downwardly and wherein both the outlet for slag 5 and synthesis gas are located at the lower end of the reactor. The present invention at least in a preferred embodiment is directed to an improved reactor of the type where slag and synthesis gas are separately discharged from said reactor as in e.g. WO-A-2004/005438 and US-A-5803937. A problem with the syngas cooler of WO-A-2004/005438 and also with the apparatus of US-A-5803937 is 1o that the heat exchanging surfaces introduce a large complexity to the design of said apparatuses. Another problem with the syngas cooler of WO-A-2004/005438 and also with the apparatus of US-A-5803937 is that the heat exchanging surfaces are vulnerable to fouling from feedstocks with for instance a high alkaline content. There is thus a desire to process high alkaline feedstocks as well as a desire to provide more simple gasification is reactors. Object of the Invention It is the object of the present invention to substantially overcome or at least ameliorate one or more of the disadvantages of the prior art, or to provide a useful alternative. 20 Summary of the Invention The present invention in a first aspect relates to a gasification reactor comprising: - a pressure shell for maintaining a pressure higher than atmospheric pressure; - a slag bath located in a lower part of the pressure shell; - a gasifier wall arranged inside the pressure shell defining a gasification 25 chamber wherein during operation the synthesis gas can be formed, a lower open part of the gasifier wall which is in fluid communication with the slag bath and an open upper end of the gasifier wall which is in fluid communication with a quench zone; - a quench zone comprising a tubular formed part positioned within the pressure shell, open at its lower and upper end and having a smaller diameter than the pressure 30 shell thereby defining an annular space around the tubular part, wherein the lower open end of the tubular formed part is fluidly connected to the upper end of the gasifier wall and the upper open end of the tubular formed part is in fluid communication with the annular space; -4 - wherein at the lower end of the tubular part injecting means are present for injecting a liquid or gaseous cooling medium and wherein in the annular space injecting means are present to inject a liquid in the form of a mist and wherein an outlet for synthesis gas is present in the wall of the pressure shell fluidly connected to said annular 5 space. Applicants found that by using the reactor according to at least a preferred embodiment of the present invention the use of complicated heat exchange surfaces could be avoided and high alkaline and high chlorine containing feedstocks could be processed. Other preferred embodiments will be discussed hereafter. 10 The present invention at least in a preferred embodiment is also directed to the following system for preparing a purified mixture comprising carbon monoxide and hydrogen comprising of a gasification reactor, wherein the outlet for synthesis gas is fluidly connected to an inlet of a wet gas scrubber and wherein the wet gas scrubber is provided for an outlet for purified mixture comprising carbon monoxide and hydrogen. is The above system is preferable because a dry solid removal process step can be omitted and the overall system can be made more simple. The present invention at least in a preferred embodiment is also directed to a process to prepare a mixture comprising of carbon monoxide and hydrogen by partial oxidation of a solid carbonaceous feed in a gasification reactor or in a system. In such a 20 process a solid carbonaceous feed is partially oxidized in the gasification chamber with an oxygen comprising gas to form an upwardly moving gas mixture having a temperature of between 1200 and 1800 'C preferably between 1400 and 1800 'C. This mixture is first cooled in the tubular part to a temperature of between 500 and 900 'C and subsequently further cooled in the annular part to below 500 *C by injecting a mist of liquid droplets 25 into the gas flow. It has been found that the raw synthesis gas is cooled very efficiently, as a result of which the risk of deposits of sticky particles downstream of the gasification reactor is reduced. Brief description of the drawings 30 Figure 1 schematically shows a process scheme for a system for preparing a purified mixture comprising carbon monoxide and hydrogen; and Figure 2 schematically shows a process scheme for a system for preparing a purified mixture comprising carbon monoxide and hydrogen.

