WO2020205392A1 - Gazéification de textiles à taille réduite et combustibles fossiles solides - Google Patents

Gazéification de textiles à taille réduite et combustibles fossiles solides Download PDF

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Publication number
WO2020205392A1
WO2020205392A1 PCT/US2020/024833 US2020024833W WO2020205392A1 WO 2020205392 A1 WO2020205392 A1 WO 2020205392A1 US 2020024833 W US2020024833 W US 2020024833W WO 2020205392 A1 WO2020205392 A1 WO 2020205392A1
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WIPO (PCT)
Prior art keywords
composition
syngas
feedstock
gasifier
size reduced
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PCT/US2020/024833
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English (en)
Inventor
William Lewis Trapp
Justin William Murphy
Nathan Mitchell West
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Eastman Chemical Company
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Publication date
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Publication of WO2020205392A1 publication Critical patent/WO2020205392A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/48—Apparatus; Plants
    • 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
    • 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
    • Y02P20/141—Feedstock
    • Y02P20/143—Feedstock the feedstock being recycled material, e.g. plastics

Definitions

  • waste gasifiers which typically air supplied fluidized bed gasifiers that can readily accept a variety of component sizes and mixed stock types have been proposed or used.
  • waste gasifiers typically operate at low to medium temperatures in the range of 500°C to 1000°C using air as an oxidizer, and given the lower operating temperature, incomplete oxidation reactions occur resulting the generating of high quantities of residues that can appear in both the gas phase (syngas stream) and bottoms solid phase; e.g. tarry substances.
  • the types of residues and their quantity will vary depending on the feedstock composition.
  • waste gasifiers have the advantage of accepting a highly variable sizes and compositions of feedstocks
  • the resulting syngas compositions are also widely variable over time rendering them unusable for making chemicals without installation of expensive post treatments systems to clean up and purify the syngas streams existing the gasifier vessel. Even with purification processes, the
  • waste gasifier generated syngas streams are typically used to generate energy, e.g. steam or electricity or are used as fuel stocks.
  • MSW compositions contain a variety of solids, including bottles, sheets, films, paper, rubber, cardboard, cups, trays, wood, leather, textiles, glass, metal, etc.
  • non-combustibles e.g. glass, metal, dirt
  • the mix of combustibles nevertheless remains highly variable in time from hour to hour, day to day, week to week, month to month, season to season, and by the source location.
  • the variability lies both in form, e.g.
  • compositional mix e.g. polycarbonate, polyethylene, polypropylene, polyethylene terephthalate, polyamides, epoxy resins, acrylonitrilebutadiene, acrylics, alkyds, nylons, polyacetals, polystyrene, polyurethanes, vinyls, styrene acrylonitriles, ureas and melamines, wood, cellulosics, leather, food wastes, etc., variability in source location, and variability in the large variety of mechanical handling processes commercially practiced which employ different physical and chemical separation methods.
  • size reduced textiles and textiles have a fixed carbon content that is lower than solid fossil fuel sources such as coal or petcoke.
  • size reduced textiles and textiles will combust and generate the syngas components at a more rapid rate than, for example, coal.
  • Carbon monoxide generated from size reduced textiles or textiles will, therefore, have a longer residence time to convert to carbon dioxide under gasification conditions, relative to coal.
  • size reduced textiles and textiles have a high heat value (“HHV”), even in some cases equal to or exceeding coal, its use can also result in the generation of undesirable amounts of carbon dioxide in the raw syngas stream, particularly at high temperatures and pressures, along with a reduction in the amount of carbon monoxide that could have been produced by feeding only a fossil fuel.
  • size reduced textiles and textiles have a higher hydrogen content that does, for example, solid fossil fuels, which can lead to the production of higher amounts of hydrogen in the raw syngas stream and affect the carbon
  • textiles introduced into liquid or slurry fed gasifiers may not homogeneously disperse into the slurry, dispersion, or solution fed to the gasifier.
  • syngas stream suitable for chemicals synthesis in which more carbon monoxide is formed in the syngas using feedstocks containing textiles relative to lower temperature and/or lower pressure MSW fed fixed bed waste gasifiers, and to reduce the quantity of incomplete oxidation residues (e.g. tar, char, etc.).
  • the slurry fed coal gasifier generally runs at high pressures and utilizes a slurry feed (coal and water) that can be more easily pumped and fed into the gasifier.
  • a small amount of water introduced to the gasification process is helpful and needed (e.g. 5- 20%) but more than 30% begins to be detrimental to the performance of the gasifier as the water must be heated and vaporized, using energy, and takes up space in the processing equipment. Therefore, the slurry should be as concentrated in coal as possible but still fluid enough to pump.
  • the practical range for coal/water slurry concentrations is 50% - 75% coal. To make these concentrations possible, the coal is finely ground.
  • Introducing a co-feed to the gasifier can be problematic in that the co-feed has to be mixed with the coal/water slurry feed. Since the coal/water slurry is concentrated as much as possible to the edge of pumpability for economic reasons, any introduction of a co-feed can disrupt the delicate balance and cause the slurry to be unstable (solids settle out), too viscous, two-phase, or otherwise unsuitable for feeding to the gasifier safely, reliably, and economically. For example, many plastics and textiles will float, or phase separate, or agglomerate and disrupt the homogeneity of the slurry.
  • syngas streams that are suitable for making chemicals and optionally but desirably without the need to install and operate additional equipment to clean up the syngas stream exiting the gasifier vessel other than acid gas removal processes (e.g. removal of hydrogen sulfide and carbon dioxide) or processes internal to the gasifier vessel (e.g. quench to remove soot).
  • acid gas removal processes e.g. removal of hydrogen sulfide and carbon dioxide
  • processes internal to the gasifier vessel e.g. quench to remove soot
  • the feedstock is a slurry.
  • syngas composition b. gasifying the feedstock composition together with the oxidant in a gasification zone to produce a syngas composition; and c. discharging at least a portion of the syngas composition from the gasifier.
  • gasification within the gasification zone is conducted at a temperature of at least 1000°C, or
  • the feedstock composition comprises a slurry
  • the particle size of the size reduced textiles is such that at least 90% of the particles have a particle size of less than 2 mm, or
  • the tar yield is less than 4 wt.%, or
  • the gasifier contains no membrane wall in the gasification zone, or
  • composition comprising:
  • composition comprising:
  • a feedstock slurry composition comprising size reduced textiles and a liquid, wherein size reduced textiles have a particle size of not more than 2 mm, the solids content in the slurry is at least 62 wt.% (or at least 65 wt.%, or at least 68 wt.%, or at least 69 wt.%, or at least 70 wt.%), the amount of size reduced textiles present in the feedstock stream slurry composition is 0.1 wt.% to up to 25 wt.%, or up to 20 wt.%, or up 15 wt.%, or up to 12 wt.%, or up to 10 wt.%, or up to 7 wt.%, or up to 5 wt.%, or less than 5 wt.% based on the weight of all solids in the slurry, and the water is at least 20 wt.% (or at least 65 wt.%, or at least 68 wt.%, or at
  • the slurry is stable as determined by having an initial viscosity of 100,000 cP or less at 5 minutes, or 10 minutes, or 15 minutes, or 20 minutes, or 25 minutes, or even for 30 minutes using a Brookfield R/S Rheometer equipped with V80-40 vane operating at a shear rate of 1.83/s or a Brookfield viscometer with an LV-2 spindle rotating at a rate of 0.5 rpm, measured at ambient conditions; or b.
  • the slurry is pumpable as determined by having a viscosity of less than 30,000 cP, or 25,000 cP or less, or not more than 23,000 cP, or not more than 20,000 cP, or not more than 18,000 cP, or not more than 15,000 cP, or not more than 13,000 cP, after mixing to obtain a homogeneous distribution of solids throughout the slurry and using a Brookfield R/S Rheometer equipped with V80-40 vane operating at a shear rate of 1.83/s or a Brookfield viscometer with an LV-2 spindle rotating at a rate of 0.5 rpm, measured at ambient conditions, or
  • syngas composition discharged from a gasifier and obtained by gasifying a feedstock composition comprising size reduced textiles, and said syngas stream contains no tar or less than 4 wt.% (or less than 3 wt.%, or not more than 2 wt.%, or not more than 1 wt.%, or not more than 0.5 wt.%, or not more than 0.2 wt.%, or not more than 0.1 wt.%, or not more than 0.08 wt.%, or not more than 0.05 wt.%, or not more than 0.02 wt.%, or not more than 0.01 wt.%, or nor more than 0.005 wt.%) tar, based on the weight of all condensable solids in the syngas composition.
  • syngas stream composition produced by gasifying in a gasifier, as well as a process for making a syngas stream by gasifying in a gasifier, a feedstock comprising size reduced textiles wherein said syngas stream has a compositional variability that is 5% or less measured over a time period that is the lesser of 12 days or the time period the feedstock is fed to the gasifier, said syngas compositional variability satisfied against at least one of the following gaseous compounds (in moles):
  • H2 + CO amount or its molar ratio in sequence (e.g. H2:CO ratio), or
  • H2 + CO + C02 amount or its molar ratio in sequence, or i. H2 + CO + CH4 amount, or its molar ratio in sequence, or j. H2 + CO + C02 + CH4 amount, or its molar ratio in sequence, or
  • H2S + COS amount or its molar ratio in sequence, or
  • syngas composition stream having a switching variability that is negative, zero, or not more than 15%, wherein the switching frequency is at least 1 time every two years, and the switching variability is determined by the following equation:
  • %SV is percent syngas switching variability on one or more measured ingredients in the syngas composition
  • Vdt is the syngas compositional variability of a gaseous compound(s) using a feedstock comprising size reduced textiles
  • Vffi is the syngas compositional variability of the same gaseous compound(s) using a fossil fuel only stream or a liquid stream only as the feedstock, and where the feedstocks are gasified under the same conditions, other than temperature fluctuations which may autogeneously differ as a result of having size reduced textiles in the feedstock, and the variabilities are measured and satisfied against at least one of the following gaseous compounds (in moles):
  • H2 + CO amount or its molar ratio in sequence (e.g. H2:CO ratio), or
  • H2 + CO + C02 amount or its molar ratio in sequence, or i. H2 + CO + CH4 amount, or its molar ratio in sequence, or j. H2 + CO + C02 + CH4 amount, or its molar ratio in sequence, or
  • H2S + COS amount or its molar ratio in sequence, or
  • Figure 1 is a schematic plant design for combining size reduced textiles and solid fossil fuel as a feedstock to a gasification process to produce syngas.
  • Figure 2 is another example of a plant design for gasifying a feedstock of size reduced textiles and solid fossil fuel to produce a syngas stream that is scrubbed.
  • Figure 3 is a cross section view of a gasifier injector.
  • Figure 4 is a more detailed view of the nozzle section of a gasifier injector.
  • Figure 5 is a detailed view of the locations for adding size reduced textiles to a solid fossil fuel.
  • the weight of the feedstock composition or stream includes all solids, and if present liquids, fed to the gasifier, and unless otherwise stated, does not include the weight of any gases in the feedstock composition as fed to the injector or gasifier.
  • a composition or a stream are used interchangeably.
  • a PIA or PIA reactant or composition or compound is associated with, or originates from, a recycle textile, size reduced textiles, size reduced textile derived syngas if any one of them are subjected to partial oxidation gasification, regardless of when the allotment is taken, realized, or consumed.
  • a PIA can be associated with a size reduce textile that is gasified even though the allotment is taken and deposited into a recycle inventory or transferred to a PIA when recycle textiles are received or possessed or owned by a syngas manufacturer and even though the size reduced textile is not gasified at the time the allotment is taken.
  • an allotment that is associated with or originates from gasifying a size reduced textile does not limit the timing of taking or recognizing the allotment or depositing the allotment into a recycle inventory.
  • An allotment taken when a recycle textile is owned, possessed, or receiving by a syngas manufacturer and deposited into a recycle inventory is an allotment that is associated with or originates from gasifying a size reduced textile even though, at the time of taking or depositing the allotment, the size reduced textile has not yet been gasified.
  • a feedstock stream or composition is used interchangeably with a fuel feedstock stream or composition, and contains at least a fossil fuel in the form or a solid or liquid, and a size reduced textile. When weight percentages are express based on the feedstock stream or fuel feedstock, they exclude the oxidant.
  • a solid fossil fuel used is coal, petcoke, or any other solid at 25°C and 1 atmosphere that is a byproduct from refining oil or petroleum.
  • the fossil fuel portion of the feedstock composition is to be distinguished from size reduced textiles, even if the size reduced textiles are carbonaceous and in part derived from raw materials obtained from refining crude oil.
  • a fossil fuel can include liquid fossil fuels, such as liquid hydrocarbons or streams obtained from refining crude oil, or waste streams from chemical synthetic processes.
  • feedstock composition(s) comprised of fossil fuel sources (e.g. coal, petcoke, liquid hydrocarbons) and size reduced textiles as an individual stream or combined with the fossil fuel source streams, and optionally water and other chemical additives, are fed or injected along with an oxidizer gas into a gasification reaction zone or chamber of a synthesis gas generator (gasifier) and gasified in the presence of an oxidizer such as oxygen, also fed to the gasifier.
  • fossil fuel sources e.g. coal, petcoke, liquid hydrocarbons
  • size reduced textiles as an individual stream or combined with the fossil fuel source streams
  • water and other chemical additives optionally water and other chemical additives
  • a hot gas stream is produced in the gasification zone, optionally refractory lined, at high temperature and high pressure generating a molten slag, soot, ash and gases including hydrogen, carbon monoxide, carbon dioxide and can include other gases such as methane, hydrogen sulfide and nitrogen depending on the fuel source and reaction conditions.
  • the hot gas stream is produced in the reaction zone is cooled using a syngas cooler or in a quench water bath at the base of the gasifier which also solidifies ash and slag and separates solids from the gases.
  • the quench water bath also acts as a seal to maintain the internal temperature and pressure in the gasifier while the slag, soot and ash are removed into a lock hopper.
  • the cooled product gas stream removed from the gasifier can be further treated with water to remove remaining solids such as soot, and then further treated to remove acid gas (e.g. hydrogen sulfide) after optionally further cooling and shifting the ratio of carbon monoxide to hydrogen.
  • acid gas e.g. hydrogen sulfide
  • the size reduced textiles employed in the feedstock stream to the gasifier are solid at 25°C at 1 atm.
  • the size reduced textiles are a collection of size reduced textile particles, briquettes, rods, or any other shape or size that different from the native shape of the textile from which the size reduced textile is made.
  • Textiles as used herein are natural and/or synthetic fibers, rovings, yarns, nonwoven webs, cloth, fabrics and products made from or containing any of the aforementioned items, provided that the textiles are either post consumer or post-industrial textiles. Textiles can be woven, knitted, knotted, stitched, tufted, pressing of fibers together such as would be done in a felting operation, embroidered, laced, crocheted, braided, or nonwoven webs and materials. Textiles as used herein include fabrics, and fibers separated from a textile or other product containing fibers, scrap or off spec fibers or yarns or fabrics, or any other source of loose fibers and yarns.
  • a textile also includes staple fibers, continuous fibers, threads, tow bands, twisted and/or spun yarns, grey fabrics made from yarns, finished fabrics produced by wet processing gray fabrics, and garments made from the finished fabrics or any other fabrics.
  • Textiles include apparels, interior furnishings, and industrial types of textiles. Textiles also include post-industrial textiles or post consumer textiles or both.
  • Examples of textiles in the apparel category include sports coats, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, intimate apparel, outerwear such as rain jackets, cold temperature jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves.
  • Examples of textiles in the interior furnishing category include furniture upholstery and slipcovers, carpets and rugs, curtains, bedding such as sheets, pillow covers, duvets, comforters, mattress covers; linens, tablecloths, towels, washcloths, and blankets.
  • Examples of industrial textiles include transportation (auto, airplanes, trains, buses) seats, floor mats, trunk liners, and headliners;
  • the nonwoven webs that are classified as textiles do not include the category of wet laid nonwoven webs and articles made therefrom. While a variety of articles having the same function can be made from a dry or wet laid process, the article made from the dry laid nonwoven web is classified as a textile. Examples of suitable articles that may be formed from dry laid nonwoven webs as described herein can include those for personal, consumer, industrial, food service, medical, and other types of end uses. Specific examples can include, but are not limited to, baby wipes, flushable wipes, disposable diapers, training pants, feminine hygiene products such as sanitary napkins and tampons, adult incontinence pads, underwear, or briefs, and pet training pads.
  • Nonwoven webs can also be used as padding for pillows, mattresses, and upholstery, batting for quilts and comforters.
  • nonwoven webs of the present invention may be used for medical and industrial face masks, protective clothing, caps, and shoe covers, disposable sheets, surgical gowns, drapes, bandages, and medical dressings.
  • nonwoven webs as described herein may be used for
  • Nonwoven webs may also be used for other consumer end use applications, such as for, carpet backing, packaging for consumer, industrial, and agricultural goods, thermal or acoustic insulation, and in various types of apparel.
  • the dry laid nonwoven webs as described herein may also be used for a variety of filtration applications, including transportation (e.g., automotive or aeronautical), commercial, residential, industrial, or other specialty applications.
  • Examples can include filter elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs used for microfiltration, as well as end uses like tea bags, coffee filters, and dryer sheets. Further, nonwoven webs as described herein may be used to form a variety of components for use in automobiles, including, but not limited to, brake pads, trunk liners, carpet tufting, and under padding.
  • filters e.g., gasoline, oil, water
  • nanofiber webs used for microfiltration as well as end uses like tea bags, coffee filters, and dryer sheets.
  • nonwoven webs as described herein may be used to form a variety of components for use in automobiles, including, but not limited to, brake pads, trunk liners, carpet tufting, and under padding.
  • the textiles can include single type or multiple type of natural fibers and/or single type or multiple type of synthetic fibers.
  • textile fiber combinations include all natural, all synthetic, two or more type of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fibers and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fibers, and two or more types of natural fibers and two or more types of synthetic fibers.
  • Polymers used to make the synthetic fibers can be thermoplastic or thermosetting polymers.
  • the polymer number average molecular weight can be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000 or at least 70,000 or at least 90,000 or at least 100,000 or at least 130,000.
  • the weight average molecular weight of the polymers can be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000 or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000, or at least 150,000, or at least 300,000.
  • Natural fibers include those that are plant derived or animal derived. Natural fibers can be cellulosics, hemicellulosics, and lignins. Examples of plant derived natural fibers include hardwood pulp, softwood pulp, and wood flour; and other plant fibers including those in wheat straw, rice straw, abaca, coir, cotton, flax, hemp, jute, bagasse, kapok, papyrus, ramie, rattan, vine, kenaf, abaca, henequen, sisal, soy, cereal straw, bamboo, reeds, esparto grass, bagasse, Sabai grass, milkweed floss fibers, pineapple leaf fibers, switch grass, lignin-containing plants, and the like. Examples of animal derived fibers include wool, silk, mohair, cashmere, goat hair, horsehair, avian fibers, camel hair, angora wool, and alpaca wool.
  • Synthetic fibers are those fibers that are, at least in part,
  • synthesized or derivatized through chemical reactions, or regenerated and include, but are not limited to, rayon, viscose, mercerized fibers or other types of regenerated cellulose (conversion of natural cellulose to a soluble cellulosic derivative and subsequent regeneration) such as lyocell (also known as Tencel), Cupro, Modal, acetates such as polyvinylacetate, polyamides including nylon, polyesters such as those polyethylene terephthalate (PET), copolyesters including those made with IPA, CHDM and/or 2, 2,4,4- tetramethyl-1 ,3-cyclobutanediol, polycyclohexylenedimethylene terephthalate (PCT) and other copolymers, olefinic polymers such as polypropylene and polyethylene, polycarbonates, poly sulfates, poly sulfones, polyethers such as polyether-urea known as Spandex or elastane, polyacrylates, acryl
  • the size reduced textiles are obtained from post-consumer textiles and/or post-industrial textiles (also commonly known as pre-consumer textiles).
  • Post-consumer textiles are those that have been used at least once for its intended application for any duration of time regardless of wear.
