NZ617028B2 - Apparatus and process for gasification of carbonaceous materials to produce syngas - Google Patents

Abstract

Disclosed is a process and apparatus for gasification of a carbonaceous material. The process comprises a) contacting a moving bed of carbonaceous material with a first molecular oxygen-containing gas and optionally steam and/or carbon dioxide in a gasification zone to gasify a portion of said carbonaceous material and to produce a first gaseous product; b) contacting a remaining portion of the carbonaceous material with a second molecular oxygen-containing gas and optionally steam and/or carbon dioxide in a burn-up zone to gasify additional portion of the carbonaceous material and to produce a second gaseous product and a solid ash; and c) conveying said first gaseous product, said second gaseous product, and a third molecular oxygen-containing gas to a connecting zone to produce said raw syngas, wherein a CO/CO2 molar ratio in said raw syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. Also disclosed is a process wherein the raw syngas is contacted with molecular oxygen containing gas in a tar destruction zone to produce said hot syngas. naceous material and to produce a first gaseous product; b) contacting a remaining portion of the carbonaceous material with a second molecular oxygen-containing gas and optionally steam and/or carbon dioxide in a burn-up zone to gasify additional portion of the carbonaceous material and to produce a second gaseous product and a solid ash; and c) conveying said first gaseous product, said second gaseous product, and a third molecular oxygen-containing gas to a connecting zone to produce said raw syngas, wherein a CO/CO2 molar ratio in said raw syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. Also disclosed is a process wherein the raw syngas is contacted with molecular oxygen containing gas in a tar destruction zone to produce said hot syngas.

Description

APPARATUS AND PROCESS FOR GASIFICATION 0F CARBONACEOUS ALS TO PRODUCE SYNGAS This appiication claims the benefit of US. Provisionai Application Nos. 61/516,646, 61/516,704 and 61/516,667 all filed April 6, 2011, all of which are incorporated in their ty herein by reference.

An apparatus and process is provided for gasification of carbonaceous materials to produce er gas or sis gas or syngas that includes carbon monoxide and hydrogen.

BACKGROUND Gasification of carbonaceous als to produce producer gas or synthesis gas or is well known in the art. syngas comprising carbon monoxide and hydrogen Typically, such a gasification partial starved—air oxidation of process involves a oxidation or carbonaceous material in which a sub-stoichiometric amount of oxygen is supplied to the gasification described in WO s to promote production of carbon monoxide as 2009/154788. As bed in WO 54788, a gasification process can further be influenced by addition of one or more of steam and carbon dioxide (C02). Success of a gasification process greatly depends on quality of syngas produced. Increased content of carbon monoxide (CO) and hydrogen (H2) is desirable in syngas produced. In other words, contents of diluents such as carbon dioxide (C02), nitrogen (N2) should be as low as possible especially for use of product syngas for heating value or for producing chemicals.

Various mineral matters often form part of aceous als. While the carbonaceous part of carbonaceous materials ts to C0, C02 and Hz, the mineral matters get separated from the hydro-carbonaceous part and together with any unconverted carbonaceous material or unconverted carbon form ash. The amount and composition of ash (eg. carbon content) can have an impact on the smooth running of the gasifier as well as on the disposal of ash. Melting and agglomeration of ash in the gasifier lead to partiai or complete blocking of may cause slagging and clinker formation that can gasificr. It is, therefore, advantageous to have a gasification process that avoids the melting of ash. It is also advantageous to have a low content of unburned fuel or carbon in ash.

James T. Cobb, Jr. (“Production of Synthesis Gas by Biomass Gasification,” James T. Cobb, Jr., Proceedings of the 2007 Spring National AIChE Meeting, Houston, Texas, April 22-26, 2007) describes a Consutech Gasifier (BRI Energy LLC), the first stage of which is a standard step-grate combustor (frequently used as an MSW incinerator) that operates as a gasifier at 950ºF using oxygen-enriched air. The second stage is a heat treater that operates at 2000-2250ºF and uses minimal oxygen to crack tars. describes a two stage gasifier in which carbonaceous material is fed to the first stage in which air, -enriched air or pure oxygen can be injected at a controlled rate. The first stage temperature and oxygen input is controlled such that only partial ion of carbonaceous material occurs. The gaseous product from the first stage moves to the second stage. Ash is removed from the first stage. Pure oxygen is introduced into the second stage in order to accomplish cracking and partial oxidation of any tar contained in the gaseous stream from the first stage.

A two stage gasifier such as that described in can be effective in producing syngas from various waste carbonaceous materials and good quality syngas can be produced, however, a high carbon content is generally ed in ash produced from this gasification process.

SUMMARY In a first , the present invention provides a process for gasification of a carbonaceous material to produce a raw , said process comprising: (a) contacting a moving bed of said carbonaceous al with a first molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a gasification zone to gasify a n of said carbonaceous material and to produce a first gaseous product; (b) contacting a remaining portion of said carbonaceous material with a second molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a burn-up zone to gasify an additional portion of said carbonaceous material and to produce a second s product and a solid ash comprising ; and (c) conveying said first gaseous product, said second gaseous t, and a third molecular oxygen-containing gas to a connecting zone to produce said raw syngas, wherein a CO/CO2 molar ratio in said raw syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. 10437579_1 In a second aspect, the present invention provides a process for gasification of a carbonaceous material to produce a hot syngas, said s comprising: (a) contacting a moving bed of said carbonaceous material with a first molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a cation zone to gasify a portion of said carbonaceous material and to produce a first gaseous product; (b) contacting a remaining portion of said carbonaceous material with a second molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a burn-up zone to gasify onal portion of said carbonaceous material and to produce a second gaseous product and a solid ash comprising ; (c) conveying said first gaseous t, said second gaseous product, and a third molecular oxygen containing gas to a connecting zone to produce a raw syngas comprising carbon monoxide (CO), carbon dioxide (CO2) and tar; and (d) ing said raw syngas from the connecting zone to a tar destruction zone to produce said hot syngas, wherein a CO/CO2 molar ratio in said hot syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1.

A process and apparatus are provided for gasification of a carbonaceous material. The process produces a raw syngas that can be further processed in a tar destruction zone to provide a hot syngas. The hot syngas has a molar ratio of CO/CO2 in the hot syngas is greater than about 0.75 and a ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. The carbon content of the solid ash is less than about %.

A process is provided for gasification of a carbonaceous material to produce a raw syngas. The process includes contacting said carbonaceous material with a first molecular -containing gas and optionally with one or more of steam and CO2 in a cation zone to gasify a portion of said carbonaceous material and to produce a first gaseous product.

A remaining portion of the carbonaceous material is contacted with a second molecular oxygen-containing gas and ally with one or more of steam and CO2 in a burn-up zone to gasify an additional portion of said carbonaceous material and to produce a second gaseous t and a solid ash comprising carbon. The first gaseous product and second gaseous product are ed to produce the raw syngas. The raw syngas has a CO/CO2 molar ratio greater than about 0.75 and ratio of carbon content of solid ash to carbon content of 10437579_1 aceous material feed less than about 0.1. The carbon content of the solid ash is less than about 10%. 10437579_1 In another aspect, the mass of total oxygen per unit mass of total carbon in carbonaceous material feed entering gasification zone is less than mass of total Oxygen per unit mass of total carbon in an unconverted portion of carbonaceous material feed entering burnnup zone. The gasification zone may include one or more gasification hearths and the burn—up zone may include one or more burn—up hearths. One or more of said gasification hearths accomplish preheating of the carbonaceous material by heat exchange with one or more of said first gaseous product and second gaseous product.