Figure 3 schematically shows a longitudinal cross-section of a preferred gasification reactor. Detailed description of the invention The gasification reactor according to at least a preferred embodiment the present s invention is suitably used to prepare a mixture comprising of carbon monoxide and hydrogen by partial oxidation of a solid carbonaceous feed in a gasification reactor according to at least a preferred embodiment the present invention or in a system according to at least a preferred embodiment the present invention. In such a process a solid carbonaceous feed is partially oxidized in the gasification chamber with an oxygen 10 comprising gas to form an upwardly moving gas mixture having a temperature WO 2007/125047 PCT/EP2007/053871 -6 of between 1200 and 1800 'C preferably between 1400 and 1800 'C. This mixture is cooled, in a first cooling step, in the tubular part to a temperature of between 500 and 900 0 C and subsequently further cooled, in a second 5 cooling step, in the annular part to below 500 0 C by injecting a mist of liquid droplets into the gas flow. The solid carbonaceous feed is partially oxidised with an oxygen comprising gas. Preferred carbonaceous feeds are solid, high carbon containing feedstocks, more 10 preferably it is substantially (i.e. > 90 wt.%) comprised of naturally occurring coal or synthetic (petroleum)cokes, most preferably coal. Suitable coals include lignite, bituminous coal, sub-bituminous coal, anthracite coal, and brown coal. 15 In general, this so-called gasification is carried out by partially combusting the carbonaceous feed with a limited volume of oxygen at the elevated temperature in the absence of a catalyst. In order to achieve a more rapid and complete gasification, initial pulverisation of 20 the coal is preferred to fine coal particulates. The term fine particulates is intended to include at least pulverized particulates having a particle size distribution so that at least about 90% by weight of the material is less than 90 pm and moisture content is 25 typically between 2 and 8% by weight, and preferably less than about 5% by weight. The gasification is preferably carried out in the presence of oxygen and optionally some steam, the purity of the oxygen preferably being at least 90% by volume, 30 nitrogen, carbon dioxide and argon being permissible as impurities. Substantially pure oxygen is preferred, such as prepared by an air separation unit (ASU). If the water content of the carbonaceous feed, as can be the case when coal is used, is too high, the feed is 35 preferably dried before use. The oxygen used is WO 2007/125047 PCT/EP2007/053871 -7 preferably heated before being contacted with the coal, preferably to a temperature of from about 200 to 500 0 C. The partial oxidation reaction is preferably performed by combustion of a dry mixture of fine 5 particulates of the carbonaceous feed and a carrier gas with oxygen in a suitable burner as present in the gasification chamber of the reactor according to the invention. Examples of suitable burners are described in US-A-48887962, US-A-4523529 and US-A-4510874. The 10 gasification chamber is preferably provided with one or more pairs of partial oxidation burners, wherein said burners are provided with supply means for a solid carbonaceous feed and supply means for oxygen. With a pair of burners is here meant two burners, which are 15 directed diametric into the gasification chamber. This results in a pair of two burners in a substantially opposite direction at the same horizontal position. The firing direction of the burners may be slightly tangential as for example described in EP-A-400740. 20 Examples of suitable carrier gasses to transport the dry and solid feed to the burners are steam, nitrogen, synthesis gas and carbon dioxide. Preferably nitrogen is used when the synthesis gas is used for especially power generation and as feedstock to make ammonia. Carbon 25 dioxide is preferably used when the synthesis gas is subjected to downstream shift reactions. The shifted synthesis gas may for example be used as feed gas to a Fischer-Tropsch synthesis or to prepare hydrogen methanol and/or dimethyl ether. 30 The synthesis gas discharged from the gasification reactor comprises at least H 2 , CO. and CO 2 . The suitability of the synthesis gas composition for the methanol forming reaction is expressed as the stoichiometric number SN of the synthesis gas, whereby 35 expressed in the molar contents [H 2 ], [CO], and [CO 2 ], SN WO 2007/125047 PCT/EP2007/053871 -8 = ([H 2

