WO2003080503A1 - Method for producing syngas with recycling of water - Google Patents
Method for producing syngas with recycling of water Download PDFInfo
- Publication number
- WO2003080503A1 WO2003080503A1 PCT/GB2003/001197 GB0301197W WO03080503A1 WO 2003080503 A1 WO2003080503 A1 WO 2003080503A1 GB 0301197 W GB0301197 W GB 0301197W WO 03080503 A1 WO03080503 A1 WO 03080503A1
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- WIPO (PCT)
- Prior art keywords
- water
- syngas
- gas stream
- steam
- heat
- Prior art date
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 90
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000004064 recycling Methods 0.000 title claims abstract description 6
- 239000007789 gas Substances 0.000 claims abstract description 54
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 36
- 230000008569 process Effects 0.000 claims abstract description 34
- 238000010791 quenching Methods 0.000 claims abstract description 21
- 229910002092 carbon dioxide Inorganic materials 0.000 claims abstract description 19
- 239000001569 carbon dioxide Substances 0.000 claims abstract description 18
- 238000001816 cooling Methods 0.000 claims abstract description 15
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910002091 carbon monoxide Inorganic materials 0.000 claims abstract description 13
- 239000007788 liquid Substances 0.000 claims abstract description 12
- 239000001257 hydrogen Substances 0.000 claims abstract description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract description 6
- 230000000171 quenching effect Effects 0.000 claims abstract description 6
- 125000004435 hydrogen atom Chemical class [H]* 0.000 claims abstract 2
- 238000006243 chemical reaction Methods 0.000 claims description 15
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 8
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical class [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 4
- 238000005201 scrubbing Methods 0.000 claims description 3
- 230000005611 electricity Effects 0.000 claims 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 abstract description 9
- 230000015572 biosynthetic process Effects 0.000 abstract description 7
- 230000003647 oxidation Effects 0.000 abstract description 7
- 238000007254 oxidation reaction Methods 0.000 abstract description 7
- 239000000126 substance Substances 0.000 abstract description 6
- 229910021529 ammonia Inorganic materials 0.000 abstract description 4
- 238000003786 synthesis reaction Methods 0.000 abstract description 4
- 239000000446 fuel Substances 0.000 description 12
- 230000008901 benefit Effects 0.000 description 11
- 239000002918 waste heat Substances 0.000 description 10
- 238000002309 gasification Methods 0.000 description 7
- 238000013459 approach Methods 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 6
- 239000003245 coal Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 239000002737 fuel gas Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000003546 flue gas Substances 0.000 description 3
- 239000002803 fossil fuel Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 238000011084 recovery Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 239000005864 Sulphur Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000003250 coal slurry Substances 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 150000002431 hydrogen Chemical class 0.000 description 2
- 239000003701 inert diluent Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000000376 reactant Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000010977 unit operation Methods 0.000 description 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 230000000779 depleting effect Effects 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229960004279 formaldehyde Drugs 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000002006 petroleum coke Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- -1 sulphur compound Chemical class 0.000 description 1
- 230000035899 viability Effects 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/46—Gasification of granular or pulverulent flues in suspension
- C10J3/48—Apparatus; Plants
- C10J3/485—Entrained flow gasifiers
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
- C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
- C01B3/48—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents followed by reaction of water vapour with carbon monoxide
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- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/46—Gasification of granular or pulverulent flues in suspension
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- C10J3/482—Gasifiers with stationary fluidised bed
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/78—High-pressure apparatus
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
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- C10J3/82—Gas withdrawal means
- C10J3/84—Gas withdrawal means with means for removing dust or tar from the gas
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/002—Removal of contaminants
- C10K1/003—Removal of contaminants of acid contaminants, e.g. acid gas removal
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
- C10K1/10—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids
- C10K1/101—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids with water only
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- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
- C01B2203/0255—Processes for making hydrogen or synthesis gas containing a partial oxidation step containing a non-catalytic partial oxidation step
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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- C01B2203/0283—Processes for making hydrogen or synthesis gas containing a CO-shift step, i.e. a water gas shift step
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- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/0415—Purification by absorption in liquids
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- C01B2203/0465—Composition of the impurity