In another aspect, a ratio of total amount of molecular oxygen contained in the first molecular oxygen containing gas and the second molecular oxygen containing gas to the total amount of molecular oxygen required to completely oxidize all carbon contained in carbonaceous material feed to carbon dioxide is in a range of 0.1 to 0.9, In ance with the process, molecular oxygen is introduced into the gasification zone and burn-up material on a dry zone at a rate of about 0 to about 7'5 lb—mole per tone of carbonaceous basis. The temperature of the gasification zone and burn—up zone is not greater than . 800°C.

In another aspect, a process for gasification of a carbonaceous material to produce includes contacting said carbonaceous material with a first a hot syngas. The s molecuiar oxygen—containing gas and ally with one or more of steam and C02 in a gasification zone to gasify a portion of said carbonaceous al and to produce a first carbonaceous material is contacted with a s product. A remaining portion of the second molecular oxygen—containing gas and optionally with one or more of steam and C02 in a burn-up zone to gasify onal portion of the aceous material and to produce a second gaseous product and a solid ash comprising carbon. The first s product and said second s product are combined to produce a raw syngas that includes carbon monoxide (CO), carbon dioxide (C02) and tar. The raw syngas has a CO/COZ molar ratio r than about 0.75. The raw syngas is contacted with a third molecular oxygen containing gas in a tar destruction zone to produce said hot syngas. The tar destruction zone has temperature r than about 900°C. The molar ratio of CO/COZ in the hot syngas is greater than about 0.75 and a ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. The carbon content of the solid ash is less than about 10 weight %.

A ation apparatus is provided that includes a gasification zone that includes one or more hearths; a burn—up zone continuous with the gasification zone, the burn-up zone including one or more hearths, wherein the gasification and burn-up zones are effective for providing a raw syngas having a CO/CO; molar ratio greater than about 0.75 and ratio of carbon content of solid ash to carbon content of aceous material feed is less than about 0.1; and a tar destruction zone effective for receiving the raw syngas from the gasification and burn—up zones through a connecting zone. In one aspect, the ation zone includes up to 10 hearths. In one , the burn-up zone includes up to hearths. In another , the gasifrcation apparatus es at least one solids transfer device effective for moving carbonaceous al from the gasification zone to the burn- up zone. The gasification apparatus may also include at least one gas inlet in the gasification zone, burn-up zone and tar destruction zone.

BRIEF DESCREPTION OF FIGURES The above and other aspects, features and advantages of several aspects of the process will be more apparent from the following drawings, Figure l is a schematic diagram of a gasificationnapparatus that includes a ation zone and a burn—up zone. Referring now to Figure l, the gasification- apparatus (10) includes a gasification zone (103) and a burn—up zone (200). The ation zone includes one inlet for adding gas (cg, oxygen containing gas, steam, carbon dioxide): inlet 102; the burn-up zone es one inlet for adding gas: inlet 202. A carbonaceous material feed (101) can be added into the gasification zone (103). A stream of solid ash (205) can be removed from burn-up zone (200). A stream of raw syngas (105) can be removed from the gasification zone (103).

Figure 2 is a schematic diagram of an aspect of a gasification—apparatus that includes a gasification zone and a burn—up zone n the gasification zone includes four sections or hearths. Referring now to Figure 2, the gasification—apparatus (11) includes a gasification zone (113) and a burn—up zone (230). The gasification zone (113) includes four gasification hearths: Hearth-I (310), I-IearthnIl (320), Hearth-III (330), and Hearth—IV (340). Each gasification hearth includes one inlet for adding gas: gas inlet 111 to Hearth-I, gas inlet 121 to Hearth—II, gas inlet 13} to Hearth—III, and gas inlet 141 to Hearth-IV. The burn-up zone includes one inlet for adding gas: gas inlet 202. A aceous material feed (101) can be added into Hearth-I (entry hearth) of the gasification zone (113). A stream of solid ash (205) can be removed from the burn-up zone (230). A stream of raw syngas (105) can be d from the gasification zone (1:3).

Figure 3 is a schematic diagram of an aspect of a gasification—apparatus that includes a gasification zone and a burn—up zone wherein the gasification zone includes four sections or hearths and the burn—up zone includes two sections or hearths. Referring zone (123) and a now to Figure 3, the gasification—apparatus (12) includes a gasification burn—up zone (232). The gasification zone (123) includes four gasification hearths: Hearth— I (410), Hearth—II (420), Hearth-HI (430), and —IV (440). Each gasification hearth es one inlet for adding gas: gas inlet 411 to —i, gas inlet 421 to Hearth—II, gas inlet 431 to Hearth-III, and gas inlet 441 to Hearth-IV. The p zone includes two burn-up hearths: -V (416), Hearth-VI (220). Each burn-up hearth includes one inlet for adding gas: gas inlet 511 to Hearth—V, and gas inlet 521 to Hearth-VI. A carbonaceous al feed (101) can be added into Hearth-I (entry hearth) of the gasification zone (123). A stream of solid ash (205) can be removed from Hearth-VI (exit hearth) of the burn—up zone (232). A stream of raw syngas (105) can be removed from the gasification zone (123).

Figure 4 is schematic m of an aspect of a gasificatiomapparatus that a includes reduction zone wherein the a ation zone, a burn-up zone and a tar gasiiication zone includes five sections or s. Referring now to Figure 4, the gasification—apparatus (13) includes a ation zone (143), a burn—up zone (500), a connecting zone or throat (300) and a tar ion zone (400). The gasification zone (143) includes five gasification hearths: —I (110), Hearth-II (120), Hearth—III (130), Hearth—IV (140), and Hearth-V (150). Each gasification hearth includes one inlet for adding gas: gas inlet 611 to Hearth—I, gas inlet 621 to Hearth-II, gas inlet 631 to Hearth—III, to Hearth-1V and gas inlet 651 to Hearth—V. The burn-up zone includes one gas inlet 641 inlet for adding gas: gas inlet 202. The ting zone or throat (300) includes one inlet into for adding gas: gas inlet 301. A carbonaceous material feed (101) can be added Hearth~I (entry hearth) of the gasification zone (143). A stream of solid ash (205) can be removed from the burn-up zone (500). A stream of hot syngas (405) can be removed from the tar reduction zone (400).

Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various aspects of the present process and apparatus. Also, common but well—understood elements that are useful or necessary in commercially feasible aspects are often not depicted in order to facilitate a less cted View of these various aspects.

DETAILED DESCRIPTION Definitions Unless otherwise , the following terms as used throughout this specification for the present disclosure are defined as follows and can include either the singular or plural forms of definitions below defined: The term “about” modifying any amount refers to the variation in that amount encountered in real world ions, cg, in the lab, pilot plant, or production facility. For example, an amount of an ingredient or measurement employed in a mixture or quantity when modified by “about” includes the variation and degree of care typically employed in measuring in an experimental condition in production plant or lab. For example, the amount of a component of a product when modified by “about” includes the variation between batches in a multiple experiments in the plant or lab and the variation inherent in the ical method. r or not modified by “about,” the amounts include equivalents to those amounts. Any quantity stated herein and modified by “about” can also be ed in the present disclosure as the amount not modified by “about”.