]-[CO

2 ])/([CO]+[C0 2 ]). It has been found that the stoichiometric number of the synthesis gas produced by gasification of the carbonaceous feed is lower than the desired ratio of about 2.05 for forming methanol in the 5 methanol forming reaction. By performing a water shift reaction and separating part of the carbon dioxide the SN number can be improved. Preferably hydrogen separated from methanol synthesis offgas can be added to the synthesis gas to increase the SN. 10 In one embodiment of the present invention the raw synthesis gas is cooled in the first cooling step in the tubular part to a temperature below the solidification temperature of the non-gaseous components before performing the second cooling step. The solidification 15 temperature of the non-gaseous components in the raw synthesis gas will depend on the carbonaceous feed and is usually between 600 and 1200'C and more especially between 500 and 1000 0 C, for coal type feedstocks. The first cooling step in the tubular part may be performed 20 by injecting a quench gas. Cooling with a gas quench is well known and described in for example EP-A-416242, EP-A-662506 and WO-A-2004/005438. Examples of suitable quench gases are recycle synthesis gas and steam. More preferably this first cooling is performed by injecting a 25 mist of liquid droplets into the gas flow as will be described in more detail below. The use of the liquid mist as compared to a gas quench is advantageous because of the larger cooling capacity of the mist. The liquid may be any liquid having a suitable viscosity in order to 30 be atomized. Non-limiting examples of the liquid to be injected are a hydrocarbon liquid, a waste stream etc. Preferably the liquid comprises at least 50% water. Most preferably the liquid is substantially comprised of water (i.e. > 95 vol%). In a preferred embodiment the 35 wastewater, also referred to as black water, as obtained WO 2007/125047 PCT/EP2007/053871 -9 in a possible downstream synthesis gas scrubber is used as the liquid. Even more preferably the process condensate of an optional downstream water shift reactor is used as the liquid. 5 With the term 'raw synthesis gas' is meant the gas mixture as directly obtained in the gasification reactor. This product stream may - and usually will - be further processed, for example in a dry solids removal system, wet gas scrubber and/or a shift converter. 10 With the term 'mist' is meant that the liquid is injected in the form of small droplets. If water is to be used as the liquid, then preferably more than 80%, more preferably more than 90%, of the water is in the liquid state. 15 Preferably the injected mist has a temperature of at most 50 0 C below the bubble point at the prevailing pressure conditions at the point of injection, particularly at most 15 0 C, even more preferably at most 10 0 C below the bubble point. To this end, if the 20 injected liquid is water, it usually has a temperature of above 90 0 C, preferably above 150 0 C, more preferably from 200 0 C to 230 0 C. The temperature will obviously depend on the operating pressure of the gasification reactor, i.e. the pressure of the raw synthesis as 25 specified further below. Hereby a rapid vaporization of the injected mist is obtained, while cold spots are avoided. As a result the risk of ammonium chloride deposits and local attraction of ashes in the gasification reactor is reduced. 30 Further it is preferred that the mist comprises droplets having a diameter of from 50 to 200 jLm, preferably from 100 to 150 tim. Preferably, at least 80 vol.% of the injected liquid is in the form of droplets having the indicated sizes.