  • Post industrial size reduced textiles include rework, regrind, scrap, trim, out of specification textiles (e.g. fibers, yarns, webs, cloths, fabrics, finished textiles) that have not been used for their intended application, or any textiles that have not been used by the end consumer.
  • the form of the textiles useful to make size reduced textiles are not limited, and can include any of the forms of articles or materials used to make textiles described above; e.g. fibers, yarns, fabrics, cloths, finished article forms, or pieces thereof.
  • the size reduced textiles can be of varying age and composition.
  • the source of the post-consumer or postindustrial textiles are not limited, and can include textiles present in and separated from municipal solid waste streams (“MSW”).
  • MSW Municipal solid waste streams
  • an MSW stream can be processed and sorted to several discrete components, including textiles, fibers, papers, wood, glass, metals, etc.
  • Other sources of textiles include those obtained by collection agencies, or by or for or on behalf of textile brand owners or consortiums or organizations, or from brokers, or from postindustrial sources such as scrap from mills or commercial production facilities, unsold fabrics from wholesalers or dealers, from mechanical and/or chemical sorting or separation facilities, from landfills, or stranded on docks or ships.
  • the textiles used to make the size reduced textiles are within one of the components or streams that are separated from an MSW source.
  • the size reduced textiles do not need to be densified by any method that compacts the textiles and heats a thermoplastic polymer in the textile, or heats a thermoplastic material added to the textile, to provide a binding matrix that encapsulates or otherwise binds thermosetting polymers and natural fibers in the textiles (“densification”).
  • Densified textiles also include processes that agglomerate the textiles through heat generated by frictional forces or particles made by extrusion or other external heat applied to the textile to soften or melt a portion or all of the textile.
  • the size reduced textiles are not densified, or isolated size reduced textiles are not densified, or the sized reduced textiles fed to a gasifier are not densified, or the size reduced textiles are not densified prior to combining them with a fuel fed to a gasifier.
  • the size reduced textiles are fed to a fuel for gasification, or to a gasifier neat, or slurried and fed to a gasifier.
  • the textiles are reduced in size by any means, including by chopping, shredding, harrowing, confrication, pulverizing, or cutting a feedstock of textiles to make size reduced textiles.
  • the size reduced textiles can continue to be cut, comminuted, pulverized or otherwise size reduced to obtain the desired average particle size if one desires to obtain particles.
  • the form of the size reduced textiles will depend on the desired method of size reduction.
  • the size reduced textiles can be in the form of coarse or fine particles, even a powder (of any shape other than the original shape of the textile feed).
  • the size reduced textiles can be in the form of shredded pieces, long strips, or randomly shaped pieces having a wide variety of shapes.
  • Examples of different kinds of suitable size reducing processes and equipment as stand-alone or coupled together include air swept mills, knife cutting, fine grinders that can have multiple grinding zones with internal classification systems, choppers with finer knives at the end, disintegrators that can handle shredding of textiles even high moisture feeds and then optional fine cutting or milling into smaller size such as a powder, high speed cutting blades that can have multiple zones for moving coarser material to finer material.
  • the size reducing equipment can also include drying before cutting or simultaneous with drying.
  • At least a portion or all of the size reduced textiles in a feedstock composition or stream, or the feedstock composition or stream fed to a gasifier or into the gasification zone, are obtained from textiles or contain textile fibers.
  • the size reduced textiles contain, or as fed to a gasifier or a feedstock to a gasifier contain, at least 10 wt.%, or at least 15 wt.%, or at least 20 wt.%, or at least 25 wt.%, or at least 30 wt.%, or at least 35 wt.%, or at least 40 wt.%, or at least 45 wt.%, or at least 50 wt.%, or at least 55 wt.%, or at least 60 wt.%, or at least 65 wt.%, or at least 70 wt.%, or at least 75 wt.%, or at least 80 wt.%, or at least 85 wt.%, or at least 90 wt.%, or at least 95 wt.% or at least 97 wt.% or at least 98 wt.% or at least 99 wt.% or at least 99.5 w
  • any of the mentioned embodiments which includes size reduced textiles obtained from textiles or containing textile fibers, at least 20%, or at least 30%, or at least 50%, or at least 75%, or at least 80%, or at least 90%, or at least 95%, or at least 98% of the fibers in the textiles feedstock have an aspect ratio L:D of at least 1.5:1 , or at least 1.75:1 , or at least 2:1 , or at least 2.25:1 , or at least 2.5:1 , or at least 2.75:1 , or at least 3:1 , or at least 3.25:1 , or at least 3.5:1 , or at least 3.75:1 , or at least 4:1 , or at least 4.5:1 , or at least 5:1 , or at least 5.5:1 , or at least 6:1.
  • Non-combustible inorganic matter such as metals and minerals that prevent the size reduced textiles from being incinerated and emitted may be contained in the size reduced textiles for gasification.
  • examples include tin, cobalt, manganese, antimony, titanium, sodium, calcium, sulfur, zinc, and aluminum, their oxides and other compounds thereof may be present in the size reduced textiles because a gasifier, and especially slagging gasifiers, are well equipped to handle minerals and metals in a feedstock.
  • titanium and calcium that may be present in the size reduced textiles can be slag modifiers.
  • the amount of calcium compounds present in the ash of size reduced textiles are at least 30 wt.%, or at least 40 wt.%, or at least 50 wt.%, or at least 55 wt.%, or at least 60 wt.%, or at least 63 wt.%, based on the weight of size reduced textiles ash.
  • the upper amount is desirably not more than 90 wt.%, or not more than 80 wt.%, or not more than 75 wt.%, based on the weight of size reduced textiles ash.
  • the amount of sodium compounds present in the ash of size reduced textiles are at least 2 wt.%, or at least 3 wt.%, or at least 4 wt.%, or at least 5 wt.%, or at least 6 wt.%, or at least 7 wt.%, based on the weight of the size reduced textiles ash.
  • the upper amount is desirably not more than 20 wt.%, or not more than 17 wt.%, or not more than 15 wt.%, based on the weight of size reduced textiles ash.
  • the amount of titanium compounds present in the ash of size reduced textiles are at least 30 wt.%, or at least 40 wt.%, or at least 50 wt.%, or at least 60 wt.%, or at least 70 wt.%, or at least 75 wt.%, based on the weight of size reduced textiles ash.
  • the upper amount is desirably not more than 96 wt.%, or not more than 90 wt.%, or not more than 86 wt.%, based on the weight of the size reduced textiles ash.
  • the amount of iron compounds present in the ash of size reduced textiles used in the feedstock is at least 1.5 wt.%, or at least 2 wt.%, based on the weight of size reduced textiles ash.
  • the amount of aluminum compounds present in the ash of size reduced textiles used in the feedstock is at least 2 wt.%, or at least 3 wt.%, or at least 5 wt.%, or at least 10 wt.%, based on the weight of the size reduced textiles ash.
  • the amount of silicon compounds present in the ash of size reduced textiles used in the feedstock is at least 2 wt.%, or at least 5 wt.%, or at least 10 wt.%, or at least 15 wt.%, based on the weight of the size reduced textiles ash.
  • the size reduced textiles contain low levels or no halide containing polymers, in particular polyvinyl chloride, polyvinyl fluoride, polyvinylidene fluoride, and polytetrafluoroethane, and other fluorinated or chlorinated polymers, especially if the size reduced textiles are fed to a refractory lined gasifier.
  • halide containing polymers in particular polyvinyl chloride, polyvinyl fluoride, polyvinylidene fluoride, and polytetrafluoroethane, and other fluorinated or chlorinated polymers, especially if the size reduced textiles are fed to a refractory lined gasifier.
  • the release of chlorine or fluorine elements or radicals over time can impact the longevity of refractory lining on gasifiers operating at high temperature and pressure.
  • the size reduced textiles contain less than 10 wt.%, or not more than 8 wt.%, or not more than 6 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3.5 wt.%, or not more than 3 wt.%, or not more than 2.5 wt.%, or not more than 2 wt.%, or not more than 1.5 wt.%, or not more than 1 wt.%, or not more than 0.5 wt.%, or not more than 0.25 wt.%, or not more than 0.1 wt.%, or not more than 0.05 wt.%, or not more than 0.01 wt.%, or not more than 0.005 wt.%, or not more than 0.001 wt.%, or not more than 0.0005 wt.%, or not more than 0.0001 wt.%, or not more than 10 wt.%, or not more than 8
  • the size reduced textiles as a co-fuel in a feedstock composition, have the advantage of not requiring thermal treatment beyond drying prior to their introduction into the gasification zone or their introduction to one or more components of a feedstock composition.
  • the size reduced textiles are desirably not pyrolyzed or torrefied prior to their introduction into the gasifier, and desirably, the size reduced textiles are not obtained from a source of size reduced textiles which have been pyrolyzed or torrefied.
  • the size reduced textiles are not, one size reduced, thereafter melted or extruded prior to their entry into the gasifier.
  • the size reduced textiles are not softened by external application of heat, or melted or extruded, or do not receive a pyrolysis thermal treatment, or do not receive a thermal treatment above 225°C, or above 210°C, or above 200°C, or above 195°C, or above 190°C, or above 175°C, or above 160°C, or above 150°C, or above 140°C, or above 130°C, or above 120°C, or above 1 10°C, or above 100°C, or above 90°C, or above 80°C, or above 60°C, or above 58°C or above their nominal temperature at their ambient conditions prior to their introduction into the gasification zone.
  • the size reduced textiles can be dried before their combination with a fuel for gasification or before their introduction into a gasifier, however, this would not be necessary in a slurry-based feedstock composition such as in water, or a petroleum-based oil, hydrocarbon or oxygenated hydrocarbon fuel feedstock.
  • recycle textile derived syngas reacting said recycle textile derived syngas to make a recycle content intermediate, polymer, or article (Recycle PIA) each of which have their origin at least in part to said recycle textile derived syngas or (ii) assigning a recycle content allotment, obtained from said recycle textile, to an intermediate, polymer, or article to produce a Recycle PIA;
  • Examples of articles that are included in PIA are fibers, yarns, tow, continuous filaments, staple fibers, rovings, fabrics, textiles, flake, sheet, compounded sheet, and consumer articles.
  • the allotment can be assigned to an intermediate, polymer, or article to produce a Recycle PIA directly from a recycle content value taken from the recycle textile or size reduced textiles or from the step of gasifying a feedstock containing a solid fossil fuel and recycle textiles or size reduced textiles, or the allotment can be assigned to the intermediate, polymer, or article to product a recycle PIA indirectly by assigning the recycle content value taken from a recycle inventory into which recycle content value is deposited from the recycle content present in the recycle or in the size reduced textiles or the step of gasifying a feedstock containing a solid fossil fuel and recycle textiles or size reduced textiles.
  • the Recycle PIA is a polymer or article (e.g. fiber) of the same family or classification of polymers or articles (e.g. fibers) contained in or one the recycle textile used in step (i).
  • a Recycle PIA can be made by a process in which recycled textiles are gasified according to any of the processes described herein.
  • a manufacturer of syngas, or one among its Family of Entities, or an entity contracted with either of them (collectively the “Recipient”), receiving recycle textiles (whether postindustrial or post-consumer), optionally and desirably from an industrial supplier of said articles (e.g. textiles) or fibers contained in or on said textile, and
  • One or more of the Recipients size reducing said textile or fibers to make a size reduced textile
  • recycle textile derived syngas (i) reacting said recycle textile derived syngas to make a recycle content intermediate, polymer, or article (Recycle PIA) each of which have their origin at least in part to said recycle textile derived syngas or
  • the allotment can be assigned to an intermediate, polymer, or article to produce a Recycle PIA directly from a recycle content value taken from the recycle textile or size reduced textiles or from the step of gasifying a feedstock containing a solid fossil fuel and recycle textiles or size reduced textiles, or the allotment can be assigned to the intermediate, polymer, or article to product a recycle PIA indirectly by assigning the recycle content value taken from a recycle inventory into which recycle content value is deposited from the recycle content present in the recycle textile or in the size reduced textiles or the step of gasifying a feedstock containing a solid fossil fuel and recycle textiles or size reduced textiles.
  • an entirely circular or closed loop process in which textiles can be recycled multiple times to make the same family or classification of textiles.
  • the industrial supplier may furnish a processor entity with the textile or articles containing the textile to process those textiles or articles into a form suitable or more suitable for gasification as further described herein to make size reduced textiles, and in turn, the processor entity supplies the size reduced textiles or precursors thereof to the manufacturer of syngas or one among its Family of Entities who can either feed to size reduced textiles as such to a feedstock stream to a gasifier, or can further process the precursors or size reduced textiles into a final size suitable for gasification by any suitable process, such as
  • the gasification processes, equipment, and designs used can be any of those mentioned herein.
  • the syngas made using feedstocks containing the size reduced textiles can then either by converted through a reaction scheme to make Recycle PIA, or the allotments created by such gasification step can be stored in an inventory of allotments, and from the inventory of allotments from any source, a portion thereof can be withdrawn and assigned to an intermediate, polymer or article to make
  • Recycle PIA To close the circularity of the textile, at least a portion of the Recycle PIA can by furnished to the supplier of the textiles, or it can be supplied to any entity contracted with the supplier to process the Recycle PIA into a different form, different size, or to combine with other ingredients or textiles (e.g. compounders and/or sheet extruders), or to make articles containing the PIA, for supply to or on behalf of the supplier.
  • the Recycle PIA furnished to the industrial supplier or one of its contracted entities is desirably in the same family or type of textile as the textile or article containing the textile was supplied by the industrial supplier to the Recipient.
  • A“recycle content allotment” or“allotment” means a recycle content value that is:
  • An allotment can be an allocation or a credit.
  • a recycle waste is any one of waste streams identified throughout this disclosure, including the size reduced textiles, the textiles from which they originate, or the feedstock composition containing the size reduced textiles,
  • the recycle content value (whether by mass or percentage or any other unit of measure) can optionally be determined according to a standard system for tracking, allocating, and/or crediting recycle content among various compositions.
  • A“recycle content value” is a unit of measure representative of a quantity of material having its origin in recycle textile or size reduced textile.
  • the recycle content value can have its origin in any type of recycled textile or any recycle textile processed in any type of process before being gasified.
  • the particular recycle content value can be determined by a mass balance approach or a mass ratio or percentage or any other unit of measure and can be determined according to any system for tracking, allocating, and/or crediting recycle content among various compositions.
  • a recycle content value can be deducted from a recycle inventory and applied to a product or composition to attribute recycle content to the product or composition.
  • a recycle content value does not have to originate from gasifying recycle textile, and can be a unit of measure having its known or unknown origin in any technology used to process recycle textile.
  • at least a portion of the recycle textiles from which an allotment is obtained is also gasified as described throughout the one or more embodiments herein; e.g. combined with a fossil fuel and subjected to gasification.
  • At least a portion of the recycle content allotment or allotment or recycle value deposited into a recycle content inventory is obtained from recycle textile or size reduced textiles. Desirably, at least 60%, or at least 70%, or at least 80%, or at least 90% or at least 95%, or up to 100% of the:
  • a recycle content allotment can include a recycle content allocation or a recycle content credit obtained with the transfer or use of a raw material. In one embodiment or in combination with any of the mentioned
  • the polymer, intermediate, composition, article or stream receiving the recycle content allotment can be or contain a portion of a non recycle composition (e.g., compound, polymer, feedstock, product, or stream).
  • A“non-recycle” means a composition (e.g., compound, polymer, feedstock, product, or stream) none of which was directly or indirectly derived from recycled waste of any kind, including textile.
  • A“recycle content allocation” and“allocation” means a type of recycle content allotment, where the entity or person supplying a composition sells or transfers the composition to the receiving person or entity, and the person or entity that made the composition has an allotment at least a portion of which can be associated with the composition sold or transferred by the supplying person or entity to the receiving person or entity.
  • the supplying entity or person can be controlled by the same entity or person(s) or a variety of affiliates that are ultimately controlled or owned at least in part by a parent entity (“Family of Entities”), or they can be from a different Family of Entities.
  • a recycle content allocation travels with a composition and with the downstream derivates of the composition.
  • A“recycle content credit” and“credit” mean a type of recycle content allotment, where the allotment is available for sale or transfer or use, or is sold or transferred or used, either:
  • an allotment may be deposited into a recycle inventory, and a credit may be withdrawn from the inventory and applied to a composition to make a Recycle PIA. This would be the case where an allotment is created from a recycle textile and deposited into a recycle inventory, and deducting a recycle content value from the recycle inventory and applying it to a
  • composition to make a Recycle PIA that either has no portion originating from syngas or does have a portion originating from syngas but such syngas making up the portion of the composition was not a recycle content syngas.
  • Recycle PIA reactants do not contain recycle content.
  • the composition receiving an allotment to make a Recycle PIA originates in part from a syngas stream obtained by any gasification process.
  • the feedstock to the gasification process may optionally contain solid fossil fuel such as coal.
  • the feedstock may optionally also contain a combination of solid fossil fuel and recycle textiles or size reduced textiles.
  • step b optionally by combining it with a solid fossil fuel as a feedstock to a gasifier, optionally according to any of the designs or processes described herein; and d. optionally at least a portion of the composition in step b.
  • syngas stream originates from a syngas stream, optionally the syngas stream having been obtained by any of the feedstocks and methods described herein.
  • the steps b. and c. do not have to occur simultaneously. In one embodiment, they occur within a year of each other, or within six (6) months of each other, or within three (3) months of each other, or within one (1 ) month of each other, or within two (2) weeks of each other, or within one (1 ) week of each other, or within three (3) days of each other.
  • the process allows for a time lapse between the time an entity or person receiving the recycle textile and creating the allotment (which can occur upon receipt or ownership of the recycle textile) and the actual processing of the recycle textile in a gasifier.
  • “recycle inventory” and“inventory” mean a group or collection of allotments (allocations or credits) from which deposits and deductions of allotments in any units can be tracked.
  • the inventory can be in any form (electronic or paper), using any or multiple software programs, or using a variety of modules or applications that together as a whole tracks the deposits and deductions.
  • the total amount of recycle content withdrawn (or applied to the Recycle PIA) does not exceed the total amount of recycle content allotments or credits on deposit in the recycle inventory (from any source, not only from gasification of recycle textiles). However, if a deficit of recycle content value is realized, the recycle content inventory is
  • the timing for rebalancing can be either determined and managed in accordance with the rules of a particular system of accreditation adopted by the recycle content syngas manufacturer or by one among its Family of Entities, or alternatively, is rebalanced within one (1 ) year, or within six (6) months, or within three (3) months, or within one (1 ) month of realizing the deficit.
  • the timing for depositing an allotment into the recycle inventory, applying an allotment (or credit) to a composition to make a Recycle PIA, and gasifying a recycle textile, need not be simultaneous or in any particular order.
  • the step of gasifying a particular volume of recycle textiles occurs after the recycle content value or allotment from that volume of recycle textile is deposited into a recycle inventory.
  • the allotments or recycle content values withdrawn from the recycle inventory need not be traceable to recycle textiles or gasifying recycle textiles, but rather can be obtained from any waste recycle stream, and from any method of processing the recycle waste stream.
  • At least a portion of the recycle content value in the recycle inventory is obtained from recycle textiles, and optionally at least a portion of recycle textiles are processed in the one or more gasification processes as described herein, optionally within a year of each other and optionally at least a portion of the volume of recycle textiles from which a recycle content value is deposited into the recycle inventory is also processed by any or more of the gasification processes described herein.
  • the determination of whether a Recycle PIA is derived directly or indirectly from recycled waste is not on the basis of whether intermediate steps or entities do or do not exist in the supply chain, but rather whether at least a portion of the recycle textile molecules fed to the gasifier can be traced into a Recycle PIA.
  • the Recycle PIA is considered to be directly derived from recycle textile or have direct contact with recycle textile if at least a portion of the molecules in the Recycle PIA can be traced back, optionally through one or more intermediate steps or entities, to at least a portion of the recycle content syngas molecules. Any number of intermediaries and intermediate derivates can be made before the Recycle PIA is made.