“Carbonaceous material” as used herein refers to carbon rich material such as coal, and petrochemicals. However, in this specification, carbonaceous material includes any carbon matcriai whether in solid, liquid, gas, or plasma state. Among the numerous items that can be considered carbonaceous material, the present disclosure contemplates: carbonaceous al, carbonaceous liquid product, carbonaceous industrial liquid recycle, carbonaceous municipal solid waste (MSW or msw), aceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood waste, carbonaceous ' uction material, aceous vegetative material, carbonaceous industrial waste, carbonaceous fermentation waste, carbonaceous petrochemical coproducts, aceous alcohol production coproducts, carbonaceous coal, tires, plastics, waste plastic, coke oven tar, fibersoft, lignin, black liquor, polymers, waste polymers, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, energy crops, forest processing residues, wood sing residues, livestock wastes, poultry wastes, food processing residues, fermentative process their ations. wastes, l ucts, spent grain, spent microorganisms, or The temi “fibersoft” or “Fibersof’t”or “fibrosoft” or “fibrousoft” means a type of carbonaceous material that is produced as a result of softening and concentration of various substances; in an example aceous material is produced via steam autoclaving of various substances. In another example, the fibersoft can include steam autoclaving of pal, industrial, commercial, medical waste resulting in a fibrous mushy material.

The term “municipal solid waste” or “MSW” or “msw” means waste comprising household, commercial, industrial and/or residual waste.

The term “syngas” or “synthesis gas” means synthesis gas which is the name given to a gas mixture that contains varying s of carbon monoxide and hydrogen.

Examples of tion s inciude steam reforming of natural gas or arbons to produce hydrogen, the gasification of coal and in some types of waste—to—energy gasification facilities. The name comes from their use as intermediates in creating tic natural gas (SNG) and for producing ammonia or methanol. Syngas includes use lubricant via as an intermediate in producing synthetic petroleum for use as a fuel or Fischer—Tropsch synthesis and previously the Mobil methanol to gasoline process. Syngas consists primarily of hydrogen, carbon monoxide, and some carbon e, and has less than half the energy density (i.e., BTU content) of natural gas. Syngas is combustible and often used as a fuel source or as an intermediate for the production of other chemicals.

“Ton” or “ton” refers to U.S. short ton, i.e. about 907.2 kg (2000 lbs).

As used herein, the term "tar" includes, without limitation, a gaseous tar, a liquid tar, a soiid tar, a tar—forming substances, or mixtures thereof, which lly comprise hydrocarbons and derivatives thereof. A large number of well known tar measurement methods exist that may be utilized to measure tar. One large family of techniques includes analytical methods based on liquid or gas phase chromatography coupled with a detector.

The most frequent detectors in the case of measurement of tars are the flame-ionization detector (FID) and the mass spectrometer. Another family of techniques includes ometric methods, which include detecting and analyzing at Spectrum. This is for example infrared, ultraviolet (UV) or scence spectrometry, and LIBS (Laser- lnduced Breakdown oscopy) technique. Another technique for monitoring of combustion infrared gases is FTIR (Fourier Transform InfraRed) spectrometry. laneous documents mention this technique, such as for e W02006015660, WOO3060480 and U.S. Pat. No. 5,984,998.

There exist other known electronic methods which allow continuous monitoring of tars. These techniques include detectors with electrochemical cells and sensors with semiconductors. Various gravimetric techniques may also be utilized for tar measurements. In one aspect, the amount of tar may be expressed as equivalent ppm of carbon. In this aspect, the hydrocarbon may be benzene or an alcohol, such as ol.

In this aspect, reducing content of tar may mean a tar tration equivalent or tar equivalents corresponding to less than abouth ppm benzene.

Detailed Description The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be ined with reference to the .

A processes and apparatus is provided for gasification of carbonaceous material to produce In the a gasification-apparatus is used for gasification of a syngas. process, aceous material. The gasificationwapparatus includes a gasification zone and a burn— is introduced in the of the up zone. A carbonaceous material feed gasification zone gasification—apparatus. A first molecular oxygen containing gas is supplied to the gasification zone and thus the carbonaceous material feed is treated with molecular chemical transformation of carbonaceous material. oxygen in order to initiate and facilitate A portion of the carbonaceous material feed is gasified in the gasification zone to produce and eSpecially a first gaseous product. Supply of oxygen into the gasification—apparatus into the gasification zone is controlled in order to entially promote formation of carbon de from aceous material. A sub~stoichiometric amount of oxygen is supplied in order to promote production of carbon de. This action causes lete conversion of carbonaceous al in the gasification zone; only a portion of carbonaceous material is gasified in the gasification zone. The remaining portion of carbonaceous material is transferred to the burn—up zone. A second molecular oxygen containing is supplied to the burn-up zone and thus the gas remaining portion of carbonaceous material is treated with molecular oxygen in order to facilitate chemical transformation of unconverted portion of aceous material into gaseous components.

An additional n of said carbonaceous al is thus gasified in the burn-up zone to produce a second gaseous t. The first gaseous product and the second gaseous product are combined to form a raw syngas.

In one aspect the gasification zone and burn-up zone are physically separate units.

In one aspect the gasification zone and bum-up zone are parts of one single unit. The cation zone may be any gasification equipment disclosed in prior art such as and not limited to moving bed, fixed bed, fluidized bed, entrained flow, counter—current ("up draft"), co-cun‘en’t ("down draft”), counter—current fixed bed, co-current fixed bed, counter-current moving bed, co-cnrrent moving bed cross draft, hybrid, cross flow, cross flow moving bed, or a part thereof. The burn-up zone may be any gasification equipment sed in prior art such as and not limited to moving bed, fixed bed, fluidized bed, entrained flow, counter-current ("up draft"), co-current (”down draft“), counter-current fixed bed, rent fixed bed, counter-current moving bed, co-current moving bed cross draft, , cross flow, cross flow moving bed, or a part thereof. In one aspect flow of solid is downward and flow of gas is upward in at least a part of the burn-up zone. In one is a counter current aspect, the gasification zone is a cross flow unit and the burn—up zone unit. In one aspect, the gasification zone is a cross flow unit and the burn—up zone is a current m0ving bed unit. In one , the gasification zone is a cross flow moving bed unit and the burn-up zone is a counter current unit with gas flowing upward and solid moving downward.