WO 2007/125047 PCT/EP2007/053871 - 10 To enhance quenching of the raw synthesis gas, the mist is preferably injected with a velocity of 30-90 m/s, preferably 40-60 m/s. Also it is preferred that the mist is injected with 5 an injection pressure of at least 10 bar above the pressure of the raw synthesis gas as present in the gasification reactor, preferably from 20 to 60 bar, more preferably about 40 bar, above the pressure of the raw synthesis gas. If the mist is injected with an injection 10 pressure of below 10 bar above the pressure of the raw synthesis gas, the droplets of the mist may become too large. The latter may be at least partially offset by using an atomisation gas, which may e.g. be N 2 , C0 2 , steam or synthesis gas, more preferably steam or 15 synthesis gas. Using atomisation gas has the additional advantage that the difference between injection pressure and the pressure of the raw synthesis gas may be reduced to a pressure difference of between 5 and 20 bar. Further it has been found especially suitable when 20 the mist is injected in a direction away from the gasification reactor, or said otherwise when the mist is injected in the flow direction of the raw synthesis gas. Thus preferably the mist is injected in a partially upward direction when applied in the tubular part or in a 25 downwardly direction when applied in the annular space. Hereby no or less dead spaces occur which might result in local deposits on the wall of the annular space and the tubular formed part of the quenching section. Preferably the mist is injected under an angle of between 30-60', 30 more preferably about 450, with respect to a plane perpendicular to the longitudinal axis of the tubular part. In the annular part the mist is preferably directed in a vertical downwardly direction. According to a further preferred embodiment, the 35 injected mist is at least partially surrounded by a WO 2007/125047 PCT/EP2007/053871 - 11 shielding fluid. Herewith the risk of forming local deposits is reduced. The shielding fluid may be any suitable fluid, but is preferably selected from the group consisting of an inert gas such as N 2 and CO 2 , synthesis 5 gas, steam and a combination thereof. According to an especially preferred embodiment, the amount of injected mist is selected such that the raw synthesis gas leaving the quenching sections comprises at least 40 vol.% H 2 0, preferably from 40 to 60 vol.% H 2 0, 10 more preferably from 45 to 55 vol.% H 2 0. In another preferred embodiment the amount of water added relative to the raw synthesis gas is even higher than the preferred ranges above if one chooses to perform a so-called overquench. In an overquench type process the 15 amount of water added, preferably the amount added in the annular space, is such that not all liquid water will evaporate and some liquid water will remain in the cooled raw synthesis gas. Such a process is advantageous because a downstream dry solid removal system can be omitted. In 20 such a process the raw synthesis gas leaving the gasification reactor is saturated with water. The weight ratio of the raw synthesis gas and water injection can be 1:1 to 1:4. It has been found that herewith the capital costs can 25 be substantially lowered, as no further or significantly less addition of steam in an optional downstream water shift conversion step is necessary. With capital costs is here meant the capital costs for steam boilers which are required to generate steam needed to be injected into the 30 feed to the water shift conversion step. It has been further found that by omitting the dry solid removal system the capital costs can be substantially lowered as well. The dry solid removal system can be omitted in the overquench operation. The dry solids removal system can 35 also be omitted in a process embodiment wherein the WO 2007/125047 PCT/EP2007/053871 - 12 synthesis gas temperature at the outlet of the reactor downstream of the annular space is below 500'C. In a preferred method of the present invention, the raw synthesis gas, and especially the synthesis gas as 5 saturated with water, leaving the quenching section is preferably shift converted whereby at least a part of the water is reacted with CO to produce CO 2 and H 2 thereby obtaining a shift converted synthesis gas stream. As the person skilled in the art will readily understand what is 10 meant with a shift converter, this is not further discussed. Preferably, before shift converting the raw synthesis gas, the raw synthesis gas is heated in a heat exchanger against the shift converted synthesis gas stream. Herewith the energy consumption of the method is 15 further reduced. In this respect it is also preferred that the liquid is heated before using the liquid injecting it as a mist in the process of the present invention. Preferably heating of this liquid is performed by indirect heat exchange against the shift converted 20 synthesis gas stream. Any desired molar ratio of H 2 /CO may be obtained by subjecting one part of the synthesis gas to a water shift reaction obtaining a CO depleted stream and by-passing the water shift unit with another part of the synthesis 25 gas and combining the CO depleted stream and the by-pass stream. By choosing the ratio of by-pass and shift feed one may achieve most desired ratios for the preferred downstream processes. Detailed description of the drawings 30 The invention will now be described by way of example in more detail with reference to the accompanying non limiting drawings. Same reference numbers as used below refer to similar structural elements. Reference is made to Figure 1. Figure 1 schematically 35 shows a system 1 for producing synthesis gas. In a WO 2007/125047 PCT/EP2007/053871 - 13 gasification reactor (2) a carbonaceous stream and an oxygen-containing stream may be fed via lines (3), (4), respectively to a gasification reactor (2). In gasification reactor (2) a raw synthesis gas and a slag 5 is obtained. To this end usually several burners (not shown) are present in the gasification reactor (2). Usually, the partial oxidation in the gasification reactor (2) is carried out at a temperature in the range from 1200 to 1800 0 C, preferably between 1400 and 1800 'C 10 and at a pressure in the range from 1 to 200 bar, preferably between 20 and 100 bar, more preferably between 40 and 70 bar. The ash components as are present in most of the preferred feeds will form a so-called liquid slag at 15 these temperatures. The slag will preferably form a layer on the inner side of the wall of reactor (2), thereby creating an isolation layer. The temperature conditions are so chosen that the slag will create one the one hand such a protective layer and on the other hand is still 20 able to flow to a lower positioned slag outlet (7) for optional further processing. The produced raw synthesis gas is fed via line (5) to a quenching zone (6); herein the raw synthesis gas is usually cooled to below 500 0 C, for example to about 25 400 0 C. To the quenching section (6) liquid water is injected via line 17 in the form of a mist, as will be further discussed in Figure 3 below. The amount of mist to be injected in the quenching section (6) will depend on various conditions, including 30 the desired temperature of the raw synthesis gas leaving the quenching section (6). According to a preferred embodiment of the present invention, the amount of injected mist is selected such that the raw synthesis gas leaving the quenching section (6) has a H 2 0 content of 35 from 45 to 55 vol.%.