  • a Recycle PIA can be indirectly derived from recycled textiles if no portion of its molecules are obtained from recycle content syngas molecules or some portion of is molecules are obtained from recycle content syngas molecules but the Recycle PIA has a recycle content value that exceeds the recycle content value associated with the recycle content syngas molecules, and in this latter case, a Recycle PIA can be both directly and indirectly derived from recycle textile.
  • the Recycle PIA is indirectly derived from recycle textile or recycle content syngas. In another embodiment, the Recycle PIA is directly derived from recycle textile or recycle content syngas. In another
  • the Recycle PIA is indirectly derived from recycle textile or recycle content syngas and no portion of the Recycle PIA is directly derived from the recycle textile or recycle content syngas.
  • all Recycle PIA compositions may contain 5 wt.% recycle content value.
  • the amount of recycle content in the products is proportional to the amount of recycle content in the feedstock to make the products; or
  • b. adopt an asymmetric distribution of recycle content values among its product(s) based on the same fractional percentage of recycle content in the one or more feedstocks, or based on the amount of allotment received. For example, if 5 wt.% of the gasifier feedstock is recycle textile, or if the allotment value is 5 wt.% of the entire gasifier feedstock, then one volume or batch of Recycle PIA can receive a greater amount of recycle content value that other batches or volume of Recycle PIA.
  • One batch of PVA can contain 20% recycle content by mass, and another batch can contain zero 0% recycle content, even though both volumes may be compositionally the same, provided that the amount of recycle content value withdrawn from a recycle inventory and applied to the Recycle PIA does not exceed the amount of recycle content value deposited into the recycle inventory, or if a deficit is realized, the overdraft is rebalanced to zero or a positive credit available status as described above.
  • a manufacturer can tailor the recycle content to volumes of Recycle PIA sold as needed among customers, thereby providing flexibility among customers some of whom may need more recycle content than others in a PVA volume.
  • Both the symmetric distribution and the asymmetric distribution of recycle content can be proportional on a Site wide basis, or on a multi-Site basis.
  • the recycle content input (recycle textiles or allotments) can be within a Site, and recycle content values from said inputs are applied to one or more compositions made at the same Site to make Recycle PIA.
  • the recycle content values can be applied symmetrically or asymmetrically to one or more different compositions made at the Site.
  • recycle content input or creation can be to or at a first Site, and recycle content values from said inputs are transferred to a second Site and applied to one or more
  • compositions made at a second Site can be applied symmetrically or asymmetrically to the compositions at the second Site.
  • the Recycle PIA has associated with it, or contains, or is labelled, advertised, or certified as containing recycle content in an amount of at least 0.01 wt.%, or at least 0.05 wt.%, or at least 0.1 wt.%, or at least 0.5 wt.%, or at least 0.75 wt.%, or at least 1 wt.%, or at least 1.25 wt.%, or at least 1.5 wt.%, or at least 1.75 wt.%, or at least 2 wt.%, or at least 2.25 wt.%, or at least 2.5 wt.%, or at least 2.75 wt.%, or at least 3 wt.%, or at least 3.5 wt.%, or at least 4 wt.%, or at least 4.5 wt.%, or at least 5 wt.%, or at least 6 wt.%, or at least 7 wt.%, or at least 10
  • the recycle content associated with the Recycle PIA can be associated by applying an allotment (credit or allocation) to any polymer and/or article made or sold.
  • the allotment can be contained in an inventory of allotments created, maintained or operated by or for the Recycle PIA manufacturer.
  • the allotment can be obtained from any source along any manufacturing chain of products provided that its origin is in gasifying a feedstock containing a solid fossil fuel and size reduced textiles.
  • the amount of recycle content in a reactant compound or composition, or the amount of recycle content applied to the Recycle PIA, or the amount of recycle textile (recycle textile feedstock) needed to feed the gasifier to claim a desired amount of recycle content in the Recycle PIA in the event that all the recycle content from the recycle textile feedstock is applied to the Recycle PIA, can be determined or calculated by any of the following methods:
  • the amount of an allotment associated with the Recycle PIA is determined by the amount certified or declared by the supplier of transferred Recycle PIA, or
  • the Recycle PIA manufacturer can make Recycle PIA, or process a reactant compound or composition and make a Recycle PIA, or make Recycle PIA by obtaining any source of a reactant compound or composition from a supplier, whether or not such reactant compound or composition has any recycle content, and either:
  • composition or ii. from any person or entity, obtaining a recycle content allotment without a supply of a reactant compound or composition from said person or entity transferring said recycle content allotment.
  • the allotment in (i) can be obtained from a supplier of the reactant compound or composition used to make Recycle PIA, and the supplier also supplies and transfers the reactant compound or composition to the Recycle PIA manufacturer or within its Family of Entities.
  • the circumstance described in (i) allows a Recycle PIA manufacturer to obtain a supply of a reactant compound or composition that has non-recycle content, yet obtain a recycle content allotment from the reactant compound or composition.
  • the reactant compound or composition supplier transfers a recycle content allotment to the Recycle PIA manufacturer as well as a supply of reactant compound or composition to the Recycle PIA manufacturer, where the recycle content allotment is not associated with the reactant compound or composition supplied, provided that the recycle content allotment transferred has its origins in gasifying recycle size reduced textile.
  • the recycle content allotment does not have to be tied to an amount of recycle content in a reactant compound or composition or to any monomer used to make Recycle PIA, but rather the recycle content allotment transferred by the reactant compound or composition supplier can be associated with other products having their origin in a recycle textile derived syngas stream other than those in a reaction scheme to make polymer and/or articles. This allows flexibility among the reactant compound or composition supplier and Recycle PIA manufacturer to apportion a recycle content among the variety of products they each make. In each of these cases, however, the recycle content allotment has its origins in gasifying recycle textiles.
  • the reactant compound or composition supplier transfers a recycle content allotment to the Recycle PIA manufacturer and a supply of reactant compound or composition to the Recycle PIA manufacturer, where the recycle content allotment is associated with reactant compound or composition.
  • the reactant compound or composition being supplied can be derived from recycle textile feedstock and at least a portion of the recycle content allotment being transferred can be the recycle content in the reactant compound or composition.
  • the recycle content allotment transferred to the Recycle PIA manufacturer can be up front with the reactant compound or composition supplied, optionally in installments, or with each reactant compound or composition portion supplier, or apportioned as desired among the parties.
  • the allotment in (ii) is obtained by the Recycle PIA manufacturer (or its Family of Entities) from any person or entity without obtaining a supply of reactant compound or composition from the person or entity.
  • the person or entity can be a reactant compound or composition manufacturer that does not supply reactant compound or composition to the Recycle PIA
  • the person or entity can be a manufacturer that does not make a reactant compound or composition.
  • the circumstances of (ii) allows a Recycle PIA manufacturer to obtain a recycle content allotment without having to purchase any reactant compound or composition from the entity supplying the recycle content allotment.
  • the person or entity may transfer a recycle content allotment through a buy/sell model or contract to the Recycle PIA
  • the person or entity may outright sell the allotment to the Recycle PIA manufacturer or one among its Family of Entities.
  • the person or entity may transfer a product, other than a reactant compound or composition, along with its associated recycle content allotment to the Recycle PIA manufacturer. This can be attractive to a Recycle PIA
  • the allotment can be deposited into a recycle inventory (e.g. an inventory of allotments).
  • the allotment is an allocation created by the manufacturer of the recycle textile derived syngas stream.
  • the Recycle PIA manufacturer can also make a polymer and/or article, whether or not a recycle content is applied to the polymer and/or article and whether or not recycle content, if applied to the polymer and/or article, is drawn from the inventory.
  • the recycle textile derived syngas stream manufacturer and/or the Recycle PIA manufacturer may:
  • any recycle content allotment can be deducted in any amount and applied to a polymer and/or article to make a Recycle PIA.
  • a Recycle inventory of allotments can be generated having a variety of sources for creating the allotments.
  • Some recycle content allotments (credits) can have their origin in methanolysis of recycle waste, or from mechanical recycling of waste textile or metal recycling, and/or from pyrolyzing recycle waste, or from any other chemical or mechanical recycling technology.
  • the recycle inventory may or may not track the origin or basis of obtaining a recycle content value, or the inventory may not allow one to associate the origin or basis of an allotment to the allotment applied to Recycle PIA.
  • an allotment is deducted from an allotment inventory and applied to Recycle PIA regardless of the source or origin of the allotment, provided that a recycle content allotment derived from a recycle textile feedstock containing a solid fossil fuel and size reduced textiles is present in the allotment inventory as the time of withdrawal, or a recycle content allotment is obtained by the Recycle PIA manufacturer as specified in step (i) or step (ii), whether or not that recycle content allotment is actually deposited into the inventory.
  • the recycle content allotment obtained in step (i) or (ii) is deposited into an inventory of allotments.
  • the recycle content allotment deducted from the inventory and applied to the Recycle PIA is associated with gasifying a recycle textile feedstock containing a solid fossil fuel and size reduced textiles.
  • the inventory of allotments can be owned by the recycle textile derived syngas manufacturer, or by the Recycle PIA manufacturer, or operated by either of them, or owned or operated by neither but at least in part for the benefit of either of them, or licensed by either of them.
  • the recycle textile derived syngas can be owned by the recycle textile derived syngas manufacturer, or by the Recycle PIA manufacturer, or operated by either of them, or owned or operated by neither but at least in part for the benefit of either of them, or licensed by either of them.
  • the recycle textile derived syngas can be owned by the recycle textile derived syngas manufacturer, or by the Recycle PIA manufacturer, or operated by either of them, or owned or operated by neither but at least in part for the benefit of either of them, or licensed by either of them.
  • the recycle textile derived syngas can be owned by the recycle textile derived syngas manufacturer, or by the Recycle PIA manufacturer, or operated by either of them, or owned or operated by neither but at least in part for the benefit of either of them, or licensed by
  • manufacturer or the Recycle PIA manufacturer may also include either of their Family of Entities. For example, while either of them may not own or operate the inventory, one among its Family of Entities may own such a platform, or license it from an independent vendor, or operate it for either of them.
  • an independent entity may own and/or operate the inventory and for a service fee operate and/or manage at least a portion of the inventory for either of them.
  • the Recycle PIA manufacturer obtains a supply of reactant compound or composition from a supplier, and also obtains an allotment from the supplier, where such allotment is derived from gasifying a feedstock containing a solid fossil fuel and size reduced textiles, and optionally the allotment is associated with the reactant compound or composition supplied.
  • at least a portion of the allotment obtained by the Recycle PIA manufacturer is either:
  • Recycle PIA not made by the supply of reactant compound or composition, such as would be the case where Recycle PIA is already made and stored in inventory or future made Recycle PIA; or c. deposited into an inventory from which is deducted an allotment applied to Recycle PIA (the Recycle PIA applied allocation or credit) and the deposited allotment either does, or does not, contribute to the amount of allotments from which the Recycle PIA applied allotment is drawn.
  • an allotment applied to Recycle PIA the Recycle PIA applied allocation or credit
  • recycle textile feedstock is used to make Recycle PIA composition or that the Recycle PIA was obtained from a recycle content allotment associated with a reactant compound or composition. Further, it is not necessary that an allotment be applied to the recycle textile feedstock for making the Recycle PIA to which recycle content is applied. Rather, as noted above, the allotment, even if associated with a reactant compound or composition when the reactant compound or composition is obtained, can be deposited into an electronic inventory. In one embodiment, however, the reactant compound or composition associated with the allotment is used to make the Recycle PIA compound or composition.
  • the Recycle PIA is obtained from a recycle content allotment associated with gasifying a recycle textile feedstock. In one embodiment, at least a portion of the allotments obtained from gasifying solid fossil fuel and size reduced textiles are applied to Recycle PIA to make a Recycle PIA.
  • the recycle textile derived syngas stream manufacturer generates an allotment by gasifying a combination of solid fossil fuel and size reduced textiles, and either:
  • compositions; and the deposited allotment either is or is not associated with the particular allotment applied to the reactant compounds or compositions; or
  • d. is deposited into an inventory and stored for use at a later time.
  • the package can be any suitable package for containing a polymer and/or article, such as a drum, railroad car, isotainer, totes, polytote, bale, IBC totes, compressed bale, jerrican, polybag, spools, roving, winding, or cardboard packaging.
  • the identifier can be a certificate document, a product
  • the identifier need not state or represent that the recycle content is derived from gasifying a feedstock containing a solid fossil fuel and size reduced textiles. Rather, the identifier can merely convey or communicate that the Recycle PIA has or is sourced from a recycle content, regardless of the source. However, the Recycle PIA has a recycle content allotment that, at least in part, is
  • one may communicate recycle content information about the Recycle PIA to a third party where such recycle content information is based on or derived from at least a portion of the allocation or credit.
  • the third party may be a customer of the recycle textile derived syngas manufacturer or Recycle PIA manufacturer or supplier, or may be any other person or entity or governmental organization other than the entity owning the either of them.
  • the communication may electronic, by document, by advertisement, or any other means of communication.
  • a system or package comprising:
  • an identifier such as a credit, label or certification associated with said Recycle PIA or article made thereby, where the identifier is a representation that the polymer and/or article or article made thereby has, or is sourced from, a recycle content provided that the Recycle PIA or article made thereby has an allotment, or is made from a reactant compound or composition, at least in part originating directly or indirectly from gasifying solid fossil fuels and size reduced textiles.
  • the system can be a physical combination, such as package having at least Recycle PIA as its contents and the package has a label, such as a logo, that the contents such as the Recycle PIA has or is sourced from a recycle content.
  • the label or certification can be issued to a third party or customer as part of a standard operating procedure of an entity whenever it transfers or sells Recycle PIA having or sourced from recycle content.
  • the identifier does not have to be physically on the Recycle PIA or on a package, and does not have to be on any physical document that accompanies or is associated with the Recycle PIA.
  • the identifier can be an electronic credit transferred electronically by the Recycle PIA manufacturer to a customer in connection with the sale or transfer of the Recycle PIA product, and by sole virtue of being a credit, it is a representation that the Recycle PIA has recycle content.
  • the identifier itself need only convey or communicate that the Recycle PIA has or is sourced from a recycle content, regardless of the source.
  • articles made from the Recycle PIA may have the identifier, such as a stamp or logo embedded or adhered to the article.
  • the identifier is an electronic recycle content credit from any source.
  • the identifier is an electronic recycle content credit having its origin in gasifying a feedstock containing a solid fossil fuel and size reduced textiles.
  • the Recycle PIA is made from a reactant compound or
  • Recycle PIA composition whether or not the reactant is a recycle content reactant (recycle textile feedstock).
  • Recycle textile feedstock a recycle content reactant
  • a Recycle PIA composition can be designated as having recycle content based on and derived from at least a portion of the allotment, again whether or not the recycle textile feedstock is used to make the Recycle PIA composition.
  • the allotment can be withdrawn or deducted from inventory.
  • the amount of the deduction and/or applied to the Recycle PIA can correspond to any of the methods described above, e.g. a mass balance approach.
  • a Recycle PIA compound or composition can be made by having an inventory of allotments, and reacting a reactant compound or composition a synthetic process to make a Recycle PIA, and applying a recycle content to that Recycle PIA to thereby obtain a Recycle PIA by deducting an amount of allotment from an inventory of allotments.
  • a Recycle PIA manufacturer may have an inventory of allotments by itself or one among its Family of Entities owning, possessing, or operating the inventory, or a third party operating at least a portion of the inventory for the Recycle PIA manufacturer or its Family of Entities or as a service provided to the Recycle PIA manufacturer or one among its Family of Entities.
  • the amount of allotment deducted from inventory is flexible and will depend on the amount of recycle content applied to the Recycle PIA. It should be at least sufficient to correspond with at least a portion if not the entire amount of recycle content applied to the Recycle PIA.
  • the method of calculation can be a mass balance approach, or the methods of calculation described above.
  • the inventory of allotments can be established on any basis and may be a mix of basis, provided that at least some amount of allotment in the inventory is attributable to gasifying a feedstock containing a solid fossil fuel and size reduced textiles.
  • the recycle content allotment applied to the Recycle PIA does not have to have its origin in gasifying a feedstock containing a solid fossil fuel and size reduced textiles, and instead can have its origin in any other method of generating allotments from recycle waste, such as through methanolysis or gasification of recycle waste, provided that the inventory of allotments also contains an allotment or has an allotment deposit having its origin in gasifying a feedstock containing a solid fossil fuel and size reduced textiles.
  • the recycle content applied to the Recycle PIA is an allotment obtained from gasifying a feedstock containing a solid fossil fuel and size reduced textiles.
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a polymer and/or article composition where the allotment is associated with a recycle textile derived syngas stream, and the reactant compound or composition used to make the Recycle PIA did not contain any recycle content or it did contain recycle content; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a polymer and/or article composition where the allotment is derived directly or indirectly with a recycle content reactant compound or composition, whether or not such reactant compound or composition volume is used to make the Recycle PIA; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a Recycle PIA composition where the allotment is derived directly or indirectly from a recycle textile feedstock used to make the Recycle PIA to which the allotment is applied, and:
  • feedstock is applied to the Recycle PIA and instead is stored in an inventory, and a recycle content from any source or origin is deducted from the inventory and applied to Recycle PIA; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a reactant compound or composition used to make a Recycle PIA to thereby obtain a Recycle PIA, where the allotment was obtained with the transfer or purchase of the same reactant compound or composition used to make the Recycle PIA and the allotment is associated with the recycle content in a reactant compound or composition; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a reactant compound or composition used to make a Recycle PIA to thereby obtain a Recycle PIA, where the allotment was obtained with the transfer or purchase of the same reactant compound or composition used to make the Recycle PIA and the allotment is not associated with the recycle content in a reactant compound or composition but rather on the recycle content of a monomer used to make the reactant compound or composition; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a reactant compound or composition used to make a Recycle PIA to thereby obtain a Recycle PIA, where the allotment was not obtained with the transfer or purchase of the reactant compound or composition and the allotment is associated with the recycle content in the reactant compound or composition; or
  • a Recycle PIA manufacturer applies at least a portion of an allotment to a reactant compound or composition used to make a Recycle PIA to thereby obtain a Recycle PIA, where the allotment was not obtained with the transfer or purchase of the reactant compound or composition and the allotment is not associated with the recycle content in the reactant compound or composition but rather with the recycle content of any monomers used to make the reactant compound or
  • a Recycle PIA manufacturer obtains an allotment having it origin in gasifying a feedstock containing a solid fossil fuel and size reduced textiles, and:
  • the Recycle PIA, or articles made thereby can be offered for sale or sold as Recycle PIA containing or obtained with recycle content.
  • the sale or offer for sale can be accompanied with a certification or representation of the recycle content claim made in association with the Recycle PIA or article made with the Recycle PIA.
  • the obtaining of an allotment and designating can be by the Recycle PIA manufacturer or within the Recycle PIA
  • allocation or credit can occur through a variety of means and according to the system employed by the Recycle PIA manufacturer, which can vary from manufacturer to manufacturer. For example, the designation can occur internally merely through a log entry in the books or files of the Recycle PIA manufacturer or other inventory software program, or through an
  • the Recycle PIA can be sold.
  • a method of offering to sell or selling polymer and/or articles by:
  • the designation can be the amount of allotment deducted from inventory, or the amount of recycle content declared or determined by the Recycle PIA manufacturer in its accounts. Thus, the amount of recycle content does not necessarily have to be applied to the Recycle PIA product in a physical fashion.
  • the designation can be an internal designation to or by the Recycle PIA manufacturer or its Family of Entities or a service provider in contractual relationship to the Recycle PIA manufacturer or its Family of Entities, and
  • the amount of recycle content represented as contained in the Recycle PIA sold or offered for sale has a relationship or linkage to the designation.
  • the amount of recycle content can be a 1 :1 relationship in the amount of recycle content declared on a Recycle PIA offered for sale or sold and the amount of recycle content assigned or designated to the Recycle PIA by the Recycle PIA manufacturer.
  • step a) of obtaining an allotment and the step of making Recycle PIA from a reactant compound or composition can be simultaneous and related if one employs a recycle textile feedstock composition to make the Recycle PIA since the recycle textile feedstock is both a reactant compound or composition and has a recycle content allotment associated with it.