In aspect, the ation zone may include one or more sections or gasification hearths for contacting said carbonaceous material with a first molecular oxygen—containing gas and optionally with one or more of steam and CO; to gasify a portion of said carbonaceous material and to produce a first gaseous product. In various aspects, the ation zone includes 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 sections or gasification hear-tbs. In one aspect, the burn—up zone includes one or more burn—up hearths for contacting remaining portion of said carbonaceous material with a second molecular oxygen-containing gas to gasify an additional portion of said aceous material and to produce a second gaseous product and solid ash. In various aspects, the burn—up zone may e I, 2, 3, 4, or 5 sections or burn-up hearths. In one aspect, the gasification» apparatus es one gasification hearth and one burn—up hearth. In one aspect, the gasification-apparatus includes two ation hearths and one burn-up hearth. In one , the gasification-apparatus includes three gasification hearths and one p hearth. In one aspect, the gasification—apparatus includes four gasification hearths and one burn—up hearth. In one aspect, the gasification—apparatus includes five gasification hearths and one burn—up hearth. In one aspect, the gasification—apparatus includes two gasification hearths and two burn—up hearths. In one aspect, the gasification—apparatus includes three gasification hearths and two burn-up hearth. In one aspect, the gasification—apparatus es four ation hearths and two burn—up hearth. In one aspect, the gasification— apparatus includes five gasification hearths and two burn—up hearth. In one aspect, one or more of said gasification s may be used to accomplish preheating of said carbonaceous material. Said preheating can be accomplished by heat exchange with one or In one aspect, one or more of said first gaseous product and said second gaseous product. and down-flow of more of said burn-up hearths provide arrangement for up-flow of gas solid. that is Raw syngas produced in the process described above often includes tar undesirable for downstream operation and use. Reduction of tar content of raw syngas can be accomplished by contacting said raw syngas with a third molecular oxygen containing Partial oxidation andior cracking of tar contained in said raw gas in a tar destruction zone.

A hot syngas is thus ed with no or syngas is accomplished in the tar reduction zone. a substantially low tar content. Therefore, in one aspect, said gasification—apparatus includes a tar reduction zone for treating said raw syngas comprising said first gaseous product and said second gaseous product with a third molecular oxygen containing gas.

The tar reduction zone can be a horizontal or a al chamber with circular or square or rectangular other cross section. The tar reduction zone can be inclined to the or any horizontal or vertical direction. The tar reduction zone can be connected to the gasification zone and the burn-up zone through zone or to the burn—up zone or to both the gasification tar reduction zone is connected one or more connecting zones or threats. In one , the to the gasification zone h one connecting zone. A gas inlet can be attached ly to the tar reduction zone. One or more gas inlets can be attached to one or more connecting zones (threats). The third lar oxygen containing gas can be introduced directly into the tar reduction zone. The third molecular oxygen containing gas can be introduced into the tar reduction zone through one or more gas inlets attached to one or more connecting zones.

Gas inlets for introduction of the first molecular oxygen ning gas can be attached to the gasification zone or one or more hearths contained therein. Gas inlets for introduction of the second molecular oxygen ning gas can be attached to the burn—up zone or one or more healths contained therein. Steam or C02 may also be introduced h one or more of these gas inlets. In one aspect, one or more of first molecular introduced through the gas inlets attached oxygen containing gas, steam and C02 may be to the ation zone or to one or more hearths contained therein. In one aspect, one or are pro—mixed prior to more of first molecular oxygen containing gas, steam and C02 supplying to the gas inlets attached to the gasiflcation zone or to one or more hearths contained therein. In one aspect, one or more of second molecular oxygen containing gas, steam and C02 are xed prior to supplying to the gas inlets attached to the p zone or to one or more hearths contained therein.

In one aspect the ation zone includes an entry hearth and one or more additional gasification s, wherein the aceous material feed is introduced into the entry hearth. In one aspect, the first molecular oxygen containing gas is not supplied through gas inlet attached to the entry hearth. In one aspect, no gas inlet is attached the in the entry hearth optionally comes in entry hearth. The carbonaceous material introduced that contain heat. contact with one or more of the first and the second gaseous product thus be Heat contained in said one or more of the first and the second gaseous product may exchanged with the carbonaceous material thereby accomplishing drying or pre—drying of carbonaceous material. A dried or pro-dried carbonaceous al is thus transferred to subsequent s. Thermal decomposition or gasification of a portion of carbonaceous material may also occur in the entry hearth. facilitate One or more mechanical devices such as transfer rams may be used to hearth to the next movement of solid inside the gasification zone e.g. from one gasification and inside the bum-up zone, egg. from one burn«up hearth to the next and to facilitate transfer of solid from the gasification zone to the burn up zone. In one , the bottom of the gasification zone is positioned at a level above the bottom of the burn—up zone in order to facilitate movement of solid. In one aspect, the bottom of any gasification hearth is placed at a level lower than the bottom of the previous hearth as solid moves from the of any p hearth is placed entry hearth to the burn-up zone. In one aspect, the bottom the exit at a level lower than the bottom of the previous hearth as solid moves towards . In an aspect wherein the gasification zone includes an entry hearth and one or more additional gasification s, no transfer ram is used in the entry hearth; in this entry hearth, solid is pushed into the next gasification hearth by feeding more feed solid (carbonaceous material). In one aspect, one or more transfer rams (ash removal rams) are used in the burn—up zone to remove solid ash. Several methods can be employed to remove solid ash out of the burn-up zone. In one aspect, a water seal is used in which an ash removal ram pushes solid ash into a pool of water, using water as a seal in order to minimize, preferably avoid, air leakage into the bum—up zone. The wet ash is then moved out of the water using a conveyor belt. In another aspect, the ash is removed through a lock-hopper system to minimize, preferably avoid air e into the burn-up zone. For example double ash doors comprising an upper ash door and a lower ash door can be used to provide the seal. In one aspect, keeping the lower ash door closed to provide a seal, the upper ash door is opened to allow ash to fall downward into a non-combustion zone in which the ash can cool down. In order to remove ash, the upper ash door is closed first to provide the seal and then the lower ash door is opened and an ash removal ram pushes cooled ash out of gasifier. This method removes dry ash and can have advantage if ash has such direct usage of ash. any direct usage as no drying is required prior to A high enough temperature is attained in the gasification~apparatus to facilitate gasification of carbonaceous material. However, the temperature is maintained low enough so that non—carbonaceous mineral matter contained in carbonaceous material feed In other words, temperature in any part of may not melt inside the gasification—apparatus. the gasification zone or of the burn-up zone may not exceed the melting point temperature of ash comprising said non-carbonaceous mineral . Typically, a gas phase temperature not exceeding 800°C is maintained in the gasification zone as well as in the burn-up zone. In one aspect, temperatures in the gasification zone and in the burn—up zone said rbonaceous are maintained in the range 260-800“C. Thus solid ash sing mineral matter accumulates in the p zone and a stream of solid ash is removed from the burn—up zone.

The tar reduction zone provides a short contact time but is operated at a high enough ature in order to ensure adequate destruction of tar. The temperature in the tar reduction zone can be between 900 and 2000°C. Reaction time or t time in the tar reduction zone can be in a range of about 0.5 to about 5 seconds.

Raw syngas is produced that may include carbon monoxide (CO) and carbon e (C02). It is desirable to have more C0 and less C02 in the raw syngas. In one In one aspect, the CO/C02 molar ratio in said raw syngas is r than about 0.75. aspect, the C0/C02 molar ratio in said raw syngas is greater than about 1.0. In one aspect, CO/COZ molar ratio in said raw syngas is greater than about 1.5. Hot syngas may e carbon monoxide (CO) and carbon dioxide (C02). It is desirable to have more C0 and less C02 in the hot syngas. In one aspect, the CO/CO; molar ratio in said hot syngas is greater than about 0.75. In one aspect, the COICO; molar ratio in said hot syngas is greater than about 1.0. In one aspect, CO/COZ molar ratio in said hot syngas is greater than about 1.5.