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- C01B2203/0465—Composition of the impurity
- C01B2203/0485—Composition of the impurity the impurity being a sulfur compound
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- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/0465—Composition of the impurity
- C01B2203/0495—Composition of the impurity the impurity being water
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/08—Methods of heating or cooling
- C01B2203/0872—Methods of cooling
- C01B2203/0877—Methods of cooling by direct injection of fluid
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- C01B2203/08—Methods of heating or cooling
- C01B2203/0872—Methods of cooling
- C01B2203/0883—Methods of cooling by indirect heat exchange
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/08—Methods of heating or cooling
- C01B2203/0872—Methods of cooling
- C01B2203/0888—Methods of cooling by evaporation of a fluid
- C01B2203/0894—Generation of steam
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/14—Details of the flowsheet
- C01B2203/146—At least two purification steps in series
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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- C01B2203/146—At least two purification steps in series
- C01B2203/147—Three or more purification steps in series
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- C—CHEMISTRY; METALLURGY
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/14—Details of the flowsheet
- C01B2203/148—Details of the flowsheet involving a recycle stream to the feed of the process for making hydrogen or synthesis gas
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
- C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
- C10J2300/1643—Conversion of synthesis gas to energy
- C10J2300/165—Conversion of synthesis gas to energy integrated with a gas turbine or gas motor
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- C—CHEMISTRY; METALLURGY
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
- C10J2300/1656—Conversion of synthesis gas to chemicals
- C10J2300/1668—Conversion of synthesis gas to chemicals to urea; to ammonia
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- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/1671—Integration of gasification processes with another plant or parts within the plant with the production of electricity
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
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- C10J2300/1678—Integration of gasification processes with another plant or parts within the plant with air separation
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- C10J2300/1696—Integration of gasification processes with another plant or parts within the plant with phase separation, e.g. after condensation
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- C10J2300/00—Details of gasification processes
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- C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
- Y02E20/18—Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/10—Process efficiency
- Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
Definitions
- This invention relates to the production of synthesis gas (hereinafter referred to as "syngas”) which is a mixture of gases containing at least hydrogen and an oxide of carbon from a carbonaceous feedstock.
- syngas synthesis gas
- Syngas is a term well nown to those versed . in the art of the production of gas from fossil fuels such as natural gas, coal, oil, or other hydrocarbons such as petcoke. Syngas is used mainly for the synthesis of chemicals such as ammonia, methanol, hydrogen, and Fischer Tropsche hydrocarbons, but it can be used as a thermal fuel such as is used for feeding to gas turbines to generate power. Such a gas turbine may be part of an integrated gasification combined cycle (IGCC) arrangement for the generation of electric power. IGCC is a widely practised process for converting by partial oxidation fossil fuels into raw syngas which is cleansed and treated to become suitable for use as gas turbine fuel .
- IGCC integrated gasification combined cycle
- a major design consideration in particularly an IGCC plant is the recovery of the heat generated during partial oxidation. Typically up to 20% of the chemical energy in the original fuel is released as heat in the partial oxidation step. That is, only 80-90% of the feedstock chemical energy is converted to syngas, the remainder being released as gasification waste heat . The cost and effectiveness of the recovery system for this waste heat has a major effect on a plant's commercial viability.
- This invention seeks to provide a process in which there is an improvement in the cost and effectiveness of the recovery system for this waste heat. Specifically, this invention relates to the production of syngas by a process comprising at least the steps of -.
- Figure 1 is a schematic flowsheet showing the interrelationship between these unit operations for a preferred embodiment of the present invention.
- Steps such as the use of cold makeup water in the desaturation step, steam raising, sulphur compounds removal, heat interchanging, heat transfer by means of hot water distribution, syngas expansion, and syngas re-saturation may be used in the present process depending on the particular feedstock and desired end product .
- the pressure in the POX section is above
- the very hot temperature (often well over 1,100°C) of the partially oxidised stream is reduced using liquid water.
- This is preferably effected by directly quenching the gases by contact with sufficient liquid water in a manner such that liquid water remains when the mixture of hot gases and liquid water reach thermal equilibrium.
- This direct contact method has the advantage of removing much of the solid material present in the raw syngas. These solid particles are generally removed from the system through a liquid water purge stream. This is known as "blowdown" .