  • the step of deducting an allotment from an inventory of allotments does not require its application to a Recycle PIA product.
  • the deduction also does not mean that the quantity disappears or is removed from the inventory logs.
  • a deduction can be an adjustment of an entry, a withdrawal, an addition of an entry as a debit, or any other algorithm that adjusts inputs and outputs based on an amount recycle content associated with a product and one or a cumulative amount of allotments on deposit in the inventory.
  • a deduction can be a simple step of a reducing/debit entry from one column and an addition/credit to another column within the same program or books, or an algorithm that automates the deductions and entries/additions and/or applications or designations to a product slate.
  • the step of applying an allotment to a Recycle PIA product where such allotment was deducted from inventory also does not require the allotment to be applied physically to a Recycle PIA product or to any document issued in association with the Recycle PIA product sold.
  • a Recycle PIA manufacturer may ship Recycle PIA product to a customer and satisfy the“application” of the allotment to the Recycle PIA product by electronically transferring a recycle content credit to the customer.
  • the amount of recycle content in the recycle textile feedstock or in the Recycle PIA will be based on the allocation or credit obtained by the manufacturer of the Recycle PIA composition or the amount available in the Recycle PIA manufacturer’s inventory of allotments.
  • a portion or all of the allocation or credit obtained by or in the possession of a manufacturer of Recycle PIA can be designated and assigned to a recycle textile feedstock or Recycle PIA on a mass balance basis.
  • the assigned value of the recycle content to the recycle textile feedstock or Recycle PIA should not exceed the total amount of all allocations and/or credits available to the manufacturer of the Recycle PIA or other entity authorized to assign a recycle content value to the Recycle PIA.
  • the polymer and/or article manufacturer need not purchase a recycle reactant compound or composition from a particular source or supplier, and does not require the polymer and/or article
  • the polymer or article manufacturer may use any source of reactant compound or composition and apply at least a portion of the allocation or credit to at least a portion of the reactant compound or composition feedstock or to at least a portion of the polymer and/or article product.
  • the association by the polymer and/or article manufacturer may come in any form, whether by on in its inventory, internal accounting methods, or declarations or claims made to a third party or the public.
  • composition the use including converting recycle size reduced textile in any synthetic process, such as gasification, to make recycle textile derived syngas and/or Recycle PIA.
  • a recycle size reduced textiles that includes converting a reactant compound or composition in a synthetic process to make polymer and/or articles and applying at least a portion of an allotment to the polymer and/or article to the reactant compound or composition, where the allotment has its origin in gasifying a feedstock containing a solid fossil fuel and recycle size reduced textiles or has its origin in an inventory of allotments where at least one deposit made into the inventory has its origin in gasifying a feedstock containing a solid fossil fuel and recycle size reduced textiles.
  • the reactant compound or composition such a reactant compound or composition can be stored in a storage vessel and transferred to a Recycle PIA manufacturing facility by way of truck, pipe, or ship, or as further described below, the reactant compound or composition production facility can be integrated with the Recycle PIA facility.
  • the reactant compound or composition may be shipped or transferred to the operator or facility that makes the polymer and/or article.
  • the process for making Recycle PIA can be an integrated process.
  • One such example is a process to make Recycle PIA by:
  • the facilities to make Recycle PIA, the reactant compound or composition, or the syngas can be stand-alone facilities or facilities integrated to each other. For example, one may establish a system of producing and consuming a reactant compound or composition, as follows:
  • a. provide a reactant compound or composition manufacturing facility configured to produce a reactant compound or composition
  • b. provide a polymer and/or article manufacturing facility having a reactor configured to accept a reactant compound or composition from the reactant compound or composition manufacturing facility and making a polymer and/or article; and c. a supply system providing fluid communication between these two facilities and capable of supplying a reactant compound or composition from the reactant compound or composition manufacturing facility to the polymer and/or article
  • reactant compound or composition manufacturing facility generates or participates in a process to generate allotments and gasifies a feedstock containing solid fossil fuel and recycle size reduced textiles, and:
  • the reactant compound or composition manufacturing facility can make Recycle PIA by accepting any reactant compound or composition from the reactant compound or composition manufacturing facility and applying a recycle content to a polymer and/or article made with the reactant compound or composition by deducting allotments from its inventory and applying them to the Recycle PIA, optionally in amounts using the methods described above.
  • the allotments withdrawn from inventory and applied can be allotments obtained by any source of recycle content, and need not necessarily be allotments associated with gasifying recycle size reduced textiles.
  • a. provide a gasification manufacturing facility configured to
  • b. provide a reactant compound or composition manufacturing facility configured to accept a recycle textile derived syngas stream from the gasification manufacturing facility and making, through a reaction scheme one or more downstream products of said syngas to make an output composition comprising a reactant compound or composition;
  • c. provide a polymer and/or article manufacturing facility having a reactor configured to accept a reactant compound or composition and making an output composition comprising a recycle content Recycle PIA;
  • a supply system providing fluid communication between at least two of these facilities and capable of supplying the output composition of one manufacturing facility to another one or more of said manufacturing facilities.
  • the polymer and/or article manufacturing facility can make Recycle PIA.
  • the gasification manufacturing facility can have its output in fluid communication with the reactant compound or composition
  • the manufacturing facility which in turn can have its output in fluid communication with the polymer and/or article manufacturing facility.
  • the manufacturing facilities of a) and b) alone can be in fluid communication, or only b) and c).
  • the polymer and/or article manufacturing facility can make Recycle PIA directly by having the size reduced textiles content syngas produced in the gasification manufacturing facility converted all the way to Recycle PIA, or indirectly by accepting any reactant compound or composition from the reactant compound or composition manufacturing facility and applying a recycle content to Recycle PIA by deducting allotments from its inventory and applying them to the Recycle PIA, optionally in amounts using the methods described above.
  • the allotments obtained and stored in inventory can be obtained by any of the methods described above,
  • the fluid communication can be gaseous or liquid or both.
  • the fluid communication need not be continuous and can be interrupted by storage tanks, valves, or other purification or treatment facilities, so long as the fluid can be transported from the manufacturing facility to the subsequent facility through an interconnecting pipe network and without the use of truck, train, ship, or airplane.
  • the facilities may share the same site, or in other words, one site may contain two or more of the facilities. Additionally, the facilities may also share storage tank sites, or storage tanks for ancillary chemicals, or may also share utilities, steam or other heat sources, etc., yet also be considered as discrete facilities since their unit operations are separate.
  • a facility will typically be bounded by a battery limit.
  • the integrated process includes at least two facilities co-located within 5, or within 3, or within 2, or within 1 mile of each other (measured as a straight line). In one embodiment, at least two facilities are owned by the same Family of Entities.
  • an integrated Recycle PIA generating and consumption system includes:
  • a. Provide a gasification manufacturing facility configured to
  • b. provide a reactant compound or composition manufacturing facility configured to accept a recycle textile derived syngas stream from the gasification manufacturing facility and making, through a reaction scheme, one or more downstream products of said syngas to make an output composition comprising a reactant compound or composition;
  • c. provide a polymer and/or article manufacturing facility having a reactor configured to accept said reactant compound or composition and making an output composition comprising a polymer and/or article;
  • a piping system interconnecting at least two of said facilities, optionally with intermediate processing equipment or storage facilities, capable of taking off the output composition from one facility and accept said output at any one or more of the other facilities.
  • the system does not necessarily require a fluid communication between the two facilities, although fluid communication is desirable.
  • the recycle textile derived syngas can be delivered to the reactant compound or composition facility through the interconnecting piping network that can be interrupted by other processing equipment, such as treatment, purification, pumps, compression, or equipment adapted to combine streams, or storage facilities, all containing optional metering, valving, or interlock equipment.
  • the equipment can be a fixed to the ground or fixed to structures that are fixed to the ground.
  • the interconnecting piping does not need to connect to the reactant compound or composition reactor or the cracker, but rather to a delivery and receiving point at the respective facilities.
  • the interconnecting pipework need not connect all three facilities to each other, but rather the interconnecting pipework can be between facilities a)-b), or b)- c), or between a)-b)-c).
  • the total amount of carbon in the size reduced textiles added to the solid fossil fuel is at least 70 wt.%, or at least 75 wt.%, or at least 80 wt.%.
  • the total amount of carbon in the size reduced textiles are at least 60 wt.%, or at least 65 wt.%, or at least 70 wt.%, or at least 75 wt.%, or at least 80 wt.%.
  • the total amount of hydrogen in the size reduced textiles are desirably at least 5 wt.%, or at least 8 wt.%, or at least 10 wt.%.
  • the ratio of total hydrogen to total carbon in the size reduced textiles feed is higher than that of any other source of fuel fed to the gasifier.
  • the ratio of total hydrogen to total carbon in the size reduced textile used in the gasifier feedstock is at least 0.075, or at least 0.08, or at least 0.085, or at least 0.09, or at least 0.095, or at least 0.1 , or at least 0.1 1 , or at least 0.12, or at least 0.13 by weight.
  • the size reduced textiles used in the feedstock composition have an average fixed carbon content of less than 75 wt.%, or not more than 70 wt.%, or not more than 65 wt.%, or not more than 60 wt.%, or not more than 55 wt.%, or not more than 45 wt.%, or not more than 40 wt.%, or not more than 35 wt.%, or not more than 30 wt.%, or not more than 25 wt.%, or not more than 20 wt.%, or not more than 15 wt.%, or not more than 10 wt.%, or not more than 8 wt.%, or not more than 6 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3 wt.%, or not more than 2 wt.%, or not more than 1 wt.%, based on the weight of the size reduced textiles
  • syngas compositional variations attributable to the use of size reduced textiles can be negligible by keeping the size reduced textiles concentration in the solids low.
  • the amount of size reduced textiles present in the feedstock stream are up to 25 wt.%, or up to 20 wt.%, or up 15 wt.%, or up to 12 wt.%, or up to 10 wt.%, or up to 7 wt.%, or up to 5 wt.%, or less than 5 wt.% based on the weight of the solids in the fuel feedstock stream or composition, or can range from 0.1 wt.% to 25 wt.%, or from 0.1 wt.% to 20 wt.%, or from 0.1 wt.% to 15 wt.%, or from 0.1 wt.% to 12 wt.%, or from 0.1 wt.% to 7 wt.%, or from 0.1 wt.% to 5 wt.%, or from 0.1 wt.% to less than 5 wt.%, or from 0.1 wt.% to 4 wt.%, or from
  • size reduced textiles have, on average, a much lower fixed carbon content than solid fossil fuels, the amount of carbon dioxide they generate will be more than that of the solid fossil fuels at the same residence time as the solid fossil fuels in the gasification zone and on the same weight basis. Desirably, the amount of the size reduced textiles is low to obtain the advantage of minimizing an increase of carbon dioxide content over that generated by the solid fossil fuels alone.
  • the amount of size reduced textiles relative to all sources of fuel (solid, liquid or gas), or relative to solids, fed to the gasifier is not more than 10 wt.%, or not more than 9 wt.%, or not more than 8 wt.%, or not more than 7 wt.%, or not more than 6 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3.5 wt.%, or not more than 3 wt.%, or not more than 2.75 wt.%, or not more than 2.5 wt.%, or not more than 2.25 wt.%, or not more than 2 wt.%, or not more than 1.75 wt.%, or not more than 1.5 wt.%, or not more than 1.25 wt.%, or not more than 1 wt.%, based on the weight of all gasifier fuel fed to the gasifier (and fuel does not include the oxidizer, steam, water
  • Examples of the content of size reduced textiles present in the feedstock composition include 0.25 wt.% to less than 5 wt.%, or from 0.25 wt.% to 4 wt.%, or from 0.25 wt.% to 3 wt.%, or from 0.25 wt.% to 2.5 wt.%, or from 0.5 wt.% to 5 wt.%, or from 0.5 wt.% to 4 wt.%, or from 0.5 wt.% to 3 wt.%, or from 0.5 wt.% to 2.5 wt.%, or from 1 wt.% to 5 wt.%, or from 1 wt.% to 4 wt.%, or from 1 wt.% to 3 wt.%, or from 1 wt.% to 2.5 wt.% each based on the weight of the fuel or solids in the feedstock composition.
  • the size reduced textiles used in the gasifier feedstock composition have an average fixed carbon content that is at least 3% less, or at least 5 % less, or at least 7 % less, or at least 9 % less, or at least 10 % less, or at least 13 % less, or at least 15 % less, or at least 17 % less, or at least 20 % less, or at least 23 % less, or at least 25 % less, or at least 27 % less, or at least 30 % less, or at least 32 % less, or at least 35 % less, or at least 38 % less, or at least 40 % less, or at least 43 % less, or at least 45 % less, or at least 47% less, or at least 50 % less, or at least 55 % less, or at least 60 % less, or at least 70 % less, or at least 80 % less, or at least 90 % less, or at least 95 % less, than the fixed carbon content of coal, or optionally all solid
  • the size reduced textiles can have an average sulfur content that is fairly sizable since high temperature or slagging gasifiers are well equipped to handle sulfur, although in practice textiles have a very low or only trace amounts of sulfur.
  • the size reduced textiles can have an average sulfur content of up to 1 wt.%, or up to 0.5 wt.%, or up to 0.25 wt.%, or up to 0.1 wt.%, or up to 0.05 wt.%, or up to 0.01 wt.%, or up to 0.005 wt.%, or up to 0.0001 wt.%, based on the weight of the size reduced textiles.
  • the size reduced textiles may have a widely varying ash content depending on the type of textile they are made from and the purity the size reduced textiles stream to the select size reduced textiles.
  • the size reduced textiles may have an average ash content of at least 1 wt.%, or at least 2 wt.%, or at least 3 wt.%, or at least 4 wt.%, or at least 5 wt.%, or at least 5.5 wt.%, or at least 6 wt.%, or at least 7 wt.%, or at least 10 wt.%, or at least 15 wt.%, or at least 20 wt.%, or at least 25 wt.%, or at least 30 wt.%, or at least 35 wt.%, or at least 40 wt.%, or at least 45 wt.% based on the weight of the size reduced textiles.
  • the size reduced textiles may have an average ash content of not more than 60 wt.%, or not more than 55 wt.%, or not more than 55 wt.%, or not more than 55 wt.%, or not more than 55 wt.%, or not more than 40 wt.%, or not more than 30 wt.%, or not more than 20 wt.%, or not more than 15 wt.%, or not more than 10 wt.%, desirably not more than 8 wt.%, or not more than 7 wt.%, or not more than 6 wt.%, or not more than 5.5 wt.%, or not more than 5 wt.%, or not more than 4.5 wt.%, or not more than 4 wt.%, or not more than 3 wt.%, or not more than 2.5 wt.%, based on the weight of the size reduced textiles.
  • the average oxygen content in the size reduced textiles can be at zero or at least 0.1 wt.%, or at least 0.5 wt.%, or at least 1 wt.%, or at least 2 wt.%, or at least 4 wt.%, or at least 6 wt.%, or at least 8 wt.%, or at least 10 wt.%, or at least 13 wt.%, or at least 15 wt.%, or at least 18 wt.%, or at least 20 wt.%, based on the weight of the size reduced textiles.
  • the amount of oxygen is kept low, such as not more than 20 wt.%, or not more than 15 wt.%, or not more than 10 wt.%, or not more than 8 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 2 wt.%, or not more than 1 wt.%, based on the weight of the size reduced textiles.
  • the content of minerals, metals and elements other than carbon, hydrogen, oxygen, nitrogen, and sulfur, in the size reduced textiles can be at least 0.01 wt.%, or at least 0.1 wt.%, or at least 0.5 wt.%, or at least 1 wt.%, or at least 1.5 wt.%, or at least 1.8 wt.%, or at least 2 wt.%, or at least 2.3 wt.%, or at least 2.5 wt.%, or at least 2.8 wt.%, or at least 3 wt.%, based on the weight of the size reduced textiles.
  • the upper amount is not particularly limited, and generally would not exceed 8 wt.%, or not exceed 7 wt.%, or not exceed 6 wt.%, or not exceed 5 wt.%, or not exceed 4.5 wt.%, or not exceed 4 wt.%, or not exceed 3.8 wt.%.
  • the size of the size reduced textiles are desirably not larger than the maximum size the gasifier in use can accept.
  • Many coal fed gasifiers can grind or mill the coal to a desired size before feeding them to the gasification zone. Relying upon such grinding or milling operations to achieve the desired size reduced textiles particle size is not advisable since such solid fossil fuel mills do not cut but rather crush and grind and would not be an effective means to further size reduce the textiles.
  • the size of the size reduced textiles is desirably not larger than the target size to be fed to the gasifier prior to combining them with a fuel feed to a gasifier or prior to adding them to a liquid fed to a gasifier.
  • the actual particle size of the size reduced textiles can vary with the type of gasifier used. For example, size reduced textiles having an average size of 1/4 inch or less in their largest dimension cannot be
  • fixed bed or moving bed gasifiers can accept larger particle sizes.
  • suitable sizes of size reduced textiles fed to a fixed bed or moving bed gasifier are not more than 12 inches, or not more than 8 inches, or not more than 6 inches, or not more than 5 inches, or not more than 4 inches, or not more than 3.75 inches, or not more than 3.5 inches, or not more than 3.25 inches, or not more than 3 inches, or not more than 2.75 inches, or not more than 2.5 inches, or not more than 2.25 inches, or not more than 2 inches, or not more than 1.75 inches, or not more than 1.5 inches, or not more than 1.25 inches.
  • the size can be at least 2mm, or at least 1/8 inches, or at least 1 ⁇ 4 inches, or at least 1 ⁇ 2 inches, or at least 1 inch, or at least 1.5 inches, or at least 1.75 inches, or at least 2 inches, or at least 2.5 inches, or at least 3 inches, or at least 3.5 inches, or at least 4 inches, or at least 4.5 inches, or at least 5 inches, or at least 5.5 inches.
  • Such relatively large size reduced textiles are better suited for use in fixed or moving bed gasifiers, especially those that are updraft fixed or moving bed gasifiers.
  • the fossil fuel (coal or petcoke) and the size reduced textiles are size reduced for multiple purposes.
  • the size reduced textiles are of a small size as is the fossil fuel source to (i) allow for faster reaction once inside the gasifier due to mass transfer limitations, (ii) to create a slurry that is stable, fluid and flowable at high concentrations of solids to water in slurry fed gasifiers, (iii) to pass through processing equipment such as high-pressure pumps, valves, and feed injectors that have tight clearances,
  • the solids in the gasifier feedstock including the size reduced textiles, have a particle size of 2 mm or smaller.
  • This embodiment is particularly attractive to entrained flow gasifiers, including dry feed and slurry fed gasifiers, and to fluidized bed gasifiers.
  • a stated size means that at least 90 wt.% of the size reduced textiles have a largest dimension in the stated size, or alternatively that 90 wt.% of the size reduced textiles pass through sieve designated for that particle size. Either conditions satisfy the particle size designation.
  • Size reduced textiles sized larger than 2 mm for an entrained flow gasifier have the potential for being blown through the gasification zone of entrained flow gasifiers without completely gasifying, particularly when the gasification conditions are established to gasify solid fossil fuel having a particle dimension of 2 mm or smaller.
  • the size of the size reduced textiles as such or as combined with a fossil fuel, or in the gasifier feed, or injected into the gasification zone is 2 mm or smaller or constitute those particles passing through a 10 mesh, or 1.7 mm or smaller (those particles passing through a 12 mesh), or 1.4 mm or smaller (those particles passing through a 14 mesh), or 1.2 mm or smaller (those particles passing through a 16 mesh), or 1 mm or smaller (those particles passing through a 18 mesh), or 0.85 mm or smaller (those particles passing through a 20 mesh), or 0.7 mm or smaller (those particles passing through a 25 mesh) or 0.6 mm or smaller (those particles passing through a 30 mesh), or 0.5 mm or smaller (those particles passing through a 35 mesh), or 0.4 mm or smaller (those particles passing through a 40 mesh), or 0.35 mm or smaller (those particles passing through a 45 mesh), or 0.3 mm or
  • the size reduced textiles have a particle size that, after optional sieving, is acceptable for gasifying within the design parameters of the type of gasifier used.
