EP1973840A2 - Systeme et procedes hybrides de conversion d energie - Google Patents

Systeme et procedes hybrides de conversion d energie

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Publication number
EP1973840A2
EP1973840A2 EP07718204A EP07718204A EP1973840A2 EP 1973840 A2 EP1973840 A2 EP 1973840A2 EP 07718204 A EP07718204 A EP 07718204A EP 07718204 A EP07718204 A EP 07718204A EP 1973840 A2 EP1973840 A2 EP 1973840A2
Authority
EP
European Patent Office
Prior art keywords
stage
syngas
feedstock
production
gas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP07718204A
Other languages
German (de)
English (en)
Inventor
Momtaz N. Mansour
Ravi R. Chandran
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Manufacturing and Technology Conversion International Inc
Original Assignee
Manufacturing and Technology Conversion International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Manufacturing and Technology Conversion International Inc filed Critical Manufacturing and Technology Conversion International Inc
Publication of EP1973840A2 publication Critical patent/EP1973840A2/fr
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
    • F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
    • F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
    • F01K23/067—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle the combustion heat coming from a gasification or pyrolysis process, e.g. coal gasification
    • 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
    • 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
    • C10J3/466—Entrained flow processes
    • 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
    • C10J3/721—Multistage gasification, e.g. plural parallel or serial gasification stages
    • C—CHEMISTRY; METALLURGY
    • 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
    • C10K1/02—Dust removal
    • C10K1/024—Dust removal by filtration
    • C—CHEMISTRY; METALLURGY
    • 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
    • C10K1/20—Purifying combustible gases containing carbon monoxide by treating with solids; Regenerating spent purifying masses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F23G5/027—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment pyrolising or gasifying stage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/44—Details; Accessories
    • F23G5/46—Recuperation of heat
    • 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
    • C10J2300/1656—Conversion of synthesis gas to chemicals
    • 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
    • C10J2300/1671—Integration of gasification processes with another plant or parts within the plant with the production of electricity
    • 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
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1838—Autothermal gasification by injection of oxygen or steam
    • 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
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1846—Partial oxidation, i.e. injection of air or oxygen only
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/30—Pyrolysing
    • F23G2201/304—Burning pyrosolids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/40—Gasification
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2206/00—Waste heat recuperation
    • F23G2206/20—Waste heat recuperation using the heat in association with another installation
    • F23G2206/203—Waste heat recuperation using the heat in association with another installation with a power/heat generating installation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2217/00—Intercepting solids
    • F23J2217/10—Intercepting solids by filters
    • F23J2217/103—Intercepting solids by filters ultrafine [HEPA]
    • 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
    • Y02E20/12—Heat utilisation in combustion or incineration of waste
    • 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]
    • 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]
    • 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