- this step is downstream of the shift reaction and is distinct from the quench and any associated scrubber.
- This step is usually known as desaturation because, in reducing the temperature of the raw syngas, the majority of the water remaining in the syngas (as steam) after the shift reaction is condensed, thus leaving a relatively dry gas.
- tubular heat exchangers can be used, in the present invention it is preferred to use direct contact cooling.
- the device normally used to effect this step is referred to as a "Desaturator" and consists of a tower containing trays or packing up which flows the syngas and down which flows a relatively large volume of liquid water. On entering the tower this water is relatively cold.
- the water leaving the tower can have a temperature close to that of the incoming syngas, and the syngas leaving the tower can have a close temperature approach to that of the incoming water.
- the advantage of the close temperature approach of the syngas leaving the tower is that known sulphur compound removal processes, such as SelexolTM work better at low temperatures .
- the low water content of the syngas is also advantageous within the SelexolTM unit in that the water balance over the unit is such that water evaporates into the purified syngas - giving a helpful evaporative cooling effect. It is an advantage of a preferred embodiment of this invention that the amount of water reacted in the shift reaction together with any that is required to make up for blowdown losses, plus any water required as make-up when a coal slurry feedstock is used is about equal to the economical amount required to effect the final cooling of the syngas.
- the present invention can provide a low water consumption syngas production process.
- the temperature of the water flowing to the top of the Desaturator is below 140°C, preferably below 100°C more preferably below 80°C, more preferably below 60°C, more preferably below 0°C, more preferably below 30°C, and most preferably below 25°C.
- a major advantage of this invention arises from the recycling of heat in the form of hot water from the Desaturator to the quench, particularly when there is a close temperature approach between the incoming syngas from the shift reactor and the outgoing water.
- This recycled heat significantly increases the water content of the resulting quenched syngas, which in turn means that the following equilibrium shift reaction converts more of the carbon monoxide to carbon dioxide.
- the temperature of the recycled water is generally above 80°C, preferably above 100°C, more preferably above 120°C, more preferably above 140°C, more preferably above 160°C, more preferably above 180°C, and most preferably above 200°C.
- the majority is used for other process heating duties, with any balance being used to raise low pressure steam.
- the high temperature achieved by the close approach at the bottom of the Desaturator gives added advantages in that the exergy of the heat (i.e its higher temperature) allows significantly more, higher pressure, steam to be generated from the heat recovered in the Desaturator. If some of the flow of hot water from the bottom of the Desaturator is used in the preferred way i.e. to generate steam, its temperature on leaving the boiler is above 140°C, more preferably above 150°C, more preferably above 160°C, more preferably above 170°C, and most preferably above 180°C. This has the very significant advantage of allowing higher pressure steam to be generated with the waste heat .
- a further important advantage of this invention is that it facilitates a rise in the concentration of steam present in the quenched syngas from a level whereat the shift catalyst is only just operating within its required conditions - for example at a steam to dry gas ratio of below 1 - to a level whereat the shift catalyst is comfortably within its required conditions - for example a steam to dry gas ratio of above 1.
- This invention can raise the steam to dry gas ratio to above 1, more preferably above 1.2, more preferably above 1.4, more preferably above 1.6, and most preferably above 1.8, by volume .
- the desulphurised syngas is to be used for electric power production by utilising it as a fuel for a gas turbine, which is usually followed by a steam turbine driven by steam at least partly raised from the heat in the exhaust of the gas turbine, then, depending on the desired (required) NO x levels in the flue gas, water vapour/heat may be added to the syngas by passing it through a saturator.
- a saturator depending on the locally permitted emission concentration of NO X/ it may not be necessary to carry out this step. This is because, in this invention, the carbon dioxide formed by the shift reaction is very effective in reducing the amount of NO x formed during the combustion of the syngas in the gas turbine.
- the use of a saturation step may become necessary if carbon dioxide is removed from the syngas because of, for example, environmental regulations.
- Another important advantage of this invention is the fact that the carbon dioxide in the syngas is generally present at a relatively high partial pressure in the syngas stream, which is itself preferably at a high pressure. This means that should it be desired to remove the carbon dioxide, for example to reduce carbon emissions to the atmosphere for environmental reasons, the cost of its removal is very much less than the cost of removing the same quantity of carbon dioxide from e.g. flue gases at atmospheric pressure.