WO 2007/125047 PCT/EP2007/053871 - 14 As shown in the embodiment of Figure 1, the raw synthesis gas leaving the quenching section (6) is further processed. To this end, it is fed via line (8) into a dry solids removal unit (9) to at least partially 5 remove dry ash in the raw synthesis gas. Preferred dry solids removal units (9) are cyclones or filter units as for example described in EP-A-551951 and EP-A-1499418. Dry ash is removed form the dry solids removal unit via line 18. 10 After the dry solids removal unit (9) the raw synthesis gas may be fed via line (10) to a wet gas scrubber (11) and subsequently via line (12) to a shift converter (13) to react at least a part of the water with CO to produce CO 2 and H 2 , thereby obtaining a shift 15 converted gas stream in line (14). As the wet gas scrubber (11) and shift converter (13) are already known per se, they are not further discussed here in detail. Waste water from gas scrubber (11) is removed via line (22) and optionally partly recycled to the gas 20 scrubber (11) via line (23). Part of the wastewater, black water, from gas scrubber (11) may be preferably used as liquid water as injected via line (17). This is advantageous because any solid compounds present in the black water will be removed from the process via the dry 25 solids removal unit (9). Further improvements are achieved when the raw synthesis gas in line (12) is heated in a heat exchanger (15) against the shift converted synthesis gas in line (14) that is leaving the shift converter (13). 30 Further it is preferred according to the present invention that energy contained in the stream of line (16) leaving heat exchanger (15) is used to warming up the water in line (17) to be injected in quenching section (6). To this end, the stream in line (16) may be WO 2007/125047 PCT/EP2007/053871 - 15 fed to an indirect heat exchanger (19), for indirect heat exchange with the stream in line (17). As shown in the embodiment in Figure 1, the stream in line (14) is first fed to the heat exchanger (15) before 5 entering the indirect heat exchanger (19) via line (16). However, the person skilled in the art will readily understand that the heat exchanger (15) may be dispensed with, if desired, or that the stream in line (14) is first fed to the indirect heat exchanger (19) before heat 10 exchanging in heat exchanger (15). The stream leaving the indirect heat exchanger (19) in line (20) may be further processed, if desired, for further heat recovery and gas treatment. If desired the heated stream in line (17) may also be 15 partly used as a feed (line (21)) to the gas scrubber (11). Reference is made to Figure 2. Figure 2 schematically shows a system (101) for producing synthesis gas similar to system 1 of Figure 1. To avoid duplication only the 20 differences between Figure 1 and 2 will be discussed in detail. Most of the process conditions and functions of the streams and process units are as in Figure 1. A carbonaceous stream and an oxygen containing stream are fed via lines (103), (104), respectively to a 25 combustion chamber (102), thereby obtaining a raw synthesis gas and a slag. The produced raw synthesis gas is fed via line (105) to a quenching zone (106) as in Figure 1. To the quenching section (6) liquid water is injected via line 30 (17) in the form of a mist, as will be further discussed in Figure 3 below. The amount of mist to be injected in the quenching section (6) relative to the raw synthesis gas is higher than in the process of Figure 1. In this overquench type 35 process the amount of water added is such that not all WO 2007/125047 PCT/EP2007/053871 - 16 liquid water will evaporate and some liquid water will remain in the cooled raw synthesis gas. Such a process is advantageous because a downstream dry solid removal system can be omitted as is shown in Figure 2. The weight 5 ratio of the raw synthesis gas and water injection can be 1:1 to 1:4. As shown in the embodiment of Figure 2, the raw synthesis gas leaving the quenching section (106) is further processed in wet gas scrubber (111) and 10 subsequently via line (112) to a shift converter (113). Wastewater from gas scrubber (111) is removed via line (122) and optionally partly recycled to the gas scrubber 111 via line (123). Part of the wastewater, black water, from gas scrubber (11) may be preferably used as liquid 15 water as injected via line (117). Raw synthesis gas in line (112) is heated in a heat exchanger (115) against the shift converted synthesis gas in line (114) that is leaving the shift converter (113). Stream in line (116) is fed to an indirect heat exchanger (119), for indirect 20 heat exchange with the stream in line (117). As shown in the embodiment in Figure 2, the stream in line (114) is first fed to the heat exchanger (115) before entering the indirect heat exchanger (119) via line (116). The stream leaving the indirect heat exchanger (119) in line (120) 25 may be further processed, if desired, for further heat recovery and gas treatment. If desired the heated stream in line (117) may also be partly used as a feed (line (121)) to the gas scrubber (111). Figure 3 shows a longitudinal cross-section of a 30 gasification reactor which may be used in the system 1 of Figure 1 or in the system (101) of Figure 2. Figure 3 illustrates a preferred gasification reactor comprising the following elements: - a pressure shell (31) for maintaining a pressure 35 higher than atmospheric pressure; WO 2007/125047 PCT/EP2007/053871 - 17 - an outlet (25) for removing the slag, preferably by means of a so-called slag bath, located in a lower part of the pressure shell (31). The lower end of the reactor may suitably be designed as described in 5 WO-A-2005/052095. Slag may be removed from the pressure shell (31) via slag bath (25) via a slag sluicing device as for example described in US-B-6755980.; - a gasifier wall (32) arranged inside the pressure shell (31) defining a gasification chamber (33) wherein 10 during operation the synthesis gas can be formed, a lower open part of the gasifier wall (32) which is in fluid communication with the outlet for removing slag (25). The open upper end (34) of the gasifier wall (32) is in fluid communication with a quench zone (35). The gasifier wall 15 (32) is cooled by a number of conduits through which water and more preferably evaporating water flows. A suitable design for such a cooled wall (32) is a so called membrane wall. Membrane walls comprise of a number of parallel and interconnected tubes, which together form 20 a gas-tight body. The tubes are preferably positioned in a vertical direction such that evaporating water can be more easily used as the cooling medium. - a quench zone (35) comprising a tubular formed part (36) positioned within the pressure shell (31), open 25 at its lower and upper end and having a smaller diameter than the pressure shell (31) thereby defining an annular space (37) around the tubular part (36).The wall of the tubular part (36) is preferably cooled by a number of conduits through which water and more preferably 30 evaporating water flows. A suitable design for such a cooled wall is the membrane wall as described above. The annular space (37) may have a varying width along the vertical length on said space. Suitable the width increases with the direction of the gas flowing in said 35 space (37). The lower open end of the tubular formed part WO 2007/125047 PCT/EP2007/053871 - 18 (36) is fluidly connected to the upper end of the gasifier wall (32). The upper open end of the tubular formed part (36) is in fluid communication with the annular space (37) via deflector space (38). 5 At the lower end of the tubular part (36) injecting means (39) are present for injecting a liquid or gaseous cooling medium. Preferably the direction of said injection are as described earlier in case of liquid mist injections are applied. In the annular space (37) 10 injecting means (40) are present to inject a liquid in the form of a mist, preferably in a downwardly direction, into the synthesis gas as it flows through said annular space (37). Figure 2 further shows an outlet (41) for synthesis gas is present in the wall of the pressure 15 shell (31) fluidly connected to the lower end of said annular space (37). If Reactor (31) is used to prepare a water-saturated synthesis gas as illustrated in Figure 2 a water bath (not shown) may be present in the lower end of the annular space (37). Alternatively the water 20 saturated synthesis gas is directly discharged from the annular space (37). Preferably the quench zone is provided with cleaning means (42) and/or (43), which are preferably mechanical rappers, which by means of vibration avoids and/or 25 removes solids accumulating on the surfaces of the tubular part and/or of the annular space respectively. The advantages of the reactor according to Figure 3 are its compactness in combination with its simple design. By cooling with the liquid in the form of a mist 30 in the annular space additional cooling means in said part of the reactor can be omitted which makes the reactor more simple. Preferably both via injectors (39) and injectors (40) a liquid, preferably water, is injected in the form of a mist according to the method of 35 the present invention.