  • the present disclosure can, in one embodiment, provide efficient, feedstock flexible, environmentally clean and cost-effective alternative energy and/or chemicals production from sources other than petroleum and natural gas. Disclosed subject matter can therefore be of importance to sustainable economic development, global energy security and world peace.
  • the disclosure provides unprecedented level of investment security, particularly for the production of alternative liquid hydrocarbon fuels from capital intensive facilities as summarized below.
  • syngas (primarily consisting of CO and H2) can be produced from any hydrocarbon feedstock, including: natural gas, naphtha, residual oil, petroleum coke, coal, and biomass.”
  • syngas composition most importantly the H 2 /CO ratio, varies as a function of production technology and feedstock. Steam methane reforming yield H 2 /CO ratios of 3/1 while coal gasification yields ratios closer to unity or lower. Conversely, the required properties of the syngas are a function of the synthesis process. Fewer moles of product almost always occur when H 2 and CO are converted to fuels and chemicals. Consequently, syngas conversion processes are more thermodynamically favorable at higher H 2 and CO partial pressures.” [0011] Another crucial observation in the NREL report is:
  • the low pressure steam being referred to in the above is the steam derived from the exothermic heat of the processes that converts the CO and hydrogen laden syngas to liquid fuels and chemicals.
  • the present disclosure provides in one embodiment for unprecedented flexibility in the feedstock (other than petroleum and natural gas) on the front end.
  • the disclosed methods can also employ both endothermic Thermochemical conversion processes and exothermic processes and can provide unique opportunities for thermal integration, which is recognized by the NREL report as having the greatest impact on the plant economics.
  • hybrid conversion system that can be flexible for the use of a wide spectrum of resources and feedstock and can be sufficiently versatile to provide many added value products including clean energy and chemical products.
  • processes disclosed herein can produce, for example, shaft power and/or electricity from the expansion of hot, hydrogen-laden synthetic fuel gas (syngas) produced by gasification or steam reforming of inferior feedstock such as coal, bitumen, tar from sands and wastes, including biomass, municipal solid waste (MSW) sewage sludge and certain industrial wastes.
  • This cycle can include species change to higher volume gases and vapors such as hydrogen and CO.
  • the present disclosure also introduces, among other things, another topping cycle that makes use of a "species change" resulting in a larger volume working fluid.
  • a species change is found in the generation, at high pressure, of a hydrogen laden synthetic fuel gas, where the synthetic fuel itself can be employed as a working medium.
  • the change in volume at pressure and high temperature can be employed for further improvement of the overall energy conversion efficiency of a system.
  • a species change cycle could be a topping cycle conversion device upstream of a gas turbine (or a gas reciprocating engine) that can consume the synthetic fuel.
  • the gas turbine or the gas engine
  • the gas engine can still have a bottoming steam cycle.
  • a species change cycle could also be a topping cycle to a fuel cell stack (such as a molten carbonate fuel cell stack or a solid oxide fuel cell stack), with opportunities to use the heat rejected from the fuel cell stack for further improvements in the overall energy conversion process.
  • a fuel cell stack such as a molten carbonate fuel cell stack or a solid oxide fuel cell stack
  • a species change cycle could be used as a topping cycle for certain high efficiency piston engine that consumes the synthetic gas as a bottoming cycle to further improve the overall energy conversion process.
  • a hydrocarbon vapor cycle could also be used to convert the sensible heat in the engine exhaust to power.
  • One such an embodiment for power generation includes a fluid-bed gasifier or an indirectly heated Thermochemical conversion process that can be operated at an appropriate pressure and a moderate temperature.
  • This can be combined with one or more of an appropriate entrained flow, higher temperature and pressure gasification system for conversion of char generated from the fluid bed device to synthetic fuel gas, in situ and/or external hot gas cleanup subsystem, a synthetic fuel gas expander, a fuel cell and/or a gas turbine, and a steam bottoming cycle.
  • This system can, for example, augment the overall efficiency of a conventional gasification combined cycle power system and can expand the spectrum of feedstock that can be employed for the generation of clean electricity or shaft power.
  • power can be generated from a bottoming cycle and used for indirectly heating a Thermochemical conversion process as opposed to, for example using only synthetic gas to do so in fired heaters.
  • This can be particularly useful in a situation such as when a facility's primary products are liquid fuels produced from the synthesis gas.
  • the pressurized hydrogen laden synthetic gas generated by the entrained gasification stage can also be employed as the working medium of the species change cycle to produce more electric power for indirectly heating the Thermochemical conversion reactor. This can further reduce or eliminate the consumption of syngas in fired indirect heater and make more of the syngas available for production of liquid fuels.
  • tail gas from a synthesis reactor(s) used for liquid fuel production can be reheated and expanded through a turbo expander and produce shaft power and/or electricity following which this tail gas can then be utilized in a fired heater, for example in a pulsed heater, to provide indirect heat for Thermochemical conversion of the feedstock.
  • ceramic membranes or nanofilters may be employed in one or both of a Thermochemical conversion system and a higher pressure, higher temperature char gasification system to continuously separate H2 and CO from product gases so as to enhance feedstock conversion rates and generate high value syngas for subsequent use in an expander, synthesis reactor, fuel cell, gas turbine, or the like.
  • feedstock may be dried in a dryer and then processed in an indirectly heated, moderate temperature Thermochemical reactor.
  • Steam and air or enriched air may be used as the fluidization medium.
  • Membrane or nano filters can be used to continuously separate H2 and CO (optional) from the product gas.
  • the separated H2 and CO streams can be routed through a heat recovery steam generator to cool the gases and then sent to a syngas compressor.
  • One or more internal cyclones can capture and continuously re-circulate the relatively large char particles while the H2 and CO depleted product gas stream comprising CO2, hydrocarbon vapors, steam, and fine char particles can continuously leave the reactor.
  • This stream can enter a pulse gasifier, which can operate auto-thermally with air or enriched air or oxygen and steam addition to effect partial oxidation and autothermal gasification reactions.
  • the gasifier may be operated in a slagging or non ⁇ slagging/dry ash rejection mode, generally depending on the degree of the refractory or unreactive nature of the char.
  • One or more sorbents may be added to a gasifier to promote sonic enhanced ash agglomeration and sulfur, chlorine and alkali capture as necessary. Cyclones and ceramic barrier filter (optional) can be employed to capture ash and/or spent sorbents.
  • Hot, clean product gas can be sent to a heat exchanger (may comprise tapered tubes) for transferring heat to the Thermochemical reactor.
  • Gases exiting from the heat exchanger may be routed through a steam superheater and a heat recovery steam generator to recover the sensible heat from the product gas.
  • a CO2 scrubber may be employed to capture CO2 and increase the partial pressure of H2 and CO in the fuel gas stream. This stream can then be joined with the H2 and CO coming from the membrane or nano filters and compressed in a syngas compressor.
  • the compressed syngas can be passed through a synthesis reactor and/or fuel cell and/or gas turbine to generate liquid fuel and/or electricity.
  • a bottoming steam cycle may be employed to generate supplemental electricity and/or process steam.
  • the presently disclosed methods and systems can in one embodiment provide electric power, liquid fuels and/or shaft power for the electric utility, industry and transportation markets.
  • the disclosed systems and processes can provide such in a cost effective and environmentally benign manner from a very wide spectrum of fuels including inferior fossil fuels/or and waste feedstock and can do so in a clean, environmentally responsible and cost effective manner.
  • a moderate temperature fluid-bed reactor can be provided, according to one embodiment of the disclosed subject matter, for "pre-processing” and conditioning the feedstock material for further processing.
  • One preferred embodiment for this fluid-bed reactor is an indirectly heated moderate temperature Thermochemical process.