- the partial pressure advantage factor is of the order of one hundred.
- this invention provides a process for the production of syngas from a carbonaceous feedstock, which comprises the steps of: partially oxidising the fuel with an oxygen-containing gas to yield a gas stream containing carbon monoxide generally at supra-atmospheric pressure, usually above 10 atmospheres, quenching the said gas stream with liquid water thus increasing the steam content of the gas stream, and subjecting the gas stream to a carbon monoxide shift reaction whereby carbon monoxide reacts with steam to form carbon dioxide and hydrogen, wherein the process includes the steps of condensing out at least some of the water from the shifted gas stream, preferably by means of a direct contact cooling, to cool the stream and to heat up process make-up water, and recycling at least some of the condensed water and at least some of the heat of the heated make-up water back to the quench step.
- the evolved shift reaction heat is used to raise steam, and, preferably after further cooling the syngas stream is passed through a sulphur compounds depleting step.
- one means to utilise the heat from cooling the wet syngas stream is to use it to saturate the syngas used as fuel for the gas turbine of an IGCC plant thereby increasing its mass flow as taught in European Patent 0 384 781. This also reduces the gas turbine fuel flame temperature, and hence NOx formation
- the shift reaction raises the temperature of the reactants substantially and thereby increases the number of possible applications of the waste heat produced.
- the consumption of water used as a chemical reactant in the shift reaction must be balanced by an equal quantity of make-up water to the syngas generation plant. Additional water may also be required to make up for losses incurred in blowdown from the quench and as make-up when a coal slurry feedstock is used.
- the extra amount of water present in the quenched syngas has advantage in that it both 'pushes' the equilibrium in the shift step to cause more carbon monoxide to react, and its extra mass results in a lower temperature rise from the heat of the shift reaction which in turn causes more carbon monoxide to react because of the higher shift equillibrium constant at the lower temperature .
- European Patent EP 0 575 406 relates to an IGCC process, in which it is described as preferable to feed the gasification waste heat into the gas turbine rather than to a steam cycle. It also teaches the use of shift heat to preheat the fuel gas and to generate and/or preheat any inert diluents that need to be added to the fuel before it is fed to the gas turbine. This is usually beneficial to overall IGCC efficiency, however there are practical limits to the amount of waste heat that can be used in this way, such as the choice of materials of construction for the associated equipment.
- the shift catalyst also hydrolyses COS and HCN in the syngas which would otherwise have to be separately processed.
- the use of the present invention unexpectedly can obviates the need for cooling the syngas other than that necessry to heat up the make-up water needed, which means that a greater proportion of the gasification waste heat plus that remaining from the shift reaction is recovered and recycled to the plant to improve its overall thermal efficiency.
- the use of the make-up water for gas scrubbing in the Desaturator and the reduction/removal of the need for any further diluents to be added to the fuel gas also reduces the water requirements of an IGCC plant based on the invention.
- Figure 1 is a schematic flowsheet showing the principal elements of the invention.
- Figure 2 is a preferred embodiment of the present invention using the partial oxidation of coal to produce a non-condensable fuel gas consisting of a mixture of combustible, non-combustible gases, and vapours.
- the primary fuel consisting of a coal/water slurry containing some 66% by weight of coal is reacted with 95% by volume pure oxygen at a pressure of over 65 bar in a partial oxidation unit (1) .
- the exiting gas stream is Stream 1 in Table 1.
- the resulting mixture of gases known generally as "syngas” is quenched (2) using an excess of liquid water, i.e. not all of the water evaporates, down to the saturation condition at a pressure of 63 bar and at about 245° C.
- the syngas produced after quenching passes to a scrubber (3) where it is scrubbed with makeup water pumped from the bottom of the desaturator (9) to remove particulates, and then passed to the gas processing section.
- This is Stream 2 in Table 1.
- the scrubber water bottoms is fed to the quench together with more process water pumped from the bottom of the desaturator as a balanced make-up to the quench system.
- the syngas passes through a heat interchanger (4) before entering the shift catalyst reactor (5) .
- the interchanger heat exchanger (4) is used to preheat the inlet gas/steam mixture to above the temperature required to initiate the catalytic shift reaction and to prevent steam condensing on the shift catalyst.