In addition to ning rbonaceous mineral matter, solid ash may include unconverted carbon or erted carbonaceous matter. In one , carbon content of said solid ash is less than about 10 wt %. In one aspect, carbon content of solid ash is less than 5 wt %. In one aspect, ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1. In one , ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.01.

The carbon content of ash and carbon content of carbonaceous material feed refers to carbon or a chemical that contains carbon. In this , numerous known techniques Some examples of techniques that may be used may be utilized to measure carbon content. to measure carbon include and are not limited to loss-on—ignition (LOI) tests, themogravimetric analysis (TGA), laser probe based optical methods, methods using microwave radiation, methods using nuclear magnetic resonance (NMR), and various ASTM methods (see for example ASTM D6316).

Undesirable hot spots might be created in said gasification—apparatus in one or hearths contained therein, due to more of the gasification zone and the burn—up zone, or said aceous uneven distribution of molecular oxygen containing gas in material feed. This may cause poor quality in raw syngas produced. Hot spots can also cause localized melting of ash. Formation of hot spots can be reduced or prevented by injecting more of said gasification zone and one or more of steam and carbon dioxide into one or said burn—up zone. Thus, in order to t undesirable hot spots, carbonaceous material feed may be treated with steam along with molecular oxygen in the ation zone.

Carbonaceous al feed may be treated with C02 gas along with molecular oxygen in the gasification zone. Carbonaceous material feed may be treated with steam along with molecular oxygen in the burn-up zone. Carbonaceous material feed may be treated with C02 in the burn-up the first molecular gas along with molecular oxygen zone. Thus oxygen-containing gas may include one or more of steam and carbon dioxide gas and the second molecular oxygen-containing gas may include one or more of steam and carbon e gas.

As described above, a oichiometric amount of oxygen is supplied to the gasification apparatus in order to promote production of carbon monoxide. Therefore, in one aspect, the ratio of the totai amount of molecular oxygen contained in the first molecular oxygen containing gas and the second molecular oxygen containing gas to the total amount of molecular oxygen required to completely oxidize all carbon contained in carbonaceous material feed to carbon dioxide is in a range of 0.1 to 0.9. In one aspect, the ratio of the total amount of molecular oxygen ned in the first molecular oxygen containing gas and the second molecular oxygen containing gas to the total amount of molecular oxygen required to completely oxidize all carbon contained in carbonaceous material feed to carbon dioxide is in a range of 0.1 to 0.9. In one aspect, ratio of total amount of molecular oxygen contained in the first molecular oxygen containing gas, the second molecular oxygen containing gas and the third molecular oxygen containing gas to the total amount of molecular oxygen required to completely oxidize all carbon contained in carbonaceous material feed to carbon dioxide is in a range of 0.1 to 0.9. In one , ratio of total amount of molecular oxygen contained in the first molecular oxygen containing and the third lar gas, the second molecular oxygen containing gas oxygen containing gas to the total amount of molecular oxygen required to completely oxidize all carbon contained in carbonaceous material feed to carbon dioxide is in a range 0f0.1 to 0.9.

Careful control of temperatures in the gasification zone and in the burnnup zone and rates of supplies of oxygen into the gasification zone and into the p zone are required in order to achieve low t of carbon in solid ash and high CO/COZ ratio in higher amount to per unit amount of available carbon in raw syngas. A oxygen aceous material is ed in the burn—up zone compared to the amount to oxygen in aceous material provided in the gasification per unit amount of available carbon in carbonaceous material zone. Thus the mass of total oxygen per unit mass of total carbon feed entering gasiiication zone is less than mass of total oxygen per unit mass of total carbon in unconverted portion of carbonaceous material feed entering burn—up zone. Mass of total oxygen per unit mass of total carbon in carbonaceous material feed entering cation zone can be in a range comprising 0.1 to 2.0 lb/lb. Mass of total oxygen per unit mass of total carbon in unconverted n of carbonaceous material feed entering burn-up zone can be in a range comprising 0.25 to 2.5 lb/lb. Any chemically bonded oxygen contained in the carbonaceous material as well as chemically bonded oxygen contained in any steam or CO; that is supplied may participate in the chemical ormation and gasification of carbonaceous material. It is, therefore, important to consider any chemically bonded oxygen contained in the aceous material as well as chemically bonded oxygen contained in any steam or C02 that is supplied in determining amount of molecular oxygen to be supplied.

In order to supply molecular oxygen said first molecular oxygen ning gas include air. In order to supply molecular oxygen said first molecular may oxygen containing gas may include enriched air. In order to supply molecular oxygen said first molecular oxygen containing gas may include pure oxygen. In order to supply lar e air. In order to supply oxygen said second molecular oxygen containing gas may molecular oxygen said second molecular oxygen containing gas may e enriched air, In order to supply lar oxygen said second lar oxygen ning gas may include pure oxygen.

In one aspect, molecular oxygen containing gas is distributed horizontally inside gas is one or more gasification hearths. In one aspect, lar oxygen containing distributed vertically in one or more burn—up hearths. In one , introduction of molecular oxygen ning gas in one or more burn-up hearths is tinuous. In one device. In one aspect, one or aspect, one or more of gas inlets are equipped with cooling inlets. In one aspect, one or more more of said cooling devices are water jackets on the gas In one aspect, additional nozzles on the surface of gas inlets extend out of transfer rams. transfer rams are used for uction of molecular oxygen containing gas.

The third molecular oxygen containing gas may include air. The third molecular air. The third molecular oxygen containing oxygen containing gas may include enriched gas may include pure oxygen.

In one aspect, the same molecular oxygen containing gas is supplied to one or more of gasification zone, burn—up zone and tar reduction zone. In one aspect, different molecular oxygen containing gases are supplied to the gasification zone, the burnmup zone and the tar reduction zone.

Total amount of molecular oxygen introduced in the gasification zone and the burn—up zone through said molecular oxygen containing gas can be in a range of about 0 to about 75 1b-moles per ton of carbonaceous material on a dry basis. In various aspects, amounts of molecular oxygen supplied to the gasification zone and to the burn-up zone 0 to 50, 0 to 75, 5 to 10, 10 tolS, 15 to 20, 20 to may include a range selected from: 0 to 5, and 65 to , 25 to 30, 30 to 35, 35 to 4G, 40 to 45, 45 to 50, 50 to 55, 55 to 60, 60 to 65, 7'0 lb—moles per ton of carbonaceous material feed on a dry basis. In various aspects, and burn— amounts of molecular oxygen supplied to one or more of the gasification hearths 0 to 5, 0 to 50, O to 75, 5 to 10, 10 tolS, 15 up hearths may include a range ed from: to 20, 20 to 25,25 to 30, 30 to 35, 35 to 40, 40 to 45, 45 to 50, 50 to 55, 55 to 60, 60 to 65, and 65 to 70 lb—moles per ton of carbonaceous material feed on a dry basis.