  • the particle sizes of size reduced textiles and the solid fossil fuels can be sufficiently matched to retain the stability of the slurry and avoid a solid/solid phase separation at high solids concentrations prior to entering the gasification zone in the gasifier.
  • a feedstock composition that phase separates, whether between solids/liquid or solid/solids in a slurry, or solids/solids in a dry feed, or solid/liquid in a liquid feedstock, can plug lines, created localized zones of gasified size reduced textiles, create inconsistent ratios of fossil fuel/size reduced textiles, and can impact the consistency of the syngas composition.
  • Variables to consider for determining the stability of the feedstock composition include setting an optimal particle size of the size reduced textiles, and variables for determining the optimal particle sizes include the bulk density of the solid fuel as fed to the gasification zone, the concentration of all solids in the slurry if a slurry is used or the solid/solid concentration in a dry feed, the effectiveness of any additives employed such as surfactants/stabilizers/viscosity modifiers, and the velocity and turbulence of the feedstock composition to the gasifier and through the injector nozzles.
  • the bulk density of the size reduced textiles is within 150%, or within 1 10%, or within 100%, or within 75%, or within 60%, or within 55%, or within 50%, or within 45%, or within 40%, or within 35% of the bulk density of the ground fossil fuel that is used as a feed introduced to the gasification zone.
  • the bulk density of the size reduced textiles would be within 21 % of the ground coal.
  • the bulk density of the size reduced textiles and the fossil fuel after final grinding is determined on a dry basis (without addition of water) even if they are ultimately used as a slurry.
  • the maximum particle size of the size reduced textiles is selected to be similar (below or above) to the maximum particle size of the ground coal.
  • the maximum particle size of the size reduced textiles used in the gasifier feedstock can be not more than 50% larger than the maximum solid fossil fuel size in the gasifier feedstock, or not more than 45%, or not more than 40%, or not more than 35%, or not more than 30%, or not more than 25%, or not more than 20%, or not more than 15%, or not more than 10%, or not more than 5%, or not more than 3%, or not more than 2%, or not more than 1 % larger than the maximum solid fossil fuel size in the gasifier feedstock, or not larger than, or smaller than the maximum solid fossil fuel size in the gasifier feedstock.
  • the maximum particle size of the size reduced textiles used in the gasifier feedstock as stated above can be within (meaning not larger than and not smaller than) the stated values.
  • the maximum particle size is not determined as the maximum size of the particle distribution but rather by sieving through meshes.
  • the maximum particle size is determined as the first mesh which allows at least 90 volume % of a sample of the particles to pass.
  • the maximum particle size of that sample is deemed to correspond to the first mesh size that allowed at least 90 volume % to pass through, and in this case, a 14 mesh corresponding to a maximum particle size of 1.4 mm.
  • the size reduced textiles are desirably isolated as size reduced textiles feed for ultimate destination to be fed to a gasifier.
  • the textiles are size reduced to a suitable size and then combined with one or more fossil fuel components of the feedstock stream at any location prior to introducing the feedstock stream into gasification zone within the gasifier.
  • Textiles are not easily size reduced in the same equipment used to grind solid fossil fuels (e.g. coal), particularly in a slurry, since many of the textiles are soft, elastic and non-friable.
  • solid fossil fuels e.g. coal
  • one of the desirable locations for combining size reduced textiles having a target size for feeding into the gasifier is into the equipment used for grinding the other solid fossil fuel sources (e.g. coal, pet-coke).
  • This location is particularly attractive in a slurry fed gasifier because it is desirable to use a feed having the highest stable solids concentration possible, and at higher solids concentration, the viscosity of the slurry is also high.
  • the torque and shear forces employed in fossil fuel grinding equipment is high, and coupled with the shear thinning behavior of a solid fossil fuel (e.g. coal) slurry, good mixing of the size reduced textiles with the ground fossil fuel can be obtained in the fossil fuel grinding equipment.
  • Other locations for combining size reduced textiles with fossil fuel sources can be onto the fossil fuel loaded on the main fossil fuel belt feeding a mill or grinder, or onto the main fossil fuel before the fossil fuel is loaded onto the belt to the mill or grinder, or into a fossil fuel slurry storage tank containing a slurry of fossil fuel ground to the final size, particularly if the storage tank is agitated.
  • Figure 5 shows four locations where post-consumer size reduced textiles can be introduced. All of these points are in the low-pressure section (lower than the pressure within the gasifier or gasification zone) of the process thus reducing the cost of modifications.
  • the size reduced textiles can be introduced at location 100, the main fossil fuel belt (e.g. coal feed belt).
  • the main fossil fuel belt e.g. coal feed belt
  • the size reduced textiles are metered onto the main coal feed belt as it moves past with the coal already loaded onto the belt.
  • the size reduced textiles are added to the belt using a weigh belt feeder, or other similar device, to measure the mass of the material, and the speed of the belt to determine addition rate.
  • the coal is similarly added to the same belt and would be underneath the size reduced textiles.
  • the combined solid mixture of the coal and size reduced textiles in the proper ratio are then conveyed to surge hoppers and other storage and conveying equipment until it is ultimately fed to the coal grinding mill.
  • the coal, size reduced textiles, water and viscosity modifiers are mixed thoroughly, and the coal is reduced in size to the target grind size distribution and the mixture becomes a viscous slurry.
  • the size reduced textiles undergo very little or no size reduction since it is a softer material, but benefits from the extreme mixing in the mill due to its inclusion into the slurry production process.
  • the size reduced textiles have been size reduced the same average size as introduced into the gasification zone and do not need any further size reduction after addition to the solid fossil fuel or water used to make the slurry.
  • size reduced textiles can be introduced as shown in Figure 5 location number 110. This is the same process as described in location number 100 above, except that the size reduced textiles are added to the main coal belt first, before the coal is added. In this manner, the coal is on top. Since the size reduced textiles may have a lower bulk density than coal or other solid fossil fuel, it may be easier for the size reduced textiles to be blown off of the belt in a strong wind upon deposition or as it moves down the belt, or otherwise when screened. With the more dense solid fossil fuel covering the size reduced textiles, this dusting and loss of material can be greatly reduced.
  • the size reduced textiles can be added at location number 120, the grinding mill.
  • the existing equipment, coal, water and viscosity modifiers are already added to the grinding mill to reduce the particle size of the coal or petcoke and produce a viscous slurry high in solids.
  • the size reduced textiles can be independently conveyed to the entry point of the mill and added directly to the mill in the proper ratio. The mill will then grind the solid fossil fuel, produce the slurry and thoroughly mix in the size reduced textiles in the process. This avoids wind and weather effects on the coal, recycled material mixture.
  • the size reduced textiles can be introduced at location number 130, the slurry storage tank. Since the size reduced textiles are pre-ground to the proper particle size for introduction into the gasifier, it can be added to the slurry storage tank directly after the grinding/slurry operation. Alternatively, size reduced textiles can be added to the tank through a separate screen or the screen used by the slurry to ensure no excessively large size reduced textiles are passed to the tank. This is the last low-pressure addition point before the slurry is pumped at pressure to the gasifier. This will minimize the amount of material in process that is mixed together. The agitation in the slurry tanks will mix in the size reduced textiles size reduced textiles to ensure they are evenly distributed.
  • Granulators can be used to obtain the desired size reduction.
  • a fine/powder granulator can be used in a last step.
  • the fine/powder granulators can be in communication with a conveying system to transport the size reduced textiles to a storage vessel from which the size reduced textile particles can be fed to any location for making the feedstock stream, or the particles can be fed continuously from the fine granulator to the desired location for making the feedstock stream.
  • the feed of granulated size reduced textile particles from a storage vessel can be in a batch mode or in a continuous mode.
  • the feedstock materials e.g. fossil fuel and size reduced textiles are advantageously loose and not densified by mechanical or chemical means after the size reduced textiles are combined with the solid fossil fuel such as coal (other than natural compaction that may result from storage under its own weight).
  • the solid fossil fuel such as coal (other than natural compaction that may result from storage under its own weight).
  • the solid fossil fuel is typically ground to a size of 2 mm or less, and can be ground to any of the sizes noted above with respect to the size reduced textiles of less than 2 mm.
  • the small size of the coal and size reduced textile particles is advantageous to enhance a uniform suspension in the liquid vehicle which will not settle out, to allow sufficient motion relative to the gaseous reactants, to assure substantially complete gasification, and to provide pumpable slurries of high solids content with a minimum of grinding.
  • both size reduced textiles and recycle plastic particles are fed to the gasifier.
  • a single feedstock composition can contain the size reduced textiles and recycle plastic particles, or they may be contained in separate streams fed to the gasifier.
  • the solids fed to the gasifier include a combination of size reduced textiles and recycle plastic particles as a solid/solid combination, and desirably also solid fossil fuel particles.
  • the weight ratio of size reduced textiles to recycle plastic particles can be from 1 :99 to 99:1 , or 10:90 to 90:10, or 20:80 to 80:20, or from 30:70 to 70:30.
  • recycle plastic particles are used in combination with the size reduced textiles, the recycle plastic particles are desirably not more than any of the sizes mentioned above applicable to the size reduced textiles.
  • the solids in the feedstock composition desirably do not contain sewage sludge, wastepaper, or biomass.
  • the solids in the feedstock composition desirably do not contain sewage sludge, wastepaper, or biomass.
  • composition contains not more than 10 wt.%, or not more than 6 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3 wt.%, or not more than 2 wt.%, or not more than 1 wt.%, or not more than 0.5 wt.%, or not more than 0.25 wt.%, or not more than 0.1 wt.% of any one of sewage sludge, waste paper , biomass, or a combination of two or more, each based on the weight of the solids in the feedstock composition.
  • the size reduced textiles may contain some level of inorganic materials other than polymer, such as metals, glass (whether in the form of fibers or particles), mineral fillers, and other inorganic materials.
  • the quantity of such materials in the size reduced textiles that feed into the feedstock composition is desirably less than 8 wt.%, or not more than 6 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3.5 wt.%, or not more than 2 wt.%, or not more than 1.5 wt.%, or not more than 1 wt.%, or not more than 0.75 wt.%, or not more than 0.5 wt.%, based on the weight of the size reduced textiles.
  • the amount of solid fossil fuel, such as coal, in the feedstock or fed to the gasifier can be at least 10 wt.%, or at least 80 wt.%, or at least 85 wt.%, or at least 90 wt.%, or at least 93 wt.%, or at least 95 wt.%, or at least 97 wt.%, or at least 98 wt.%, or at least 98.5 wt.%, or at least 99 wt.%, and less than 100 wt.%, or less than 99.5 wt.%, based on the weight of solids in the feedstock.
  • Coal contains a quantity of ash that also contains elements other than carbon, oxygen, and hydrogen.
  • the quantity of elements other than carbon, hydrogen, oxygen, and sulfur in the fossil fuel, or in the feedstock composition is desirably not more than 15 wt.%, or not more than 13 wt.%, or not more than 10 wt.%, or not more than 9 wt.%, or not more than 8.5 wt.%, or not more than 8 wt.%, or not more than 7.5 wt.%, or not more than 7 wt.%, or not more than 7.5 wt.%, or not more than 7 wt.%, or not more than 6.5 wt.%, or not more than 6 wt.%, or not more than 5.5 wt.%, or not more than 5 wt.%, or not more than 4.5 wt.%, based on the dry weight of the fossil fuel or alternatively based on the weight of all dry solids in the feedstock
  • the caloric heat value of size reduced textiles is desirably similar to or better than that of coal.
  • the size reduced textiles can have a heat value of at least 13,000, or at least 13,500, or at least 14,000 BTU/lb., or in the range of 13,000 to 15,000 BTU/lb. (30 MJ/Kg - 35 MJ/Kg), while bituminous coal can have a heat value in a range of 12,500 to 13,300 BTU/lb. (29 - 31 MJ/Kg).
  • any ash or non-organic material can be melted and vitrified into the ash or slag matrix that is produced from the inorganics in the coal.
  • the concentration of solids (e.g. fossil fuel and size reduced textiles) in the feedstock composition should not exceed the stability limits of a slurry or solids/solids mix, or the ability to pump or feed the feedstock at the target solids concentration to the gasifier.
  • the solids content of a slurry should be at least 50 wt.%, or at least 55 wt.%, or at least 60 wt.%, or at least 62 wt.%, or at least 65 wt.%, or at least 68 wt.%, or at least 69 wt.%, or at least 70 wt.%, or at least 75 wt.%, the remainder being a liquid phase that can include water and liquid additives.
  • the upper limit is not particularly limited because it is dependent upon the gasifier design.
  • the solids content for a solid fossil slurry fed slagging gasifier desirably should not exceed 75 wt.%, or 73 wt.%, the remainder being a liquid phase that can include water and liquid additives (as noted above, gases are not included in the calculation of weight percentages).
  • the solids concentration of a dry fed gasifier is desirably 95 wt.% or more, or 97 wt.% or more, or 98 wt.% or more, or 99 wt.% or more, or 100 wt.%, based on the weight of the gasifier feedstock composition
  • a slurry feedstock composition is desirably stable at 5 minutes, or even 10 minutes, or even 15 minutes, or even 20 minutes, or even 1 ⁇ 2 hour, or even 1 hour, or even two hours.
  • a slurry feedstock is deemed stable if its initial viscosity is 100,000 cP or less.
  • the initial viscosity can be obtained by the following method. A 500-600 g of a well-mixed sample is allowed to stand still in a 600 ml_ liter glass beaker at ambient conditions (e.g. 25°C and about 1 atm).
  • a Brookfield R/S Rheometer equipped with V80-40 vane operating at a shear rate of 1.83/s is submerged into the slurry to the bottom of the beaker after the slurry is well mixed (e.g. a homogeneous distribution of solids was formed). After a designated period of time, a viscosity reading is obtained at the start of rotation, which is the initial viscosity reading.
  • the slurry is considered to be stable if the initial reading on starting a viscosity
  • a pumpable slurry is one which has a viscosity under 30,000 cP, or not more than 25,000 cP, or not more than 23,000 cP, and desirably not more than 20,000 cP, or not more than 18,000 cP, or not more than 15,000 cP, or not more than 13,000 cP, in each case at ambient conditions (e.g. 25°C and 1 atm). At higher viscosities, the slurry becomes too thick to practically pump.
  • the viscosity measurement to determine the pumpability of the slurry is taken by mixing a sample of the slurry until a homogeneous distribution of particles is obtained, thereafter immediately submerging a Brookfield viscometer with an LV-2 spindle rotating at a rate of 0.5 rpm into the well mixed slurry and taking a reading without delay.
  • Brookfield R/S rheometer with V80-40 vane spindle operating at a shear rate of 1.83/s can be used. The method of measurement is reported since the measured values between the two rheometers at their difference shear rates will generate different values.
  • the cP values stated above apply to either of the rheometer devices and procedures.
  • the slurry feedstock composition has a viscosity of 80,000 cP or less, or 70,000 cP or less, or 60,000 cP or less, 50,000 cP or less, or 40,000 cP or less, or 35,000 cP or less, or 25,000 cP or less, or 20,000 cP or less, or 15,000 cP or less, or 10,000 cP or less, in each case, at 5 minutes, or even 10 minutes, or even 15 minutes, or even 20 minutes, desirably at 5 minutes or at 20 minutes, or at 20 minutes and desirably at 60,000 cP or less or 40,000 cP or less.
  • the fuel is at least coal.
  • the quality of the coal employed is not limited. Anthracite, bituminous, sub-bituminous, brown coal, and lignite coal can be sources of coal feedstock.
  • the coal employed desirably has a carbon content that exceeds 35 wt.%, or at least 42 wt.%, based on the weight of the coal. Accordingly, bituminous or anthracite coal is desirable due to their higher energy content.
  • Sulfur is also typically present in solid fossil fuels.
  • the content of sulfur is less than 5 wt.%, not more than 4 wt.%, or not more than 3 wt.%, or not more than 2.5 wt.%, and also can contain a measure of sulfur, such as at least 0.25 wt.%, or at least 0.5 wt.%, or at least 0.75 wt.%, based on the weight of the solid fossil fuel.
  • coal having moisture contents less than 25 wt.% or less than 20 wt.% or less than 15 wt.% or not more than 10 wt.% or not more than 8 wt.% is desirable to improve the energy efficiency of the gasifier.
  • the coal feedstock has a heat value of at least 1 1 ,000 BTU/lb, or at least 1 1 ,500 BTU/lb, or at least 12,500 BTU/lb, or at least 13,000 BTU/lb, or at least 13,500 BTU/lb, or at least 14,000 BTU/lb, or at least 14,250 BTU/lb, or at least 14,500 BTU/lb.
  • the feedstock composition may contain minor amounts of liquid hydrocarbon oils leached from coal
  • the feedstock composition desirably contains less than 5 wt.%, or not more than 3 wt.%, or not more than 1 wt.%, or not more than 0.1 wt.% liquid (at ambient conditions) non-oxygenated hydrocarbon petroleum oils introduced as such into the feedstock composition.
  • the feedstock composition contains less than 2 wt.%, or not more than 1 wt.%, or no added liquid fraction from refining crude oil or reforming any such fraction in a slurry feedstock stream or to a slurry fed gasifier.
  • the content of liquids, or the content of water, present in the feedstock composition is desirably not more than 50 wt.%, or not more than 35 wt.%, or not more than 32 wt.%, or not more than 31 wt.%, or not more than 30 wt.%, based on the weight of the feedstock composition.
  • the content of liquids or water in the feedstock composition for a slurry fed gasifier is desirably at least 10 wt.%, or at least 15 wt.%, or at least 20 wt.%, or at least 25 wt.%, or at least 27 wt.%, or at least 30 wt.%, based on the weight of the feedstock composition.
  • the liquids present in the slurry gasifier feedstock desirably contain at least 95 wt.% water, or at least 96 wt.% water, or at least 97 wt.% water, or at least 98 wt.% water, or at least 99 wt.% water, based on the weight of all liquids fed to the gasifier.
  • the liquid content of the feedstock composition is at least 96 wt.% water, or at least 97 wt.% water, or at least 98 wt.% water, or at least 99 wt.% water, based on the weight of all liquids fed to the gasifier.
  • At least a portion of the fuel feedstock to the gasifier is a liquid at 25°C and 1 atmosphere, such as organic feedstocks, petroleum oils or fractions from refining or distilling crude oil, hydrocarbons, oxygenated hydrocarbons, or synthetic chemical compounds.
  • These liquid feedstocks can be from any fraction from petroleum distillation or refining, or any chemical synthesized at a chemical manufacturing facility, provided they are liquid.
  • These liquids are a carbon fuel source for gasifying into syngas.
  • hydrocarbon liquid fuel or oxygenated hydrocarbon liquid fuel that are liquid at 25°C and 1 atmosphere.
  • the size reduced textiles may be insoluble, partially soluble, or soluble in the liquid fuel feedstock.
  • the water present in the feedstock stream is not wastewater, or in other words, the water fed to the solids to make the feedstock stream is not wastewater.
  • the water employed has not been industrially discharged from any process for synthesizing chemicals, or it not municipal wastewater.
  • the water is desirably fresh water, or potable water.
  • the feedstock stream comprises at least ground coal and size reduced textiles.
  • the feedstock stream also comprises water.
  • the amount of water in the feedstock stream can range from 0 wt.% up to 50 wt.%, or from 10 wt.% to 40 wt.%, or from 20 wt.% to 35 wt.%.
  • the feedstock stream is desirably a slurry containing water.
  • additives can be added to and contained in the feedstock composition, such as viscosity modifiers and pH modifiers.
  • the total quantity of additives can range from 0.01 wt.% to 5 wt.%, or from 0.05 wt.% to 5 wt.%, or from 0.05 to 3 wt.%, or from 0.5 to 2.5 wt.%, based on the weight of the feedstock
  • composition The quantity of any individual additive can also be within these stated ranges.
  • the viscosity modifiers (which includes surfactants) can improve the solids concentration in a slurry gasifier feedstock.