- the scrubbed syngas and water vapour is superheated to about 300°C in the interchanger heat exchanger (4) and passed to the shift reactor (5) where most of the CO is catalytically converted to C0 2 , with the evolution of heat.
- the amount of carbon monoxide shifted to carbon dioxide is such that the approach to shift equilibrium is about 10 to 30 degrees centigrade.
- Desaturation is effected by counter-current direct contact cooling with water in a packed column.
- the bulk of the cooling is by a high capacity water circulating system using a pump (10) to transfer the heat as hot water to an LP steam boiler (11) .
- the cold process water make-up to the gasification/gas treatment systems at 15° C finally cools the exit syngas to 23° C.
- the thus cooled syngas contains typically 0.05 vol% of water - Stream 4 in Table 1.
- the gasification unit water make-up is pumped to the quench/scrubber (2) and (3) as an effective heat recycle.
- the bulk of the desaturator bottoms is used for process heating purposes as follows:
- a small stream from the cooled condensate is fed to the coal preparation unit (not shown) for coal slurrying, and the remainder used as cold water recycle in the desaturator (9) .
- the syngas is cooled below 25°C before being fed to the AGR (14) for reduction of sulphur compounds to below the limit permitted for release to atmosphere.
- the sulphur reduced syngas - Stream 5 in Table 1 together with the saturated HP and LP steam is sent to the Combined Cycle Unit (CCU) (15) for the generation of electric power.
- CCU Combined Cycle Unit
- the whole or a proportion of that cleansed syngas can be taken off for export, e.g. as a chemical feedstock for the synthesis of, say, ammonia.
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Abstract
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Priority Applications (1)
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AU2003216847A AU2003216847A1 (en) | 2002-03-21 | 2003-03-21 | Method for producing syngas with recycling of water |
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GB0206701.5 | 2002-03-21 | ||
GBGB0206701.5A GB0206701D0 (en) | 2002-03-21 | 2002-03-21 | Low water comsumption IGCC |
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WO2007068733A1 (en) * | 2005-12-16 | 2007-06-21 | Shell Internationale Research Maatschappij B.V. | Process for cooling down a hot flue gas stream |
WO2008138735A2 (en) * | 2007-05-11 | 2008-11-20 | Siemens Aktiengesellschaft | Method for producing motor energy from fossil fuels while dissipating pure carbon dioxide |
WO2008141784A2 (en) * | 2007-05-21 | 2008-11-27 | Uhde Gmbh | Method for cooling a process gas comprising hydrogen and water vapor from a device for obtaining hydrogen |
US7503947B2 (en) | 2005-12-19 | 2009-03-17 | Eastman Chemical Company | Process for humidifying synthesis gas |
CN102482081A (en) * | 2009-12-10 | 2012-05-30 | 三菱重工业株式会社 | Hydrogen production apparatus and power generation plant |
WO2013120070A1 (en) * | 2012-02-11 | 2013-08-15 | Palmer Labs, Llc | Partial oxidation reaction with closed cycle quench |
US20140103260A1 (en) * | 2011-06-23 | 2014-04-17 | Stamicarbon B.V. Acting Under The Name Of Mt Innovation Center | Process for producing a syngas intermediate suitable for the production of hydrogen |
CN111780982A (en) * | 2020-05-27 | 2020-10-16 | 中汽研汽车检验中心(天津)有限公司 | Vehicle-mounted simple emission testing device and method for non-road diesel engine |
EP3792216A1 (en) * | 2019-09-12 | 2021-03-17 | L'air Liquide, Société Anonyme Pour L'Étude Et L'exploitation Des Procédés Georges Claude | Heat integration in synthesis gas generation by means of partial oxidation |
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EP0384781A1 (en) * | 1989-02-23 | 1990-08-29 | Jacobs Engineering Limited | Improvements in operating flexibility in integrated gasification combined cycle power stations |