Total amount of steam introduced in the ation zone and the burn-up zone material feed on can be in a range of about 0 to about 50 lb-moles per ton of carbonaceous more of the gasification a dry basis. In s aspects, amount of steam added in one or 0 to 5, 5 to 10, 10 tolS, 15 zone and the burn—up zone may include a range selected from: to 20, 20 to 25, 25 to 30, 30 to 35, 35 to 40, 40 to 45, and 45 to 50 lb-rnoles per ton of carbonaceous material feed on a dry basis. In various s, amount of steam added in one or more of the gasification hearths and the burn-up hearths may include a range selected from10t0 5, 5 to 10, IO tolS, 15 to 20, 20 to 25, 25 to 30, 30 to 35, 35 to 40, 40 feed on a dry basis. to 45, and 45 to 50 lb—moles per ton of carbonaceous material Total amount of carbon dioxide gas introduced in the gasification zone and the carbonaceous burn-up zone can be in the range of about 0 to about 50 lb-moles per-ton of material feed on a dry basis. In various aspects, amount of carbon dioxide gas added in 25 zone may include a range selected one or more of the gasification zone and the burn—up from: O to 5, 5 to 10, 10 t015, 15 to 20, 20 to 25, 25 to 30, 30 to 35, 35 to 40, 40 to 45, and 45 to 50 lb—moles per ton of carbonaceous al feed on a dry basis. In various aspects, hearths and the amount of carbon dioxide gas added in one or more of the gasification burn—up hearths may include a range selected from: 0 to 5, 5 to 10, 10 t015, 15 to 20, 20 to , 25 to 30, 30 to 35, 35 to 40, 40 to 45, and 45 to 50 lb-moles per ton of aceous material feed on a dry basis.

In one aspect, both steam and carbon dioxide gas are introduced in one or more of the gasification and burn—up zones. In one aspect, one or more of steam and carbon dioxide gas are injected in one or more lines supplying oxygen to blend in with oxygen lines just before distribution nozzle.

The total amount of oxygen added in the tar reduction zone can be in a range of about 0 to about 75 lb-moles per ton of carbonaceous material feed on a dry basis. In various s, amounts of molecular oxygen supplied to the tar reduction zone may include a range selected from: 0 to.5, 0 to 50, 0 to 75, 5 to 10, 10 t015, 15 to 20, 20 to 25, to 30, 30 to 35, 35 to 40, 40 to 45, 45 to 50, 50 to 55,55 to 60, 60 to 65, and 65 to 70 lb—moles per ton of carbonaceous material feed on a dry basis.

In one aspect of said gasification—apparatus, re is ined at a negative (sub—atmospheric) pressure in order to avoid leakage of flammable and toxic syngas into around the surroundings. However, this action leads to leakage of air into the r, e.g. moving rams and doors. Such leakage of air may cause loss of raw syngas. It may also control of the gasifier draft is necessary to cause a dilution of raw syngas. Thus a careful reduce air leakage. Gasifier draft can be controlled at a negative (sub—atmospheric) is by pressure in to 0.50 inch water. One way of accomplishing this a range of 0.01 solids and manually setting a fan speed (to control hot syngas temperature) and ing Draft control can also be ed with flow control of oxygen feed rates to control draft. under the carbonaceous material bed. In one one or more of carbon dioxide and steam be than aspect, for example during start-up, pressure may atmospheric or greater atmospheric.

Air admitted with the carbonaceous material feed can be reduced by using a screw Air admitted with the feeder which material feed. compresses the carbonaceous In one carbonaceous material feed can also be reduced by using purged lock hoppers. be allowed. aspect, for example during start—up, air leakage may is introduced in one or In one aspect, a e containing gas such as natural gas zone and the tar reduction zone especially in more of the gasification zone, the p order to facilitate start-up.

The carbonaceous material fed to the gasifier may include selection from: industrial carbonaceous material, carbonaceous liquid product, carbonaceous liquid urban waste, e, carbonaceous municipal solid waste (MSW or msw), carbonaceous carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood waste, carbonaceous construction material, aceous vegetative carbonaceous industrial waste, carbonaceous fermentation waste, carbonaceous petrochemical co—products, aceous alcohol tion co—products, carbonaceous coal, tires, plastics, waste plastic, coke oven tar, fibersoft, lignin, black , polymers, waste polymers, hylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, crop residues, energy crops, forest processing residues, wood processing residues, livestock wastes, poultry wastes, food processing residues, fermentative process their combinations. 3O wastes, ethanol co-products, spent grain, spent microorganisms, or In one aspect of the present sure the aceous material fed to the gasifier includes plurality of carbonaceous materials selected from carbonaceous a material, carbonaceous liquid product, carbonaceous industrial liquid recycle, carbonaceous municipal solid waste (MSW or msw), carbonaceous urban waste, carbonaceous agricultural material, carbonaceous forestry material, carbonaceous wood waste, carbonaceous construction material, aceous tive material, carbonaceous industrial waste, carbonaceous fermentation waste, carbonaceous petrochemical co- products, carbonaceous alcohol production co—products, carbonaceous coat, tires, plastics, waste c, coke oven tar, fibersoft, lignin, black liquor, polymers, waste rs, polyethylene terephthalate (PETA), polystyrene (PS), sewage sludge, animal waste, cr0p residues, energy livestock crops, forest processing residues, wood sing residues, ethanol co» wastes, poultry wastes, food processing residues, fermentative process wastes, products, spent grain, spent microorganisms, or their combinations.

In one aspect, said carbonaceous material includes water. In one aspect, said carbonaceous material includes less than about 50 wt% water. In one aspect, said carbonaceous material includes less than about 25 wt% water. In one aspect said carbonaceous material includes less than about 15 wt% water. In one aspect, moisture content of said carbonaceous material is decreased by pro-drying.

In one aspect, said carbonaceous material includes greater than about 25 wt% inciudes carbon on a dry or water free basis. In one aspect said carbonaceous material greater than about 50 wt% carbon on a dry or water free basis. In one aspect, said carbonaceous material includes oxygen in the range of about 0 to about 50 wt% oxygen on 2O material includes hydrogen in a dry or water free basis. In one aspect said carbonaceous the range of about 0 to about 25 wt% en on a dry or water free basis. In one aspect, said carbonaceous al includes less than about 25 wt% ash on a dry or water free basis. In one aspect said carbonaceous material includes less than about 15 wt% ash on a dry or water free basis.

In various aspects, the temperature in one or more of the gasification zone and burn-up zone can be selected from temperature ranges: 260—270"C, 270—280°C, 280~290°C, 290—300°C, 300—3IO°C, 310-320°C, 320—330°C, 330-340°C, 00C, 350-360°C, 360— 370°C, 370-380°C, 380-390°C, 390~400°C, 0°C, 410—420°C, 420-430"C, 430—440°C, 0°C, 450-460°C, 460-470°C, 470-480°C, 480—490°C, 490-500°C, 500-510°C, 520- 530°C, 530-540°C, 540-550°C, 550-560°C, 0°C, 570-580°C, 580-590°C, 590-600°C, 0°C, 610—620°C, (HO-630°C, 0°C, 640-650°C, 650—660°C, 660-670°C, 670— 680°C, 680—690°C, 690-700°C, 700—?10°C, 710—720°C, 720-730°C, 730—740°C, 740-750°C, 750-760°C, 760—770°C, ”HO—780°C, 780-790°C, and 790-80()°C.