  • examples of viscosity modifiers include:
  • alkyl-substituted amine-based surfactant such as alkyl- substituted aminobutyric acid, alkyl-substituted polyethoxylated amide, and alkyl-substituted polyethoxylated quaternary ammonium salt;
  • sulfates such as salts of organic sulfonic acids including ammonium, calcium and sodium sulfonates, particularly those with lignin and sulfo-alkylated lignites;
  • alkyl-substituted aminobutyric acid surfactants include N-coco-beta-aminobutyric acid, N-tallow-beta- aminobutyric acid, N-lauryl-beta-aminobutyric acid, and N-oleyl-beta- aminobutyric acid. N-coco-beta-aminobutyric acid.
  • alkyl-substituted polyethoxylated amide surfactant include polyoxyethylene oleamide, polyoxyethylene tallowamide, polyoxyethylene laurylamide, and polyoxyethylene cocoamide, with 5-50 polyoxyethylene moieties being present.
  • alkyl-substituted polyethoxylated quaternary ammonium salt surfactant include methylbis (2-hydroxyethyl) cocoammonium chloride, methylpolyoxyethylene cocoammonium chloride, methylbis (2-hydroxyethyl) oleylammonium chloride, methylpolyoxyethylene oleylammonium chloride, methylbis (2-hydroxyethyl) octadecylammonium chloride, and methylpolyoxyethylene octadecylammonium chloride.
  • sulfonates include sulfonated
  • phosphate salts include trisodium phosphate, potassium phosphate, ammonium phosphate, sodium
  • tripolyphosphate or potassium tripolyphosphate.
  • polyoxyalkylene anionic or nonionic surfactants have 1 or more repeating units derived from ethylene oxide or propylene oxide, or 1 - 200 oxyalkylene units.
  • the surfactant is an anionic surfactant, such as salts of an organic sulfonic acid.
  • anionic surfactant such as salts of an organic sulfonic acid.
  • examples are calcium, sodium and ammonium salts of organic sulfonic acids such as 2,6-dihydroxy naphthalene sulfonic acid, lignite sulfonic acid, and ammonium lignosulfonate.
  • pH modifiers include aqueous alkali metal and alkaline earth hydroxides such as sodium hydroxide, and ammonium compounds such as 20-50 wt.% aqueous ammonium hydroxide solutions.
  • the aqueous ammonium hydroxide solution can be added directly to the feedstock composition prior to entry into the gasifier, such as in the coal grinding equipment or any downstream vessels containing the slurry.
  • the atomic ratio of total oxygen to carbon entering the gasification zone can be a value in the range of 0.70 to less than 2, or from 0.9 to 1.9, or from 0.9 to 1.8, or from 0.9 to 1.5, or from 0.9 to 1.4, or from 0.9 to 1.2, or from 1 to 1.9, or from 1 to 1.8, or from 1 to 1.5, or from 1 to 1.2, or from 1.05 to 1.9, or from 1.05 to 1.8, or from 1.05 to 1.5, or from 1.05 to 1.2.
  • the atomic ratio of free oxygen to carbon entering the gasification zone can also be within these same values.
  • the weight ratio of both total oxygen and free oxygen to carbon in pounds entering the gasification zone can also each be within these stated values.
  • the total carbon content in the feedstock composition is at least 40 wt.%, or at least 45 wt.%, or at least 50 wt.%, or at least 55 wt.%, or at least 60 wt.%, or at least 65 wt.%, and desirably at least 70 wt.%, or at least 75 wt.%, or at least 80 wt.%, or at least 85 wt.%, or at least 90 wt.%, each based on the total solids content.
  • the gasifier feedstock composition is desirably injected along with an oxidizer into a refractory-lined combustion chamber (gasification zone) of the synthesis gas generating gasifier.
  • the feedstock stream (desirably a slurry) and oxidizer are desirably sprayed through an injector into a refractory-lined combustion chamber (gasification zone) of the synthesis gas generating gasifier.
  • the gasification zone can be under significant pressure, typically about 500 psig or more, or 600 psig or more, or 800 psig or more, or 1000 psig or more.
  • the velocity or flow rate of the feedstock and oxidizer streams ejected from the injector nozzle into the gasification zone (or combustion chamber) will exceed the rate of flame propagation to avoid backflash.
  • a chemical is made from a first syngas sourced from a first gasifier fed with a first feedstock composition containing a solid fossil fuel is not combined with a second syngas stream sourced from any other gasifier fed with second fossil fuel feedstock composition where the solid fossil fuel content between the first and second feedstock compositions differ by more than 20%, or more than 10%, or more than 5%, based on the weight of the all solids fed to the gasifiers.
  • a first syngas stream generated from a first feedstock composition containing 90 wt.% coal would not be combined with a syngas stream generated from a different gasifier fed with a feedstock composition containing 70 wt.% coal or no coal, but could be combined with one containing 72 wt.% coal or more.
  • a first syngas sourced from a first gasifier fed with a first feedstock composition containing a first fixed carbon content is not combined with a second syngas stream sourced from any other gasifier fed with a second feedstock containing a second fixed carbon content, where the difference between the first and second fixed carbon contents is more than 20%, or more than 10%, or more than 5% of each other, based on the weight of the all solids fed to the gasifiers.
  • a first syngas stream generated from a first feedstock composition containing 70 wt.% fixed carbon based on the weight of the solids would not be combined with a syngas stream generated from a different gasifier fed with a feedstock composition containing 30 wt.% fixed carbon, but could be combined with one containing 56 wt.% fixed carbon if the limit of 20% is selected.
  • the feedstock composition Prior to entry into the gasifier, the feedstock composition may be subjected to a variety of other optional processes. For example, a slurry can flow through a thickener in which excess water is eliminated from the slurry to obtain the final desired solids concentration of the slurry entering into the gasifier vessel.
  • the feedstock composition may be pre-heated to prior to entry into the gasifier.
  • a slurry feedstock composition is heated to a temperature below the boiling point of water at the operating pressure existing in reaction zone. The preheater, when employed, reduces the heat load on the gasifier and improves the efficiency of utilization of both fuel and oxygen.
  • At least 80 wt.% of all of the water required for the generation of synthesis gas in reaction zone is supplied in liquid phase.
  • part of the water e.g., from 1 to about 90 percent by weight based on the weight of water, may be vaporized in the slurry feed preheater or combined with the oxidizing stream as vaporized water.
  • the oxidizer is desirably an oxidizing gas that can include air, and desirably is a gas enriched in oxygen at quantities greater than that found in air.
  • the reaction of oxygen and solid fossil fuel is exothermic.
  • the oxidant gas contains at least 25 mole% oxygen, or at least 35 mole%, or at least 40 mole%, or at least 50 mol%, or at least 70 mole%, or at least 85 mole%, or at least 90 mole%, or at least 95 mole%, or at least 97 mole%, or at least 98 mole% oxygen, or at least 99 mole%, or at least 99.5 mole% based on all moles in the oxidant gas stream injected into the reaction
  • the combined concentration of oxygen in all gases supplied to the gasification zone is also in the above stated amount.
  • the particular amount of oxygen as supplied to the reaction zone is desirably sufficient to obtain near or maximum yields of carbon monoxide and hydrogen obtained from the gasification reaction relative to the components in the feedstock composition, considering the amount relative to the feedstock composition, and the amount of feedstock charged, the process conditions, and the gasifier design.
  • steam is not supplied to the gasification zone in a slurry fed gasifier.
  • the amount of water in a slurry fed system is typically more than sufficient a co-reactant and heat sink to regulate the gasification temperature.
  • the addition of steam in a slurry fed gasifier will generally unduly withdraw heat from the reaction zone and reduce its efficiency.
  • steam is fed to the gasification zone in any type of dry fed gasifier, such as an entrainment flow gasifier, a fluidized bed gasifier, or a fixed or moving bed gasifier.
  • the addition of steam in dry fed gasifiers case is desirable to provide the raw material needed for the production of carbon monoxide.
  • reducible oxygen-containing gases may be supplied to the reaction zone, for example, carbon dioxide, or simply air.
  • no gas stream enriched in carbon dioxide or nitrogen e.g. greater than the molar quantity found in air, or greater than 2 mole%, or greater than 5 mole%, or greater than 10 mole%, or greater than 40 mole% is charged into a slurry fed gasifier.
  • Many of these gases serve as carrier gases to propel a dry feed to a gasification zone. Therefore, in another embodiment, one or more of these gases are charged to the gasification zone as a carrier gas for the dry feed of solid fossil fuel and size reduced textiles.
  • the feedstock composition containing at least size reduced textiles and solid fossil fuel flowing to the gasifier, or this feedstock composition as introduced to an injector or charge pipe, or this feedstock composition as introduced into the gasification zone, or a combination of all the above does not contain gases compressed in equipment for gas compression.
  • no gas compressed in equipment for gas compression is fed to the gasification zone or even to the gasifier. It is noteworthy that high pressure charge pumps that process the slurry feed for introduction into the gasification zone are not considered gas compressing equipment.
  • no gas stream containing more than 0.03 mole%, or more than 0.02 mole%, or more than 0.01 mole% carbon dioxide is charged to the gasifier or gasification zone.
  • no gas stream containing more than 0.03 mole%, or more than 0.02 mole%, or more than 0.01 mole% carbon dioxide is charged to the gasifier or gasification zone.
  • no gas stream containing more than 0.03 mole%, or more than 0.02 mole%, or more than 0.01 mole% carbon dioxide is charged to the gasifier or gasification zone.
  • no gas stream containing more than 0.03 mole%, or more than 0.02 mole%, or more than 0.01 mole% carbon dioxide is charged to the gasifier or gasification zone.
  • a gas stream containing more than 77 mole%, or more than 80 mole% nitrogen is charged to the gasifier or gasification zone.
  • steam is charged into the gasification zone or to the gasifier.
  • a gaseous hydrogen stream e.g. one containing more than 0.1 mole% hydrogen, or more than 0.5 mole%, or more than 1 mole%, or more than 5 mole% is not charged to the gasifier or to the gasification zone.
  • a stream of methane gas e.g.
  • the only gaseous stream introduced to the gasification zone is an oxygen rich gas stream as described above.
  • the gasifier can be fed with two or more separate streams to the gasification zone.
  • one feedstock composition can contain natural gas (methane) in a concentration of at least 50 mole% and a second feedstock composition can contain size reduced textiles as a dry feed or as a slurry or dispersion in fuel liquids other than water or in liquids containing water or containing more than 50 wt.% water based on the weight of the water.
  • the amount of methane fed to the gasifier is at least 50 mole%, or at least 70 mole% or at least 80 mole% or at least 90 mole% based on the moles of all gases fed to the gasifier, or based on the moles of all feedstock fuel and reactants fed to the gasifier, or even based on the moles of all fuel fed to the gasifier.
  • Suitable liquids as fuel include those mentioned above that are liquid at 25°C and 1 atm.
  • the gasification process desirably employed is a partial oxidation gasification reaction.
  • the oxidation process involves partial, rather than complete, oxidization of the fossil fuel and size reduced textiles and therefore is desirably operated in an oxygen-lean environment, relative to the amount needed to completely oxidize 100% of the carbon and hydrogen bonds. This is in contrast to a combustion reaction which would employ a large
  • the total oxygen requirements for the gasifier is desirably at least 5%, or at least 10%, or at least 15%, or at least 20%, in excess of the amount theoretically required to convert the carbon content of the solid fuel and size reduced textiles to carbon monoxide. In general, satisfactory operation may be obtained with a total oxygen supply of 10 to 80 percent in excess of the theoretical requirements for carbon monoxide production.
  • An example of a suitable amount of oxygen per pound of carbon is in the range of 0.4 to about 3.0-pound free oxygen per pound of carbon, or from 0.6 to 2.5, or from 0.9 to 2.5, or from 1 to 2.5, or from 1.1 to 2.5, or from 1.2 to 2.5 pounds of free oxygen per pound of carbon.
  • Mixing of the feedstock composition and the oxidant is desirably accomplished entirely within the reaction zone by introducing the separate streams of feedstock and oxidant so that they impinge upon each other within the reaction zone.
  • the oxidant stream is introduced into the reaction zone of the gasifier at high velocity both exceed the rate of flame propagation and to improve mixing with the feedstock composition.
  • the oxidant is desirably injected into the gasification zone in the range of 25 to 500 feet per second, or 50 to 400 ft/s, or 100 to 400 ft/s. These values would be the velocity of the gaseous oxidizing stream at the injector-gasification zone interface, or the injector tip velocity.
  • One method for increasing the velocity of the oxidant feed to the gasification zone is by reducing the diameter of the oxidant annulus near the tip of the injector or injector. Near the tip of the injector the annular passage converges inwardly in the shape of a hollow cone as shown in Figures 3 and 4.
  • the oxidizing gas is thereby accelerated and discharged from the injector as a high velocity conical stream having an apex angle in the desirably range of about 30° to 45°.
  • the streams from the injector converge at a point located about 0-6 inches beyond the injector face.
  • the high velocity stream of oxidizing gas hits the relatively low velocity feedstock stream, atomizing it and forming a fine mist comprising minute particles of water and particulate solid fossil fuel highly dispersed in the oxidizing gas.
  • the particles of solid carboniferous matter impinge against one another and are fragmented further.
  • the velocity of the fuel feedstock is determined by the desired throughput of syngas generation. Suitable examples of feedstock velocity introduced into gasification zone prior to contact with the oxidizing agent is in the range of 5 to 50 feet per second.
  • the feedstock composition and the oxidant can optionally be preheated to a temperature above about 200°C, or at least 300°C, or at least 400°C.
  • the gasification process does not require preheating the feedstock composition to efficiently gasify the fuel, and a pre-heat treatment step would result in lowering the energy efficiency of the process.
  • the feedstock composition, and optionally the oxidant are not preheated prior to their introduction into the gasifier.
  • a preheat treatment step would be contacting the feedstock composition or oxidant with equipment that raises the temperature of the feedstock composition sufficiently such that the temperature of the feedstock composition or oxidant stream is above 200°C, or above 190°C, or above 170°C, or above 150°C, or above 130°C, or above 1 10°C, or above 100°C, or above 98°C, or above 90°C, or above 80°C, or above 70°C, or above 60°C, immediately prior to introduction into an injector on the gasifier.
  • this step would not be considered a preheat of the feedstock composition if the feedstock composition is below 200°C upon its introduction into the injector.
  • no thermal energy is applied to the feedstock composition containing both size reduced textiles and the solid fossil fuel, or to the oxidant stream, at any point prior to its introduction into the injector, or gasifier, or gasification zone (other than the temperature increase experienced in an injector) that would increase the temperature of the stream by more than 180°C, or more than 170°C, or more than 160°C, or more than 150°C, or more than 140°C, or more than 130°C, or more than 120°C, or more than 110°C, or more than 100°C, or more than 90°C, or more than 80°C, or more than 70°C, or more than 60°C, or more than 50°C, or more than 40°C, or more than 30°C.
  • the process of the invention employs a gasification process, which is distinct from a incineration process that generates primarily carbon dioxide and water, or a pyrolysis process which is a thermal process that degrades a fuel source in the absence of air or oxygen and generates primarily a liquid, or plasma processes in that gasification does not employ a plasma arc.
  • the type of gasification technology employed is a partial oxidation entrained flow gasifier that generates syngas.
  • This technology is distinct from fixed bed (alternatively called moving bed) gasifiers and from fluidized bed gasifiers.
  • fixed bed or moving bed gasifiers
  • the feedstock stream moves in a countercurrent flow with the oxidant gas, and the oxidant gas typically employed is air.
  • the feedstock stream falls into the gasification chamber, accumulates, and forms a bed of feedstock.
  • Air or alternatively oxygen flows from the bottom of the gasifier up through the bed of feedstock material continuously while fresh feedstock continuously falls down from the top by gravity to refresh the bed as it is being combusted.
  • the combustion temperatures are typically below the fusion temperature of the ash and are non-slagging.
  • the fixed bed reaction process generates high amount of tars, oils, and methane produced by pyrolysis of the feedstock in the bed, thereby both contaminating the syngas produced and the gasifier.
  • the contaminated syngas requires significant effort and cost to remove tarry residues that would condense once the syngas is cooled, and because of this, such syngas streams are generally not used to make chemicals and are instead used in direct heating applications, or as liquid fuels.
  • Downdraft fixed or moving bed gasifiers produce less or no tar. Fixed or moving bed gasifiers already equipped or built to be equipped with tar removal processes are suitable to accept a feed of the size reduced textiles.
  • the feedstock material in the gasification zone is fluidized by action of the oxidant flowing through the bed at a high enough velocity to fluidize the particles in the bed.
  • the oxidant flowing through the bed at a high enough velocity to fluidize the particles in the bed.
  • homogeneous reaction temperatures and low reaction temperatures in the gasification zone also promotes the production of high amounts of unreacted feedstock material and low carbon conversion, and operating temperatures in the fluidized bed are typically between 800-1000°C. Further, in a fluidized bed, it is important to operate below slagging conditions to maintain the fluidization of the feedstock particles which would otherwise stick to the slag and agglomerate. By employing an entrained flow gasification, these deficiencies present with fixed (or moving bed) and fluidized bed gasifiers that are typically used to process waste materials is overcome.
  • the feedstock stream is introduced at the top 1/8 section of the gasifier, desirably at the top 1/12 of the gasifier height defined by the gasifier shell (not including the injector height protruding from the top of the shell or pipes protruding from the bottom of the shell).
  • the feedstock composition is desirably not introduced into a side wall of the gasifier.
  • the feedstock composition is not a tangential feed injector.
  • oxidant is introduced at the top 1/8 section of the gasifier, desirably at the top 1/12 of the gasifier height defined by the gasifier shell.
  • the oxidant is desirably not introduced into the side wall of the gasifier or bottom of the flow gasifier.
  • both the feedstock composition and oxidant are introduced at the top 1/8 section of the gasifier, desirably at the top 1/12 of the gasifier height defined by the gasifier shell.
  • the oxidant and feedstock composition are fed co-currently to ensure good mixing.
  • a co-current feed means that the axis of the feedstock and oxidant streams are substantially parallel (e.g.
  • not more than a 25° deviation or not more than a 20°, or not more than a 15°, or not more than a 10°, or not more than a 8°, or not more than a 6°, or not more than a 4°, or not more than a 2°, or not more than a 1 ° deviation from each other) and in the same direction.
  • the feedstock and oxidant streams are desirably introduced into the gasification zone through one or more injector nozzles.
  • the gasifier is equipped with at least one of the injector nozzles in which through that injector nozzle both a feedstock stream and an oxidant stream are introduced into the gasification zone.
  • the feedstock stream can be a dry feed or a slurry feed
  • the feedstock stream is desirably a slurry.
  • the syngas produced in the gasification process is desirably used at least in part for making chemicals.
  • Many synthetic processes for making chemicals are at high pressure, and to avoid energy input into pressurizing the syngas stream, desirably the gasifier is also run at high pressure, particularly when the syngas stream is directly or indirectly in gaseous communication with a vessel in which a chemical is synthesized.
  • Dry feeds to a gasifier operating at high pressure are specially treated to ensure that the feed can be effectively blown and injected into the high-pressure gasification zone.
  • Some techniques include entraining a flow of nitrogen at high pressure and velocity, which tends to dilute the syngas stream and reduce the concentration of desirably components such as carbon monoxide and hydrogen.
  • carrier or motive gases include carbon monoxide, but like nitrogen, these gases are compressed before feeding into or compressed with the solid fossil fuels, adding to the energy requirements and capital cost of feed lock hoppers and/or compressing equipment.
  • many dry feed gasifiers will operate at lower pressures, which for the mere production of electricity is sufficient, but is undesirable for gasifiers producing a syngas stream for making chemicals.
  • a motive gas is not necessary and can readily be fed to a high-pressure gasifier that produces syngas as high pressure, which is desirable for making chemicals.
  • the feedstock stream is not processed through a lock hopper prior to entering an injector or entering the gasification zone.
  • the feedstock composition containing size reduced textiles and solid fossil fuel is not pressurized in a lock hopper prior to feeding to the injector or gasification zone.