  • feedstock such as Refuse Derived Fuel (RDF) from Municipal Solid Wastes (MSW) 1 Coal, Peat, Agricultural Residue (AR) and energy crops can be processed to produce carbon (char) and synthetic fuel gases and condensable hydrocarbon vapors.
  • the condensable hydrocarbon vapors can be condensed, separated and used to form slurry with the char produced.
  • further processing of the synthetic fuel gases and hydrocarbon vapors can be carried out using sorbents and catalysts to steam crack the hydrocarbon vapors to some extent.
  • sorbents and catalysts to steam crack the hydrocarbon vapors to some extent.
  • membrane or nano filters may also be employed to separate the condensable hydrocarbons or tars from the water collected in a cold gas cleanup train.
  • Some or all of the synthetic fuel gases emanating from a cold gas cleanup train may be employed for firing heaters that can deliver heat to the indirectly heated Thermochemical fluid-bed reactor.
  • Electric heaters can provide some or all of the heat needed by the fluid-bed reactor depending on the application (power generation or liquid fuels production) and the mix of products being produced.
  • the synthetic fuel saved could be used to improve liquid fuels and chemical feedstock production yield from the facility.
  • tail gas from a liquid fuel synthesis reactor or fuel cell may be employed to provide the indirect heat.
  • This arrangement can maximize the partial pressure of the reactants (H2 and CO) for liquid fuel or electricity production but can also serve the need for maximizing the conversion efficiency in the synthesis reactor or fuel cell.
  • the latter in turn can eliminate the need for gas recycle, multiple stages and also can reduce the equipment size as well as the capital and operating costs.
  • the cold gas efficiency is a strong function of the fraction of the firing rate that is transferred to the bed. The higher the fraction the higher the cold gas efficiency.
  • 4 - Combustion air preheat as well as flue gas recirculation can be employed to a certain extent to improve the cold gas efficiency but it does have practical limitations including reduction in pulsation in pulse heaters and maximum firing rate in the event a pulse combustor/ fired heater is employed.
  • the moderate temperature fluid bed reactor can be a fluid bed reactor in which the exothermic heat is achieved via partial oxidation or Auto- Thermal means.
  • a PAFB as described in US Patent Number 5,255,634; Mansour, October 26, 1993 (incorporated herein by reference) can be used and operated at high throughput in the sub-stoichiometric air or oxygen mode to affect this pre-processing step at a moderate temperature.
  • an indirectly heated Thermochemical reactor is the preferred embodiment to reduce dilution of the products with effluents from exothermic partial oxidation and autothermal processes, but it is not essential.
  • the use of a pulsating combustor for the fired heaters is also not essential.
  • the present disclosure introduces the use of tapered cross-section heat exchanger tubes as another option to affect uniform heat flux in the heat exchanger tubes. The latter has, however, a small pressure drop penalty that can be overcome by the use of combustion air fans. Nevertheless, the use of tapered cross-section heat exchanger tubes can make it more feasible to reduce the number of fired combustion chambers and the associated burner management subsystems.
  • cyclones or multi-clones can be employed as solids separators.
  • a porous metal or ceramic filter or a barrier filters
  • Some such filters need to be high temperature devices in some of the embodiments.
  • the approaches employed for solids circulation can be an integral part of the process and can have significant effect on the process performance in general and the conversion of energy from solids in particular, with implications to system throughput as well as the energy conversion efficiency.
  • the bulk density of the captured fine particles is lower than the expanded fluid bed-density in the dense bed. This can limit the feasible depth to which the fines could be returned into the dense bed. For example, the depth at which the fines could be discharged in a fluid-bed by gravity drain of a dip leg from a cyclone, multi-clone or barrier filters, could be limited because of the density differences.
  • This embodiment involves providing for down comer conduit(s) and regions for downward solid flow pattern in the fluid bed. This can entrain fines returned to the fluid bed at higher elevations in the bed down to near the bottom of the dense bed. Entraining fines to near the bottom of the dense bed can increase the residence time of the fines in the dense bed before they are re-elutriated again to the free board of the fluid-bed reactor.
  • Examples include FCC and steam reforming or mild gasification fluid-bed reactors.
  • a carbon converter can be a pressurized entrained flow partial oxidation/Auto-Thermal Gasifier.
  • One preferred embodiment for the carbon converter is a pulse gasifier that is oxygen blown and operated as an auto-thermal gasifier at high pressure with hot gas clean up as described in U.S. Patent Number 6,832,565 Chandran, et al. December 21 , 2004 (incorporated herein by reference).
  • Pressurization of carbon feedstock to high pressure for injection in the pulse gasifier can be achieved at a slurry stage.
  • Recovery of condensable liquid hydrocarbons from a pre-conditioning process step can enable the formation of slurry that in turn can enable a high pressure-operating regime for a pulse gasifier.
  • the pressure of a pulse gasifier can be maintained well above the pressure required by the balance of plant so as to allow the expansion of synthetic fuel gas produced in a turbine expander.
  • Such turbine expander may be a cooled stage, with ceramic coatings on the turbine expander blades or a ceramic turbine expander.
  • a pulse gasifier can operate in a temperature range from about 1 ,750 C F to about 3,000 0 F, with preferential temperature generally depending at least in part on the nature of the feedstock. In certain embodiment, for example the case of certain low ash fusion temperature feedstock, the temperature may be lower, for instance about 1 ,650 0 F.
  • one exemplary embodiment ' is directed to the generation of electric power in a Combined Cycle Gas Turbine that requires a syngas fuel pressure of 250 PSIA.
  • the pulse gasifier could be operated at about 1 ,250 PSIA. This would allow a fuel gas expansion pressure ratio of 5:1.
  • Ceramic membranes or nano filters can be considered for reducing the partial pressure of hydrogen and CO to lower values in the gasifier to maintain reasonable gasification reaction rates at the gasifier temperature and pressure, depending on the specific application.
  • Such ceramic membranes or nano filters may also be employed in the steam reformer or Thermochemical reactor that enables the use of a wide spectrum of feedstock as a preconditioning step.
  • the pressure required by the balance of plant such as a biological process for example is on the order of about 65 PSIA.
  • the pressure of the pulse gasifier that would be employed would be on the order of only about 520 PSIA or more for an expansion pressure ratio of 8:1 or more.
  • the temperature of pulse gasifier could be on the order of between 1 ,700 0 F to about 1 ,800 0 F to avoid slag formation.
  • an innovative approach is being provided to improve the system efficiency, in this case, by reducing materially the parasitic energy consumption load and requirements of the process of making such fuels.
  • the first step would be to make first appropriate liquid fuels from syngas using processes that require significantly lower syngas pressure.
  • methanol and DME could be made using processes that require syngas pressure of only 600 psig to 750 psig.
  • This is followed by a second step, using the methanol and DME to make ethanol, for example, in a Homologation step.
  • the pressurization of the Methanol and the DME to high pressures such as 1 ,200 psig to 1 ,500 psig would require significantly lower parasitic energy consumption load since this is being achieved by pressurization of liquid phase substances.
  • the exothermic heat emanating from the process can be used to steam reform the DME at the reactor temperature to make the syngas gas needed to react via indirect heating.
  • Carbon monoxide and hydrogen separation membranes may also be used to separate the hydrogen and carbon monoxide from the products of the steam reforming process of DME to enhance the reaction rates.
  • the syngas made from the DME at pressure and the Homologation process in the presence of an appropriate Homologation Catalyst such as Co-Mo disulfide (available commercially today) would convert the methanol and the syngas into ethanol.
  • the moderate temperature fluid-bed unit can have a high throughput capacity (hence low capital cost) as well as lower maintenance and operating costs. This can also be true, via an appropriate engineering design, of the pressurized pulse gasifier. This, together with the flexibility of process optimization and system integration opportunities made possible by the disclosed system can make the disclosed hybrid systems significantly superior to other current state of the art technologies.