In various aspects, the temperature in one or more of the gasification hearths and the burn—up hearths can be selected from temperature ranges: 260—270°C, 270-280°C, 280~ 290°C, 290—300°C, 300-310°C, BIO—320°C, 320-330°C, 330—340°C, 0°C, 350-360°C, 360—370°C, 370-380°C, 380-390°C, 0°C, 400~410°C, 410—420°C, 420—4300C, 430— 440°C, 440—4SO°C, 450-460“C, 460-470°C, 470-480°C, 480-490“C, 490-500°C, 0°C, 520—530°C, 530—540°C, 540-550°C, 550-560°C, 560—570°C, 570-580°C, 580-5900C, 590— 600°C, 600-6100C, 610-620°C, 620—630°C, 0°C, 640—650°C, 650—660°C, 660-670°C, 670-680°C, 680-690°C, 690-700°C, O°C, 710—720°C, 0°C, 730-740°C, 740— 750°C, 750-760°C, 760—770°C, 770-?80°C, 780-790°C, and 790-800°C.

In one aspect, temperatures in the gasification zone and the burn-up zone are same.

In one aspect, atures in the gasification zone and the p zone are different. In one aspect, the temperature in the bum-up zone is greater than the temperature in the gasification zone. In one aspect, the temperatures in all hearths in the catiOn zone and the burn—up zone are same. In one aspect, different hearths are maintained at different temperatures. In one aspect, the ature in one or more burn-up hearth(s) can be greater than the temperature in one or more gasification hearth(s). In one aspect the the exit hearth of temperature increases from the entry hearth of the gasification zone to the burn—up zone.

In various aspects, the ature in the tar reduction zone can be seiected from temperature ranges: 900-910°C, 910—920°C, 920-930°C, 930—940°C, 940—950°C, 950- 960°C, 0°C, 970-980"C, 980—990°C, 00°C, 1000-1010°C, 1010—1020“C, 1020—1030°C, 1030—1040°C, 1040-1050°C, 1050-1060°C, 1060-t070°C, 1070—1080°C, 1080—1090°C, 1090—1100°C, 1100—1110°C, 1110—1120°C, 1120—1130°C, 1130—11400C, 150°C, 1150-1160°C, l160~1170°C, 1170~1180°C, 1180—1190°C, 1190-1200°C, 1200~1210°C, 1210—1220°C, 1220-1230°C, 240°C, 1240~1250°C, 1250-1260°C, 1260-12700C, 1270u1280°C, 1280-1290°C, 1290-1300°C, 1300-1310°C, £310—I320°C, 1320w1330°C, 1330-1340°C, 1340~1350°C, I350n1360°C, 1360-1370°C, 1370—1380°C, 390°C, 1390-14000C, 1400—E4IO°C, 1410-1420°C, 1420—1430°C, 1430—1440°C, 1440-i450°C, 1450-1460°C, 1460-1470°C, l4?0-1480°C, 1480-1490°C, 500°C, 1500-1510°C, 1510-1520°C, 1520—1530°C, 1530-1540°C, 1540-1550“C, 1550-1560°C, 1560~1570°C, 1570-1580°C, 1580-1590°C, 1590~1600°C, 1600-1610°C, 1610—1620°C, 1620—1630°C, 1630-1640°C, i640-1650°C, 1650—1660°C, 1660-1670°C, 1670-1680°C, 1680-1690°C, 1690—1700°C, 1700-1?10°C, 1710-1720°C, 1720-17300C, 1730—17400C, l740-1750"C, 1750—17600C, 1760«1770°C, 1770-1780°C, 1780—1790°C, 1790—180000, 1800—1810°C, 820°C, 1820—18300C, 1830-1840°C, 1840-18500C, 860°C, 1860—l870°C, 1870—1880°C, 1880-1890°C, 1890~l900°C, 1900-1910°C, 1910—1920°C, 930°C, 1930—1940°C, 1940—19500C, 1950—1960°C, 1960~1970°C, 1970-1980°C, 1980—1990°C, 1990—2000°C.

Specific aspects of the present disclosure are described with nce to Figures 1 to 4. Thus Figure 1 provides a schematic diagram of an aspect of the present disclosure wherein the gasification-apparatus (l0) includes a gasification zone (303) comprising one gasification hearth and a burn-up zone (200) comprising one burn—up hearth.

Carbonaceous material feed (101) is introduced in gasification zone. A first molecular the gasification zone. A first gaseous product is oxygen containing gas (102) is ed to produced in the gasification zone. Unconverted portion of carbonaceous material is transferred from the ation zone to the burn-up zone. A second molecular oxygen containing gas (202) is supplied to the burn—up zone. A second gaseous product is produced in the burn-up zone. Solid ash (205) is d from the burn—up zone. The first and the second gaseous products are combined to produce a raw syngas stream (105) that is removed from gasification zone.

Figure 2 presents a schematic diagram of gasification—apparatus (10) wherein gasification zone es four gasification hearths: Hearth—1, i.e. entry hearth (310), Hearth-II (320), Hearth—III (330), and Hearth—IV (340). Carbonaceous material feed (101) is introduced in the gasification zone in Hearth—I (entry ). Inside the gasification to Hearth—II; solid from —ll zone, solid from Hearth—I, i.e. entry hearth, is transferred is transferred to Hearth-III; and solid from Hearth-III is transferred to Hearth—IV. Solid comprising unconverted portion of carbonaceous al is transferred from Hearth—1V of gasification zone into the burn~up zone (230). A first molecular oxygen containing gas is supplied to different gasification hearths h gas inlets 111, 121, 131, and 141 that are attached to Hearth—I, Hearthall, Hearth-III, and Hearth-IV respectively. In one aSpect, no molecular oxygen containing gas is introduced into —I (entry hearth). A second molecular oxygen containing gas is supplied to the burn-up zone through gas inlet 202.

Solid ash (205) is d from the burn—up zone.

One or more mechanical devices (not shown in diagram) such as transfer rams may be used to facilitate movement of solid from one hearth to the next or from one zone to the next, in Figure 2, from Hearth—I to Hearth—II, from Hearth—II to e.g. Hearth—HI, from Hearth—III to I-Iearthnlv, from HearthJV of the gasification zone to the burn~up zone. In is pushed one aspect, no transfer ram is used in Hearth-I, the entry hearth, wherein solid into next hearth by feeding more feed solid (carbonaceous material).

Figure 3 presents a schematic diagram of an aspect of gasification—apparatus (i0) wherein the gasification zone (123) includes four hearths: d, i.e. entry hearth (410), Hearth—II (420), Hearth—III (430), and Hearth-IV (440). The burn—up zone (232) inciudes material two hearths: Hearth-V (416), and exit hearth, Hearth—VI (220). Carbonaccous feed (101) is introduced in the ation zone in Hearth-I (entry hearth). Inside the ation zone, solid from -I, i.e. entry hearth, is transferred to Hearth-II; solid is erred from Hearth-II is transferred to Hearth-III; and solid from Hearth-III to Hearth—IV. Solid comprising unconverted portion of carbonaceous material is transferred from —IV of gasification zone into —V of the p zone. Inside the burn—up to Hearth-VI first molecular zone, solid from Hearth-V is transferred (exit hearth). A oxygen containing gas is supplied to different gasification hearths through gas inlets 41 1, i5 421, 431, and 441 that are attached to -I, Hearth-II, —III, and Heartth respectively. In one aspect, no molecular oxygen containing gas is introduced into Hearth— I (entry hearth). A second molecular oxygen containing gas is supplied to different gasification hearths through gas inlets 511, and 521 that are attached to Hearth-V, and Hearth—VI (exit hearth) respectively. Solid ash (205) is removed from Hearth VI (exit hearth) of the burn—up zone.