WO1992015775A1 (en) * | 1991-03-11 | 1992-09-17 | H&G Process Contracting Limited | Improved clean power generation |
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Cited By (22)
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US7655071B2 (en) | 2005-12-16 | 2010-02-02 | Shell Oil Company | Process for cooling down a hot flue gas stream |
WO2007068733A1 (en) * | 2005-12-16 | 2007-06-21 | Shell Internationale Research Maatschappij B.V. | Process for cooling down a hot flue gas stream |
US7503947B2 (en) | 2005-12-19 | 2009-03-17 | Eastman Chemical Company | Process for humidifying synthesis gas |
US8813507B2 (en) | 2007-05-11 | 2014-08-26 | Siemens Aktiengesellschaft | Method for producing motor energy from fossil fuels while dissipating pure carbon dioxide |
WO2008138735A2 (en) * | 2007-05-11 | 2008-11-20 | Siemens Aktiengesellschaft | Method for producing motor energy from fossil fuels while dissipating pure carbon dioxide |
WO2008138735A3 (en) * | 2007-05-11 | 2010-03-18 | Siemens Aktiengesellschaft | Method for producing motor energy from fossil fuels while dissipating pure carbon dioxide |
WO2008141784A2 (en) * | 2007-05-21 | 2008-11-27 | Uhde Gmbh | Method for cooling a process gas comprising hydrogen and water vapor from a device for obtaining hydrogen |
WO2008141784A3 (en) * | 2007-05-21 | 2009-02-12 | Uhde Gmbh | Method for cooling a process gas comprising hydrogen and water vapor from a device for obtaining hydrogen |
AU2010329043B2 (en) * | 2009-12-10 | 2014-12-04 | Mitsubishi Heavy Industries, Ltd. | Hydrogen production apparatus and power generation plant |
EP2511232A1 (en) * | 2009-12-10 | 2012-10-17 | Mitsubishi Heavy Industries, Ltd. | Hydrogen production apparatus and power generation plant |
CN102482081A (en) * | 2009-12-10 | 2012-05-30 | 三菱重工业株式会社 | Hydrogen production apparatus and power generation plant |
US8601817B2 (en) | 2009-12-10 | 2013-12-10 | Mitsubishi Heavy Industries, Ltd. | Hydrogen production apparatus and power generation plant |
EP2511232A4 (en) * | 2009-12-10 | 2013-06-19 | Mitsubishi Heavy Ind Ltd | Hydrogen production apparatus and power generation plant |
US20140103260A1 (en) * | 2011-06-23 | 2014-04-17 | Stamicarbon B.V. Acting Under The Name Of Mt Innovation Center | Process for producing a syngas intermediate suitable for the production of hydrogen |
US9701535B2 (en) * | 2011-06-23 | 2017-07-11 | Stamicarbon B.V. | Process for producing a syngas intermediate suitable for the production of hydrogen |
KR20140131332A (en) * | 2012-02-11 | 2014-11-12 | 팔머 랩스, 엘엘씨 | Partial oxidation reaction with closed cycle quench |
WO2013120070A1 (en) * | 2012-02-11 | 2013-08-15 | Palmer Labs, Llc | Partial oxidation reaction with closed cycle quench |
AU2013216767B2 (en) * | 2012-02-11 | 2017-05-18 | 8 Rivers Capital, Llc | Partial oxidation reaction with closed cycle quench |
EA028822B1 (en) * | 2012-02-11 | 2018-01-31 | Палмер Лэбс, Ллк | Partial oxidation reaction with closed cycle quench |
EP3792216A1 (en) * | 2019-09-12 | 2021-03-17 | L'air Liquide, Société Anonyme Pour L'Étude Et L'exploitation Des Procédés Georges Claude | Heat integration in synthesis gas generation by means of partial oxidation |
US11524894B2 (en) | 2019-09-12 | 2022-12-13 | L'Air Liquide, Société Anonyme pour I'Etude et I'Exploitation des Procédés Georges Claude | Thermal integration in synthesis gas production by partial oxidation |
CN111780982A (en) * | 2020-05-27 | 2020-10-16 | 中汽研汽车检验中心(天津)有限公司 | Vehicle-mounted simple emission testing device and method for non-road diesel engine |
Also Published As
Publication number | Publication date |
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AU2003216847A1 (en) | 2003-10-08 |
AU2003216847A8 (en) | 2003-10-08 |
WO2003080503A8 (en) | 2004-02-12 |
GB0206701D0 (en) | 2002-05-01 |
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