WO 2007/125047 PCT/EP2007/053871 - 19 The person skilled in the art will readily understand that the present invention may be modified in various ways without departing from the scope as defined in the claims.

Claims

1. A gasification reactor comprising: - a pressure shell for maintaining a pressure higher than atmospheric pressure; - a slag bath located in a lower part of the pressure shell; 5 - a gasifier wall arranged inside the pressure shell defining a gasification chamber wherein during operation the synthesis gas can be formed, a lower open part of the gasifier wall which is in fluid communication with the slag bath and an open upper end of the gasifier wall which is in fluid communication with a quench zone; - a quench zone comprising a tubular formed part positioned within the pressure io shell, open at its lower and upper end and having a smaller diameter than the pressure shell thereby defining an annular space around the tubular part, wherein the lower open end of the tubular formed part is fluidly connected to the upper end of the gasifier wall and the upper open end of the tubular formed part is in fluid communication with the annular space; Is - wherein at the lower end of the tubular part injecting means are present for injecting a liquid or gaseous cooling medium and wherein in the annular space injecting means are present to inject a liquid in the form of a mist and wherein an outlet for synthesis gas is present in the wall of the pressure shell fluidly connected to said annular space. 20

2. The gasification reactor according to claim 1, wherein at the lower end of the tubular part injecting means are present for injecting a liquid cooling medium in the form of a mist.