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  • Organic Chemistry (AREA)
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  • General Chemical & Material Sciences (AREA)
  • Hydrogen, Water And Hydrids (AREA)
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Abstract

La présente invention concerne des systèmes hybrides de conversion flexibles pouvant être utilisés avec une gamme étendue de ressources et de charge d’alimentation. Les systèmes décrits peuvent être suffisamment versatiles pour donner de nombreux produits de valeur supplémentaires comprenant de l'énergie propre, des carburants synthétiques et des produits chimiques. Les procédés et le système selon la présente invention peuvent donner, par exemple, une puissance à l’arbre et/ou de l'électricité à partir de l'expansion du changement d'espèce des syngas chauds et chargés d’hydrogène produits par la gazéification ou le reformage à la vapeur de charge d’alimentation inférieure telle que le charbon, le bitume, le goudron provenant de sables et de déchets, y compris une biomasse, les ordures ménagères (OM), la boue d’épuration et certains déchets industriels. La présente invention concerne également des procédés d’intégration thermique sous forme de système innovant de procédés endothermiques et exothermiques et des approches cherchant à améliorer la réaction pour la production économique, propre et flexible de combustibles synthétiques gazeux et liquides ainsi que de produits chimiques.
EP07718204A 2006-01-17 2007-01-17 Systeme et procedes hybrides de conversion d energie Withdrawn EP1973840A2 (fr)