  • the gasifier is non-catalytic, meaning that gasifier does not contain a catalyst bed, and desirably the gasification process is non- catalytic, meaning that a catalyst is not introduced into the gasification zone as a discrete unbound catalyst (as opposed to captive metals in the size reduced textiles or solid fossil fuel that can incidentally have catalytic activity).
  • the gasification process in the reaction zone is desirably conducted in the absence of added catalysts and contains no catalyst bed.
  • the gasification process is also desirably a slagging gasification process; that is, operated under slagging conditions (well above the fusion temperature of ash) such that a molten slag is formed in the gasification zone and runs along and down the refractory walls.
  • the gasifier is not designed to contain a pyrolysis zone. Desirably, the gasifier is not designed to contain a
  • the gasifier is designed to not contain, or does not contain, either a combustion zone or a pyrolysis zone.
  • the pyrolysis zone incompletely consumes the fuel source leading to potentially high amounts of ash, char, and tarry products.
  • the gasifier is a single stage reactor, meaning that there is only one zone for conversion of the carbon in the feedstock to syngas within the gasifier shell.
  • the gasification zone is void or empty space defined by walls in which oxidation reactions occur and allow gases to form within the space.
  • gasification zone does not have a bath of molten material or molten material that accumulates at the bottom of the gasification zone to form a bath.
  • the gasification zone is desirably not enclosed on the bottom but rather is in gaseous communication with other zones below the gasification zone. Slag, while molten, does not accumulate at the bottom of the gasification zone but rather runs down the sides of the refractory and into a zone below the gasification zone, such as a quench zone to solidify the slag.
  • the flow of hot raw syngas in the gasifier is desirably vertically downward, or a down-flow gasifier.
  • the flow of syngas generated in the gasifier is downward from the highest point of injecting the feedstock composition, desirably from the point of all feedstock stream locations.
  • the location for withdrawing the syngas stream from the gasifier is lower that at least one location for introducing the feedstock stream, desirably lower than all locations for introducing a feedstock stream.
  • the gasifier can contain refractory lining in the gasification zone. While a steam generating membrane or jacket between the gasifier wall and the surfaces facing the gasification zone can be employed, desirably the gasifier does not contain a membrane wall, or a steam generating membrane, or a steam jacket in the gasification zone or between inner surfaces facing the gasification zone and the gasifier shell walls as this removes heat from the gasification zone. Desirably, the gasification zone is lined with refractory, and optionally there is no air or steam or water jacket between the refractory lining the gasification zone (or optionally in any reaction zone such as combustion or pyrolysis) and the outer shell of the gasifier.
  • the gasification process is desirably a continuous process meaning that the gasifier operates in a continuous mode.
  • the inclusion of size reduced textiles into the feedstock composition can be intermittent or continuous provided that a continuous feed of fossil fuel is fed to the gasifier since the gasification process in the gasifier is in a continuous mode.
  • a continuous mode for gasifier operation is meant that the gasification process is
  • the inclusion of size reduced textiles in the feedstock composition is continuous for at least 1 day, or at least 3 days, or at least 14 days, or at least 1 month, or at least 6 months, or at least 1 year.
  • a process is deemed continuous despite shut-downs due to maintenance or repair.
  • the feedstock can be fed into the gasification zone through one or more injectors.
  • the gasifier contains only one injector.
  • the gasifier contains only one location for introducing feedstock.
  • the injector nozzle serving the gasification chamber is configured to have the feedstock stream concentrically surround the oxidizer gas stream along the axial core of the nozzle.
  • the oxidizer gas stream can also surround the feedstock stream annulus as a larger, substantially concentric annulus.
  • Radially surrounding an outer wall of the outer oxidizer gas channel can be an annular cooling water jacket terminated with a substantially flat end-face heat sink aligned in a plane substantially
  • Cool water is conducted from outside the combustion chamber into direct contact with the backside of the heat sink end-face for conductive heat extraction.
  • the gasification zone, and optionally all reaction zones in the gasifier are operated at a temperature in the range of at least 1000° C, or at least 1100°C, or at least 1200°C, or at least 1250°C, or at least 1300°C, and up to about 2500°C, or up to 2000° C., or up to 1800°C, or up to 1600°C, each of which are well above the fusion temperature of ash, and are desirably operated to form a molten flow of slag in the reaction zone.
  • the reaction temperature is desirably autogenous.
  • the gasifier operating in steady state mode is at an autogenous temperature and does not require application of external energy sources to heat the gasification zone.
  • the gasification zone is generally below 1000°C, or not above 950°C, or not higher than 800°C.
  • the gasifier does not contain a zone within the gasifier shell to dry feedstock such as the coal, pet-coke, or size reduced textiles prior to gasification.
  • the increase in temperature within the injector is not considered a zone for drying.
  • the gasification zone is not under negative pressure during operations, but rather is under positive pressure during operation.
  • the gasification zone is desirably not equipped with any aspirator or other device to create a negative pressure under steady state operation.
  • the gasifier can be operated at a pressure within the gasification zone (or combustion chamber) of at least 200 psig (1.38 MPa), or at least 300 psig (2.06 MPa), or at least 350 psig (2.41 MPa), and desirably at least 400 psig (2.76 MPa), or at least 420 psig (2.89 MPa), or at least 450 psig (3.10
  • MPa or at least 475 psig (3.27 MPa), or at least 500 psig (3.44 MPa), or at least 550 psig (3.79 MPa), or at least 600 psig (4.13 MPa), or at least 650 psig (4.48 MPa), or at least 700 psig (4.82 MPa), or at least 750 psig (5.17
  • the particular operating pressure on the high end is regulated with a variety of considerations, including operating efficiency, the operating pressures needed in chemical synthesis gasifiers particularly with integrated plants, and process chemistry.
  • Suitable operating pressures in the gasification zone on the high end need not exceed 1300 psig (8.96 MPa), or need not exceed 1250 psig (8.61 MPa), or need not exceed 1200 psig (8.27 MPa), or need not exceed 1 150 psig (7.92 MPa), or need not exceed 1 100 psig (7.58 MPa), or need not exceed 1050 psig (7.23 MPa), or need not exceed 1000 psig (6.89 MPa), or need not exceed 900 psig (6.2 MPa), or need not exceed 800 psig (5.51 MPa), or need not exceed 750 psig (5.17 MPa).
  • suitable desirably ranges include 400 to 1000, or 425 to 900, or 450 to 900, or 475 to 900, or 500 to 900, or 550 to 900, or 600 to 900, or 650 to 900, or 400 to 800, or 425 to 800, or 450 to 800, or 475 to 800, or 500 to 800, or 550 to 800, or 600 to 800, or 650 to 800, or 400 to 750, or 425 to 750, or 450 to 750, or 475 to 750, or 500 to 750, or 550 to 750, each in psig.
  • the average residence time of gases in the gasifier reactor are very short to increase throughput. Since the gasifier is operated at high temperature and pressure, substantially complete conversion of the feedstock to gases can occur in a very short time frame.
  • the average residence time of the gases in the gasifier can be as short as less than 30 seconds, or not more than 25 seconds, or not more than 20 seconds, or not more than 15 seconds, or not more than 10 seconds, or not more than 7 seconds.
  • the average residence time of gases in all zones designed for conversion of feedstock material to gases is also quite short, e.g. less than 25 seconds, or not more than 15 seconds, or not more than 10 seconds, or not more than 7 seconds, or not more than 4 seconds.
  • At least 85 wt.%, or at least or more than 90 wt.%, or at least 92 wt.%, or at least 94 wt.% of the solids in the feedstock can be converted to gases (substances which remain as a gas if the gas stream were cooled to 25°C and 1 atm) and liquid (substances which are in liquid state if the gas stream is cooled to 25°C and 1 atm such as water), or more than 93 wt.%, or more than 95 wt.%, or more than 96 wt.%, or more than 97 wt.%, or more than 98 wt.%, or more than 99 wt.%, or more than 99.5 wt.%.
  • a portion of ash and/or char in the gasifier can be entrained in the hot raw syngas stream leaving the gasification reaction zone.
  • Ash particles in the raw syngas stream within the gasifier are particles which have not reached the melting temperature of the mineral matter in the solid fuel.
  • Slag is substantially molten ash or molten ash which has solidified into glassy particles and remains within the gasifier. Slag is molten until quenched and then form beads of fused mineral matter.
  • Char are porous particles that are devolatilized and partially combusted (incompletely converted) fuel particles. The particulate matter gathered in the bottom part of the gasifier, or the quench zone, are predominately slag (e.g.
  • tar or no tar is present in the gasifier, or in the quench zone, or in the gasification zone, or present in the hot raw syngas within the gasifier, or present in the raw syngas discharged from the gasifier (which can be determined by the amount of tar condensing from the syngas stream when cooled to a temperature below 50°C.).
  • Trace amounts are less than 0.1 wt.% (or less than 0.05 wt.% or less than 0.01 wt.%) of solids present in the gasifier, or less than 0.05 volume%, or not more than 0.01 vol%, or not more than 0.005 vol%, or not more than 0.001 volume%, or not more than 0.0005 vol%, or not more than 0.0001 vol% in the raw syngas stream discharged from the gasifier.
  • the process does not increase the amount of tar to a substantial extent relative to the same process except replacing the size reduced textiles with the same amount and type of solid fossil fuel used in the feedstock composition containing the size reduced textiles.
  • the quantity of tar generated in the process with the mixed feedstock containing the size reduced textiles are less than 10% higher, or less than 5% higher, or less than 3 % higher, or less than 2% higher, or not higher at all, than the amount of tar generated with the same feedstock replacing the size reduced textiles with the same solid fossil fuel under the same conditions.
  • the syngas stream as discharged from the gasifier desirably contains no or less than 4 wt.%, or less than 3 wt.%, or not more than 2 wt.%, or not more than 1 wt.%, or not more than 0.5 wt.%, or not more than 0.2 wt.%, or not more than 0.1 wt.%, or not more than 0.08 wt.%, or not more than 0.05 wt.%, or not more than 0.02 wt.%, or not more than 0.01 wt.%, or nor more than 0.005 wt.% tar, based on the weight of all condensable solids in the syngas stream.
  • condensable solids are those compounds and elements that condense at a temperature of 15°C/1 atm.
  • the tar present if at all, in the syngas stream discharged from the gasifier is less than 10 g/m3 of the syngas discharged, or not more than 9 g/m3, or not more than 8 g/m3, or not more than 7 g/m3,or not more than 6 g/m3, or not more than 5 g/m3, or not more than 4 g/m3, or not more than 3 g/m3, or not more than 2 g/m3, and desirably not more than 1 g/m3, or not more than 0.8 g/m3, or not more than 0.75 g/m3, or not more than 0.7 g/m3, or not more than 0.6 g/m3, or not more than 0.55g/m3, or not more than 0.45 g/m3, or not more than 0.4 g/m3, or not more than 0.3 g/m3, or not more than 0.2 g/m3, or not more than 0.1 g/m3, or not more than 0.05
  • the tars are those tars that would condense at a temperature of 15°C/1 atm, and includes primary, secondary and tertiary tars, and are aromatic organic compounds and other than ash, char, soot, or dust.
  • tar products include naphthalenes, cresols, xylenols, anthracenes, phenanthrenes, phenols, benzene, toluene, pyridine, catechols, biphenyls, benzofurans,
  • the tar content can be determined by GC-MSD.
  • the tar yield of the gasifier is not more than 4 wt.%, or not more than 3 wt.%, or not more than 2.5 wt.%, or not more than 2.0 wt.%, or not more than 1.8 wt.%, or not more than 1.5 wt.%, or not more than 1.25 wt.%, or not more than 1 wt.%, or not more than 0.9 wt.%, or not more than 0.8 wt.%, or not more than 0.7 wt.%, or not more than 0.5 wt.%, or not more than 0.3 wt.%, or not more than 0.2 wt.%, or not more than 0.1 wt.%, or not more than 0.05 wt.%, or not more than 0.01 wt.%, or not more than 0.005
  • the amount of char generated by gasifying the size reduced textile-solid fossil fuel feedstock stream can remain within acceptable limits.
  • the amount of char (or incompletely converted carbon in the feedstock) generated by conversion of the carbon sources in the feedstock composition is not more than 15 wt.%, or not more than 12 wt.%, or not more than 10 wt.%, or not more than 8 wt.%, or not more than 5 wt.%, or not more than 4.5 wt.%, or not more than 4 wt.%, or not more than 3.5 wt.%, or not more than 3 wt.%, or not more than 2.8 wt.%, or not more than 2.5 wt.%, or not more than 2.3 wt.%, or not more than 4.5 wt.%, or not more than 4.5 wt.%, or not more than 4.5 wt.%, or not more than 4.5 wt.%. not more than 4.5 wt.%.%.
  • char can be recycled back to the feedstock stream to the gasifier containing the size reduced textiles.
  • the efficiencies and features can be obtained without recycling char back to the gasification zone.
  • the total amount of char (or incompletely converted carbon in the feedstock) and slag (if any) generated in the gasifier or by the process is desirably not more than 20 wt.%, or not more than 17 wt.%, or not more than 15 wt.%, or not more than 13 wt.%, or not more than 10 wt.%, or not more than 9 wt.%, or not more than 8.9 wt.%, or not more than 8.5 wt.%, or not more than 8.3 wt.%, or not more than 8 wt.%, or not more than 7.9 wt.%, or not more than 7.5 wt.%, or not more than 7.3 wt.%, or not more than 7 wt.%, or not more than 6.9 wt.%, or not more than 6.5 wt.%, or not more than 6.3 wt.%, or not more than 6 wt.%, or not more than 5.9
  • the same values apply with respect to the total amount of ash, slag, and char generated in the gasifier or by the process, based on the weight of the solids in the feedstock composition. In another embodiment, the same values apply with respect to the total amount of ash, slag, char and tar generated in the gasifier or by the process, based on the weight of the solids in the feedstock composition.
  • the raw syngas stream flows from the gasification zone to a quench zone at the bottom of the gasifier where the slag and raw syngas stream are cooled, generally to a temperature below 550°C, or below 500°C, or below 450°C.
  • the quench zone contains water in a liquid state.
  • the hot syngas from the gasification zone may be cooled by directly contacting the syngas stream with liquid water.
  • the syngas stream can be bubbled through the pool of liquid water, or merely contact the surface of the water pool.
  • the hot syngas stream may be cooled in a water jacketed chamber having a height that above the top surface of the water pool to allow the hot syngas to both contact the water pool and be cooled in the water jacketed chamber.
  • Molten slag is solidified by the quench water and most of the ash, slag and char are transferred to the water in the quench tank.
  • the partially cooled gas stream having passed through the water in the quench zone, may be then discharged from the gasifier as a raw syngas stream and passed through a water scrubbing operation to remove any remaining entrained particulate matter.
  • the pressure in the quench zone is substantially the same as the pressure in the gasification zone located above the water level in the gasifier, and a portion of the quench water and solids at the bottom of the quench tank is removed by way of a lock hopper system.
  • a stream of quench water carrying fine particles exits the gasifier quench zone in response to a liquid level controller and can be directed to a settler.
  • the solids and water from the lock hopper may then flow into a water sump or settler where optionally the coarse particulate solids may be removed by screens or filter thereby producing a dispersion of fine particulate solids.
  • the raw gas stream discharged from the gasification vessel includes such gasses as hydrogen, carbon monoxide, carbon dioxide and can include other gases such as methane, hydrogen sulfide and nitrogen depending on the fuel source and reaction conditions.
  • Carbon dioxide in the raw syngas stream discharged from the gasification vessel is desirably present in an amount of less than 20 mole%, or less than 18 mole%, or less than 15 mole%, or less than 13 mole%, or not more than 1 1 mole%, based on all moles of gases in the stream.
  • Some nitrogen and argon can be present in the raw syngas stream depending upon the purity of the fuel and oxygen supplied to the process.
  • the raw syngas stream (the stream discharged from the gasifier and before any further treatment by way of scrubbing, shift, or acid gas removal) can have the following composition in mole % on a dry basis and based on the moles of all gases (elements or compounds in gaseous state at 25°C and 1 atm) in the raw syngas stream:
  • a. H2 15 to 60, or 18 to 50, or 18 to 45, or 18 to 40, or 23 to 40, or
  • C02 1.0 to 30, or 2 to 25, or 2 to 21 , or 10 to 25, or 10 to 20
  • H20 2.0 to 40.0, or 5 to 35, or 5 to 30, or 10 to 30
  • CH4 0.0 to 30, or 0.01 to 15, or 0.01 to 10, or 0.01 to 8, or 0.01 to 7, or 0.01 to 5, or 0.01 to 3, or 0.1 to 1.5, or 0.1 to 1
  • H2S 0.01 to 2.0, or 0.05 to 1.5, or 0.1 to 1 , or 0.1 to 0.5 g.
  • COS 0.05 to 1.0, or 0.05 to 0.7, or 0.05 to 0.3
  • Total sulfur 0.015 to 3.0, or 0.02 to 2, or 0.05 to 1.5, or 0.1 to 1 i.
  • N2 0.0 to 5, or 0.005 to 3, or 0.01 to 2, or 0.005 to 1 , or 0.005 to 0.5, or 0.005 to 0.3
  • the gas components can be determined by FID-GC and TCD-GC or any other method recognized for analyzing the components of a gas stream.
  • the molar hydrogen/carbon monoxide ratio is desirably at least 0.65, or at least 0.68, or at least 0.7, or at least 0.73, or at least 0.75, or at least 0.78, or at least 0.8, or at least 0.85, or at least 0.88, or at least 0.9, or at least 0.93, or at least 0.95, or at least 0.98, or at least 1.
  • the total amount of hydrogen and carbon monoxide relative to the total amount of syngas discharged from the gasifier on a dry basis is high, on the order of greater than 70 mole%, or at least 73 mole%, or at least 75 mole%, or at least 77 mole%, or at least 79 mole%, or at least 80 mole%, based on the syngas discharged.
  • the dry syngas production expressed as gas volume discharged from the gasifier per kg of solid fuel (e.g. size reduced textiles and coal) charged to all locations on the gasifier is at least 1.7, or at least 1.75, or at least 1.8, or at least 1.85, or at least 1.87, or at least 1.9, or at least 1.95, or at least 1.97, or at least 2.0, in each case as N m3 gas/kg solids fed.
  • solid fuel e.g. size reduced textiles and coal
  • the carbon conversion efficiency in one pass is good and can be calculated according to the following formula: total carbon in feed— total carbon in char and tar
  • the carbon conversion efficiency in the process in one pass can be at least 70%, or at least 73%, or at least 75%, or at least 77%, or at least 80%, or at least 82%, or at least 85%, or at least 88%, or at least 90%, or at least 93%.
  • the raw syngas stream contains particulate solids in an amount of greater than 0 wt.% up to 30 wt. %, or greater than 0 wt.% up to 10 wt.%, or greater than 0 wt.% up to 5 wt.%, or greater than 0 wt.% up to 1 wt.%, or greater than 0 wt.% up to 0.5 wt.%, or greater than 0 wt.% up to 0.3 wt.%, or greater than 0 wt.% up to 0.2 wt.%, or greater than 0 wt.% up to 0.1 wt.%, or greater than 0 wt.% up to 0.05 wt.%, each based on the weight of solids in the feedstock composition.
  • the amount of particulate solids in this case is determined by cooling the syngas stream to a
  • the cold gas efficiency of the process using the size reduced textiles/solid fossil fuel as a percent can be calculated as:
  • the cold gas efficiency is at least 60%, or at least 65%, or at least 66%, or at least 67%, or at least 68%, or at least 69%, or desirably at least 70%, or at least 71 %, or at least 72%, or at least 73%, or at least 74%, or at least 75%, or at least 76%, or at least 77%, or at least 78%, or at least 79%.
  • hydrogen and carbon monoxide from the raw syngas stream discharged from the gasifier or from a scrubbed or purified syngas stream are not recycled or recirculated back to a gasification zone in a gasifier.
  • carbon dioxide from the raw syngas stream discharged from the gasifier or from a scrubbed or purified syngas stream is not recycled or recirculated back to a gasification zone in a gasifier.
  • no portion of the syngas stream discharged from the gasifier or from a scrubbed or purified syngas stream is recycled or recirculated back to a gasification zone in a gasifier.