3. The gasification reactor according to claim I or claim 2, wherein in the annular space downwardly directed injecting means are present to inject a liquid in the 25 form of a mist and wherein the outlet for synthesis gas is present in the wall of the pressure shell fluidly connected to the lower end of the annular space.

4. The gasification reactor according to any one of claims 1 to 3, wherein the gasification chamber is provided with one or more pairs of partial oxidation burners, wherein said burners are provided with supply means for a solid carbonaceous feed and 30 supply means for oxygen.

5. A system for preparing a purified mixture comprising carbon monoxide and hydrogen comprising of the gasification reactor according to any one of claims I to 4, wherein the outlet for synthesis gas is fluidly connected to an inlet of a dry solids removal unit and wherein an inlet of a wet gas scrubber is fluidly connected to the gas outlet of the -21 dry solids removal unit and wherein the wet gas scrubber is provided for an outlet for purified mixture comprising carbon monoxide and hydrogen.

6. A system for preparing a purified mixture comprising carbon monoxide and hydrogen comprising of the gasification reactor according to any one of claims I to 4, 5 wherein the outlet for synthesis gas is fluidly connected to an inlet of a wet gas scrubber and wherein the wet gas scrubber is provided for an outlet for purified mixture comprising carbon monoxide and hydrogen.

7. The system according to claim 5 or claim 6, wherein the outlet for purified mixture comprising carbon monoxide and hydrogen of the wet gas scrubber is 10 fluidly connected to an inlet of a shift converter, said shift converter also provided with an outlet for shifted gas.

8. The system according to claim 7, wherein a heat exchanger is present in which gas from the wet gas scrubber is increased in temperature against shifted gas as obtained in the shift converter. 1s

9. A process to prepare a mixture comprising of carbon monoxide and hydrogen by partial oxidation of a solid carbonaceous feed in the gasification reactor according to any one of claims 1 to 4 or in a system according to any one of claims 5 to 8, wherein in the gasification chamber the solid carbonaceous feed is partially oxidized with an oxygen comprising gas to form an upwardly moving gas mixture having a temperature 20 of between 1200 and 1800 'C and a pressure of between 20 and 100 bar (2MPa and I OMPa), cooling said gas mixture in the tubular part to a temperature of between 500 and 900 *C and subsequently further cooling the gas in the annular part to below 500 *C by injecting a mist of water droplets into the gas flow.

10. The process according to claim 9, wherein said cooling in the tubular 25 part is performed by injecting a mist of water droplets into the gas flow.

11. The process according to claim 10, wherein the injected water mist has a temperature of above 1 50 'C.

12. The process according to claim 11, wherein the injected water mist has a temperature of at most 50 'C below the bubble point of water at the pressure of the 30 upwardly moving gas mixture.

13. The process according to any one of claims 9 to 12, wherein the mist comprises droplets having a diameter of from 50 to 200 tm.

14. The process according to any one of claims 9 to 13, wherein the mist is injected with a velocity of between 30 to 100 m/s. - 22

15. The process according to any one of claims 9 to 13, wherein the mist is injected with a velocity of between 40 to 60 m/s.

16. The process according to any one of claims 8 to 13, wherein the mist is injected using an atomising gas with an injection pressure between 5 and 20 bar (0.5 MPa 5 and 2 MPa) above the pressure of the raw synthesis gas.

17. The process according to any one of claims 10 to 16, wherein the mist is injected under an angle of between 30-60* with respect to a plane perpendicular to the longitudinal axis of the tubular part.

18. The process according to any one of claims 10 to 17, wherein the io injected mist is at least partially surrounded by a shielding fluid.

19. The process according to claim 18, wherein the shielding fluid is selected from the group consisting of an inert gas such as N 2 and C0 2 , synthesis gas, steam and a combination thereof.

20. A gasification reactor substantially as hereinbefore described with is reference to the accompanying drawings. Dated 31 May, 2010 Shell Internationale Research Maatschappij B.V. Patent Attorneys for the Applicant/Nominated Person SPRUSON & FERGUSON