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PCT/US2007/001197 WO2007084539A2 (fr) 2006-01-17 2007-01-17 Systeme et procedes hybrides de conversion d’energie

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US20110271882A1 (en) * 2006-06-01 2011-11-10 Cameron Cole Piggybacked Pyrolyzer and Thermal Oxidizer With Enhanced Exhaust Gas Transfer
CN102431974B (zh) * 2011-09-23 2013-05-08 山东大学 油田注汽锅炉富氧燃烧的多联产工艺及设备
CN103958398B (zh) 2011-09-27 2016-01-06 国际热化学恢复股份有限公司 合成气净化系统和方法
CN104169396B (zh) * 2011-11-04 2016-08-24 国际热化学恢复股份有限公司 用于原料向油和气的弹性转化的系统和方法
CN103775042A (zh) * 2013-06-18 2014-05-07 中国石油天然气股份有限公司 一种基于富氧锅炉生产高温高压蒸汽-烟气的系统及方法
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US11555157B2 (en) * 2020-03-10 2023-01-17 Thermochem Recovery International, Inc. System and method for liquid fuel production from carbonaceous materials using recycled conditioned syngas

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WO2007084539A3 (fr) 2007-12-27
CA2637587A1 (fr) 2007-07-26
US20090300976A1 (en) 2009-12-10

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