One or more mechanical devices (not shown in diagram) such as transfer rams may be used to tate movement of solid from one hearth to the next or from one zone to the next, in Figure 3, from Hearth—I to Hearth—II, from Hearth—II to from e.g. Hearthdil, -III to Hearth-IV, from Hearth-IV of the gasification zone to Hearth—V of the burn- In one aspect, no transfer ram is used in Hearth— up zone, and from Hearth-V to Hearth-VI.

I, the entry hearth, wherein solid is pushed into next hearth by feeding more feed solid (carbonaceous material).

Figure 4 presents a schematic diagram of one aspect of gasifrcation—apparatus (13) comprising a gasification zone (I43), burn-up zone (500), and a tar reduction zone (400) 3O wherein the gasification zone (143) includes five hearths: Hearth-I, i.e. entry hearth (110), Hearth—II (120), Hearth—III (130), Hearth IV (140), and Hearth-V (150). Carbonaceous material feed (101) is introduced in the gasification zone in Hearth-I. Inside the gasification zone, solid from Hearth—I, i.e. entry hearth, is transferred to Hearth—II; solid from Hearth-II is transferred to Hearth—III; solid from HearthnlII is transferred to Hearth— W, and solid from —IV is erred to Hearth-V. Solid comprising unconverted portion of carbonaceous material is transferred from Hearth—V of gasification zone into the burn—up zone (500). A first molecular oxygen containing gas is supplied to different gasification hearths though gas inlets 611, 621, 631, 641, and 651 that are ed to Hearth—I, Hearth—II, Hearth-III, Hearth-IV, and Hearth-V respectively. In one , no molecular oxygen containing gas is introduced into Hearth—l. A second molecular oxygen containing gas is supplied to the burn-up zone through gas inlet 202.

Gaseous product from burn-up zone is transferred to gasification zone and combined with s product from gasification zone to produce a raw syngas stream throat (300) into the (not shown on diagram) that is passed through a connecting zone or is introduced into the tar reduction zone (400). A third molecular oxygen containing gas throat though gas inlet 301 wherein the raw syngas stream and third oxygen containing gas is introduced directly are mixed. In one , the third molecular oxygen containing gas into the the third molecular tar reduction zone (not shown on diagram). In one aspect, oxygen containing gas is uced into the throat as well as into the tar reduction zone (not shown of raw syngas and oxygen on diagram). The mixture containing gas is subjected to treatment with heat in the tar reduction zone. A hot syngas is thus produced and a stream of hot syngas (405) is removed from the tar reduction zone.

EXAMPLES Example 1: A ication apparatus comprising a gasification zone, a burn-up zone and tar destruction zone was used in this example. Carbonaceous material feed was uced into the gasification zone. A first molecular oxygen containing gas was supplied to the gasification zone at the rate of about 10 to about 15 lb«moles per ton of waterufree aceous material to gasify a portion of the carbonaceous al and produce a first gaseous product.

Remaining carbonaceous material from the gasification zone was forwarded to the burn-up zone wherein a second molecular oxygen containing gas was supplied at the rate of about 10 to about 15 lb-moles per ton of water-free aceous material to gasify additional portion of carbonaceous material and produce a second gaseous product.

The first and second gaseous products were combined to produce a raw syngas that was allowed to enter a tar destruction zone. A third lar oxygen containing gas supplied to the tar ction zone at the rate of about 20 to about 30 es per ton of water—free carbonaceous material. A hot syngas was produced and removed from the tar ction zone. about The gasification zone was also fed a stream of carbon dioxide at the rate of to about 15 lb-moles per ton of water—free carbonaceous material. The burn—up zone about 2 to about 5 es per ton of was fed a stream of carbon dioxide at the rate of water—free carbonaceous material.

Additionally, about 20 to about 30 es of air per ton of water-free carbonaceous material d the gasification process due to leakage, in gasification For a ratio of oxygen input to burn~up zone to total oxygen input and burn-up or zone in the range of about 0.4 to about 06, conversion of organic gasifiable or volatile material content of carbonaceous material was above 90% and of al lly in the range of about 95 to about 98%. Ratio of the carbon content less than about 0.1 ash produced to the carbon content of carbonaceous material feed was ratio of CO/COZ in the hot and generally in the range of about 0.04 to about 0.10. The the hot syngas produced was greater than about 0.75; the ratio of CO/Hz in syngas about 0.4. produced was greater than 1.5; the ratio of CO/(CO+CO;) was greater than in gasification For a ratio of oxygen input to burn—up zone to total oxygen input or gasifiable volatile and burn—up zone less than about 0.4, conversion of organic or carbon content of material content of carbonaceous material was about 82%. Ratio of the feed was about 0.3. residual ash produced to the carbon content of carbonaceous material While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.

Claims (11)

CLAIMS 1.:

1. A process for cation of a carbonaceous material to produce a raw syngas, said process comprising: (a) contacting a moving bed of said carbonaceous material with a first molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a cation zone to gasify a portion of said carbonaceous material and to produce a first gaseous product; (b) contacting a remaining portion of said carbonaceous al with a second lar oxygen-containing gas and ally with one or more of steam and CO2 in a burn-up zone to gasify an additional portion of said carbonaceous material and to produce a second gaseous product and a solid ash comprising carbon; and (c) conveying said first gaseous t, said second gaseous product, and a third molecular oxygen-containing gas to a connecting zone to produce said raw syngas, wherein a CO/CO2 molar ratio in said raw syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1.

2. The process of claim 1 wherein the CO/CO2 molar ratio in said raw syngas is greater than about 1.0.

3. The process of claim 1 or claim 2 wherein the raw syngas has a tar equivalent content below about 10 ppm.

4. The process of claim 3 wherein the tar equivalent content is equivalent to a hydrocarbon selected from the group ting of benzene, alcohol, and mixtures thereof.

5. A process for gasification of a aceous material to produce a hot syngas, said process comprising: (a) contacting a moving bed of said carbonaceous material with a first molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a gasification zone to gasify a portion of said carbonaceous al and to produce a first gaseous product; 10437579_1 (b) contacting a remaining portion of said carbonaceous material with a second molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a burn-up zone to gasify additional portion of said carbonaceous material and to produce a second gaseous product and a solid ash comprising ; (c) conveying said first gaseous product, said second gaseous product, and a third molecular oxygen containing gas to a connecting zone to produce a raw syngas comprising carbon monoxide (CO), carbon dioxide (CO2) and tar; and (d) conveying said raw syngas from the connecting zone to a tar destruction zone to produce said hot , n a CO/CO2 molar ratio in said hot syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1.

6. The process of claim 5 n the CO/CO2 molar ratio in said raw syngas is greater than about 0.75.

7. The process of claim 5 wherein the CO/CO2 molar ratio in said hot syngas is greater than about 1.0.

8. The process of any one of claims 5 to 7 wherein a temperature of the tar destruction zone is greater than about 900°C.

9. The process of any one of claims 1 to 8 wherein a weight ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.05.

10. The process of any one of claims 1 to 8 wherein a weight ratio of carbon content of solid ash to carbon t of carbonaceous material feed is less than about 0.01.

11. The process of any one of claims 1 to 10 wherein carbon t of said solid ash is less than about 10%. 10371072