  • no portion of the syngas discharged from the gasifier is used to heat the gasifier.
  • no portion of the syngas made in the gasifier is burned to dry the solid fossil fuel.
  • the feedstock stream is gasified with the oxidizer such as oxygen desirably in an entrained flow reaction zone under conditions sufficient to generate a molten slag and ash.
  • the molten slag and ash are separated from the syngas and quench cooled and solidified.
  • the coal/size reduced textiles/water mixture is injected with oxygen and the coal/rubber will react with oxygen to generate a variety of gases, including carbon monoxide and hydrogen (syngas).
  • the molten slag and unreacted carbon/size reduced textiles accumulate into a pool of water in the quench zone at the bottom part of the gasifier to cool and solidify these residues.
  • the slag is discharged from the gasifier as a solid.
  • Slag is cooled and solidified within the gasifier in a quench zone within the shell of the gasifier, and is discharged from the gasifier shell as a solid.
  • These solids discharged from the gasifier are accumulated into a lock hopper which can then be emptied.
  • the lock hopper is generally isolated from the gasifier and the quench zone within the gasifier.
  • the process can be practiced on an industrial scale and on a scale sufficient to provide syngas as a raw material to make chemicals on an industrial scale.
  • At least 300 tons/day, or at least 500 t/d, or at least 750 t/d, or at least 850 t/d, or at least 1000 t/d, or at least 1250 t/d, and desirably at least 1500 t/d, or at least 1750 t/d, or even at least 2000 t/d of solids can be fed to the gasifier.
  • the gasifier is desirably not designed to be mobile and is fixed to and above the ground, and desirably stationary during operations.
  • the syngas compositional variability produced by gasifying the feedstock containing the solid fossil fuel and size reduced textiles are quite low over time.
  • the compositional variability of the syngas stream is low during a time period when the feedstock composition contains the solid fossil fuel and the size reduced textiles.
  • the compositional variability of the syngas stream can be determined by taking at least 6 measurements of the concentration of the relevant gaseous compound in moles in equal time sub periods across the entire time that the feedstock solids content are consistent and contain size reduced textiles, such entire time not to exceed 12 days.
  • the mean concentration of the gaseous compound is determined over the 6 measurements.
  • the absolute value of the difference between the number farthest away from the mean and the mean number is determined and divided into the mean number x 100 to obtain a percent compositional variability.
  • H2 + CO amount or its molar ratio in sequence (e.g. H2:CO ratio), or
  • H2 + CO + C02 amount or its molar ratio in sequence, or i. H2 + CO + CH4 amount, or its molar ratio in sequence, or j. H2 + CO + C02 + CH4 amount, or its molar ratio in sequence, or k. H2S + COS amount, or its molar ratio in sequence, or
  • the feedstock composition can be not more than 5%, or not more than 4%, or not more than 3%, or not more than 2%, or not more than 1 %, or not more than 0.5%, or not more than 0.25% during the shorter of a 12-day period or the time that size reduced textiles are present in the feedstock composition.
  • variability of the syngas stream generated by all feedstock sources containing fuel (liquid, gas, or solid) at least one of which contains size reduced textiles (“textile case”) is compared to a benchmark variability of the syngas stream generated from the same feedstocks without the size reduced textiles and the size reduced textiles amount is replaced by a corresponding amount of the same fuel (“base case”) and processed under the same conditions to obtain a % switching variability, or in other words, the syngas variability generated by switching between the two feedstock compositions.
  • the syngas variation of the textile case can be less than, or no different than, or if higher can be similar to the syngas variation of the base case.
  • the time periods to determine variations is set by the shorter of a 12-day period or the time that size reduced textiles are present in the feedstock composition, and that time period is the same time period used for taking measurements in the solid fossil fuels only case.
  • the measurements for the base case are taken within 1 month before feeding a feedstock containing size reduced textiles to the gasifier or after the expiration of feeding a feedstock containing size reduced textiles to the gasifier.
  • the variations in syngas composition made by each of the streams is measured according to the procedures states above.
  • the syngas variability from the textile case is less than, or the same as, or not more than 15%, or not more than 10%, or not more than 5%, or not more than 4%, or not more than 3%, or not more than 2%, or not more than 1 %, or not more than 0.5%, or not more than 0.25% of the syngas variability of the base case. This can be calculated as: where %SV is percent syngas switching variability on one or more measured ingredients in the syngas composition; and
  • Vt is the syngas compositional variability using feedstock(s) containing size reduced textiles and a second source of fuel together in one stream or in separate feedstock streams;
  • Vb is the syngas compositional variability using the base case streams (same type and amount of fuel feedstock without the size reduced textiles), where the solids concentration is the same in both cases, the fuel is the same in both cases other than the presence of absence of the size reduced textiles, and the feedstocks are gasified under the same conditions, other than temperature fluctuations which may autogeneously differ as a result of having size reduced textiles in the feedstock, and the variabilities are with respect to any one or more of the syngas compounds identified above. In the event that the %SV is negative, then the syngas textile case variability is less than the syngas base case.
  • the ratio of carbon monoxide/hydrogen generated from one or more streams that contain size reduced textiles and other fuel sources is similar to the carbon monoxide/hydrogen ratio generated from the same stream(s) replacing the size reduced textiles content with the same fuel (base case).
  • the carbon monoxide/hydrogen ratio between the textile case and the base case can be within 10%, or within 8%, or within 6%, or within 5%, or within 4%, or within 3%, or within 2%, or within 1.5%, or within 1 %, or within 0.5% of each other.
  • the percentage similarity can be calculated by taking the absolute value of the differences in CO/H2 ratios between the textile case and the base case and dividing that number into the CO/H2 ratio of the base case x 100.
  • the amount of C02 generated from a textile case is similar to the amount of carbon dioxide generated from a base case.
  • the process can be conducted such that the amount of CO2 generated from textile case is no more than 25%, or no more than 20%, or no more than 15%, or no more than 13%, or no more than 10%, or no more than 8%, or no more than 7%, or no more than 6%, or no more than 5%, or no more than 4%, or no more than 3%, or no more than 2%, or no more than 1 %, or no more than 0.75%, or no more than 0.5%, or nor more than 0.25%, or no more than 0.15%, or no more than 0.1 % greater than the amount of carbon dioxide generated from a base case.
  • the percentage similarity can be calculated by subtracting the amount of CO2 generated in a syngas stream using the textile case from the amount of CO2 generated in a syngas stream using the base case, and dividing that number by the C02 generated in a syngas stream using the base case x 100.
  • switching frequency between feedstocks without the size reduced textiles (base case) and the identical feedstocks except replacing a portion of the fuel with the size reduced textiles (textile case) can be at least 52x/yr, or at least 48x/yr, or at least 36x/yr, or at least 24x/yr, or at least 12x/yr, or at least 6x/yr, or at least 4x/yr, or at least 2x/yr, or at least 1 x/yr, or at least 1 x/2yr, and up to 3x/2yr, without incurring a syngas switching variability beyond the percentages express above.
  • One switch is counted as the number of times in a period that the textile case is used.
  • Coal is fed through line 1 into a coal grinding zone 2 wherein it is mixed with a water from stream 3 and ground to the desired particle size.
  • a suitable coal grinding process includes a shearing process.
  • Examples of a suitable apparatus include ball mill, a rod mill, hammer mill, a raymond mill, or an ultrasonic mill; desirably a rod mill.
  • the rod mill is desirably the wet grind type to prepare a slurry.
  • a rod mill contains a number of rods within a cylinder where the rods rotate about a horizontal or near horizontal axis. The coal is ground when it is caught between the rods and cylinder wall by the rolling/rotating action of the rods.
  • the rod mill can be the overflow type, end peripheral discharge, and center peripheral discharge, desirably the overflow type.
  • the grinder can also be equipped with a classifier to remove particles above the target maximum particle size.
  • a classifier is a vibrating sieve or a weir spiral classifier.
  • the coal grinder zone (which includes at least the grinding equipment, feed mechanisms to the grinder, and any classifiers) is a convenient location for combining size reduced textiles particles through line 4 to the coal.
  • the desired amount of coal and size reduced textiles can be combined onto a weigh belt or separately fed though their dedicated weigh belts that feed the grinding apparatus.
  • the water slurry of ground coal and size reduced textiles are discharged through line 5 and pumped into a storage/charge tank 6 that is desirably agitated to retain a uniform slurry suspension.
  • size reduced textiles can be added into the charge/storage tank 6 through line 7, particularly when this tank is agitated.
  • the feedstock composition is discharged from tank 6 directly or indirectly to the gasifier 9 through line 8 into the injector 10 in which the coal/rubber/water slurry is co-injected with an oxygen-rich gas from line 1 1 into the gasification reaction zone 12 where gasification takes place.
  • the injector 10 may optionally be cooled with a water line 13 feeding a jacket on the injector and discharged through line 14.
  • the reaction in the reaction zone 12 takes place spontaneously at an autogenous temperature in the ranges noted above, e.g. 1200°C to 1600°C and at a pressure in the ranges note above, e.g. 10 - 100 atmospheres.
  • the gaseous reaction products of the partial oxidation reaction include carbon monoxide, hydrogen, with lesser amounts of carbon dioxide and hydrogen sulfide. Molten ash, unconverted coal or rubber, and slag may also be present in the reaction zone 12.
  • the gasifier 9 is illustrated in more detail in Figure 2, also as shown in US Patent 3,544,291 , the entire disclosure of which is incorporated herein by reference.
  • the gasifier comprises a cylindrical pressure vessel 50 with a refractory lining 75 defining a cylindrical, compact, unpacked reaction zone 54.
  • the mixture of coal, size reduced textiles, water and oxygen is injected through an injector axially into the upper end of reaction zone 54 through inlet passageway 76.
  • Products of reaction are discharged axially from the lower end of reaction zone 54 through an outlet passageway 77 into a slag quench chamber 71.
  • the quench chamber 71 and the reaction zone 54 are within the outer shell 50 of the gasifier and are in continuous gaseous and fluid communication with each other during the combustion and reaction in reaction zone 54.
  • a pool of water 78 is maintained in the lower portion of quench chamber 71 and a water jacket 79 is provided in the upper portion of the quench chamber 71 to protect the pressure vessel shell from becoming overheated by hot gases from the gasification zone 54.
  • Unconverted solid fuel and molten slag and ash from the solid fuel is discharged with the product gas stream through outlet 77 into the quench chamber 71 where the larger particles of solid and any molten ash or slag drops into the pool of water.
  • the partially cooled gas is discharged from the quench chamber 71 through line 58, which optionally is also provided with a refractory lining 75.
  • the hot reaction product gas from reaction zone 12 along with the slag formed on the surfaces of refractory facing the reaction zone 12 are discharged into the quench chamber 15 where they are quickly cooled and solidified below the reaction temperature in zone 12 to form solid slag, ash, and unconverted coal which separates from the hot raw syngas to form a raw syngas stream which is discharged from the gasifier vessel.
  • the process effectuates a separation of ash, slag, and unconverted products from the reaction product gases, and has the advantage over a fixed or moving bed waste gasifier in that within the gasifier vessel, a first step of purification of the gaseous reaction products from the reaction zone 12 has occurred prior to discharging the raw syngas stream from the gasification vessel.
  • a first step of purification of the gaseous reaction products from the reaction zone 12 has occurred prior to discharging the raw syngas stream from the gasification vessel.
  • the slag and vaporized unconverted fossil fuel elements are solidified in the quench water in quench zone 15, and part of the quench water is vaporized producing steam which is useful in subsequent operations, for example, for the water-gas shift reaction of the scrubbed raw syngas stream in which hydrogen is produced by reaction of carbon monoxide with water vapor in the presence of a suitable catalyst such as an iron oxide- chromic oxide catalyst.
  • the temperature of the raw syngas stream exiting the gasification vessel through line 16 can be within a range of 150°C to 700°C, or from 175°C to 500°C. Desirably, the temperature of the raw syngas discharged from the gasifier is not more than 500°C, or less than 400°C, or not more than 390°C, or not more than 375°C, or not more than 350°C, or not more than 325°C, or not more than 310°C, or not more than 300°C, or not more than 295°C, or not more than 280°C, or not more than 270°C.
  • the temperature of the raw syngas exiting the gasification vessel is substantially reduced from the temperature of the reaction product gases within the reaction zone.
  • the temperature reduction between the gasification zone gas temperature (or alternatively all reaction zones if more than one stage is used) and the raw syngas temperature discharged from the gasifier vessel can be at least 300°C, or at least 400°C, or at least 450°C, or at least 500°C, or at least 550°C, or at least 600°C, or at least 650°C, or at least 700°C, or at least 800°C, or at least 900°C, or at least 1000°C, or at least 1050°C, or at least 1 100°C.
  • the raw syngas is discharged from the gasifier through line 16 to a suitable scrubber 17 where it is contacted with water from line 18 for the removal of remaining solid particles from the raw syngas stream.
  • Gas scrubber 17 may comprise a venturi scrubber, a plate type scrubber or a packed column, or a combination thereof, in which raw syngas stream is intimately contacted with water to effect the removal of solid particles from the raw syngas stream.
  • the scrubbed raw syngas stream is discharged through line 19 for further use in other processes, such as acid gas (e.g. sulfur compounds) removal processes to make the resulting purified syngas stream suitable for manufacture of chemicals.
  • Suitable process for acid gas removal include the RectisolTM and SelexolTM acid gas removal processes.
  • the solids-water mixture from gas scrubber 17 is discharged from the scrubber passed through line 20 optionally to line 21 where it is mixed with quench water containing solids drawn from quench zone 15 via line 22 and the mixture passed through pressure reducing valve 23 into settling tank 24.
  • a heat exchanger 25 serves to heat by heat exchange with hot quench water from line 22 the relatively cool make-up and recycle water supplied through line 26 from a suitable source and pumped to lines for quenching and/or scrubbing the product gas from the gas generator.
  • slurry concentrated slurry of ash, unconverted coal and soot in water.
  • This slurry may be optionally be recycled to grinding zone 2 via line 28.
  • a portion of the slurry from line 27 may be diverted through line 29 into mix tank 6 to adjust the concentration of solids in the water-coal-rubber slurry feed stream charged to the gasifier.
  • water and solids from settler tank 66 may be drawn off in line 83 for processing, while water and ash, unconverted coal and soot may be drawn off the settle tank 66 through line 84 and combined with the feedstock of coal, size reduced textiles and water.
  • gases released in settler 24 may be discharged through line 30 and recovered as potential fuel gases.
  • Clarified water from settler 24 is withdrawn through line 31 and recirculated to the quench water system through line 32.
  • a portion of the water from line 32, after passing through heat exchanger 25, is supplied to the quench zone 15 through line 33 and a further portion of the water is passed through line 18 to gas scrubber 17.
  • water from the quench zone can be withdrawn through line 22 to settler 24 through a control valve 23.
  • the water level can be controlled through a liquid level controller on the gasifier to maintain a substantially constant water level in quench zone.
  • the quench water through line 33 feeding the quench water zone can supplied from a syngas scrubber downstream from the gasifier as shown in Figure 2.
  • the quench water stream optionally also fed to the quench zone may be clarified or may contain from about 0.1 weight % soot to about 1.5 weight % soot based on the weight of the quench water stream feeding the gasifier.
  • high temperature surfactants can be added to the quench water directly into the quench zone/chamber.
  • surfactants include any one of the surfactants mentioned above to stabilize the feedstock composition, such as ammonium lignosulfonate or an equivalent surfactant which is thermally stable at temperatures of about 300° F. to about 600° F.
  • Other surfactants include organic phosphates, sulfonates and amine surfactants. The surfactants are used to establish a stable suspension of soot in the water at the bottom of the quench chamber, where the soot
  • concentration can be at least 1 wt.%, or in the range of about 3.0 weight % to about 15.0 weight %, each based on the weight of the water in the quench chamber.
  • concentration of active surfactants in the bottom of the quench zone can vary from about 0.01 weight % to about 0.30 weight %.
  • an internal water jacket 79 is provided within the pressure vessel shell 50 at the upper portion of the quench zone 71. Water jacket 79 prevents overheating of the pressure vessel shell below the level of refractory 75 surrounding reaction zone 54. Water is introduced into water jacket 79 from line 80 and discharged therefrom through line 81 through valve 82 and can be fed directly or indirectly (through a settler tank 66) to a scrubber 59.
  • incombustible solids settling to the bottom of quench zone 15 are withdrawn as a water-solids slurry through line 34 and valve 35 into lock hopper 36.
  • fresh water can be charged to the lock hopper 36 to displace the sour water in the lock hopper 36.
  • Cold clean water from line 39 is introduced through valve 40 into the lower part of lock hopper 36.
  • Valve 41 in line 42 is opened to establish communication between line 33 and lock hopper 36.
  • hot sour water is displaced from the lock hopper and flows through line 42 and line 33 into the quench zone 15 as part of the make-up water for the quench system.
  • valves 40 and 41 are closed and valve 38 opened to permit discharge of slag and clean water from the lock hopper through line 37.
  • stripping gas such as carbon dioxide, or gases produced by the gasifier from which acid gases have been removed by chemical treatment
  • gas can be introduced into the lower portion of lock hopper 36 through line 43 after the lock hopper has been charged with slag and sour water from the quench zone 15 and valve 35 closed.
  • Stripping gas under pressure is introduced into the lower portion of lock hopper 36 by opening valve 44 in line 43.
  • valve 41 in line 42 is opened allowing gas to pass through lines 42 and 33 into the quench zone 15.
  • the stripping gas from line 43 desorbs sour gases, i.e.
  • FIG. 2 An example of the operation of the gasifier and scrubber is illustrated in Figure 2.
  • the coal/size reduced textiles feedstock slurry is fed to the gas generator 50 through injector 51 mounted at the top 52 of the gasifier and is fed with oxygen through line 53 and injected into the gasification zone 54 to generate a raw syngas.
  • the raw syngas gases discharged from the gasifier is fed to a contactor 55.
  • Water is injected into contactor 55 from line 56 through injectors 56 and 57.
  • Intimate contact between the raw syngas from line 58 and water from line 56 is effected desirably by way of a venturi, nozzle, or plate orifice.
  • the syngas stream is accelerated, and water is injected into the accelerated gas stream at the throat of the nozzle, venturi or orifice, from a plurality of injectors 56 and 57.
  • the resulting mixture of gas and water formed in contactor 55 is directed into scrubber 59 through a dip leg 60 which extends downwardly into the lower portion of scrubber 59.
  • the gas stream from contactor 55 also carries entrained solid particles of unconsumed fuel or ash.
  • a body of water is maintained in the scrubber 59, the level of which may be controlled in any suitable manner, for example by means of a liquid level controller 61 , shown diagrammatically.
  • the dip leg 60 discharges the mixture of water and gas below the level of water contained in the scrubber 59. By discharging the mixture of gas and water through the open end of dip leg 60 into intimate contact with water, solid particles from the gas stream are trapped in the water.
  • Scrubber 59 is suitably in the form of a tower having an optionally packed section 62 above the point of entry of the gas stream from contactor 55.
  • Water from line 63 is introduced into scrubber 59 above the level of the packing material 62.
  • the gas stream is intimately contacted with water in the presence of suitable packing material, such as ceramic shapes, effecting substantially complete removal of solid particles from the gas stream.
  • Product gas comprising carbon monoxide and hydrogen and containing water vapor, atmospheric gases, and carbon dioxide, is discharged from the upper end of scrubber 59 through line 64 at a temperature corresponding to the equilibrium vaporization temperature of water at the pressure existing in scrubber 59.
  • Clean syngas from line 64 may be further processed, for example, for the production of higher concentrations of hydrogen by water-gas shift reaction and suitable downstream purification to remove sulfur.
  • Any suitable scrubber design can be used in the process.
  • Other scrubber designs include a tray type contacting tower wherein the gases are counter currently contacted with water. Water is introduced into the scrubber at a point near the top of the tower.
  • FIG. 3 To illustrate one embodiment of an injector, reference is made to Figure 3, showing a partial cut-away view of a synthesis gas gasifier at the injector location.
  • the gasifier vessel includes a structural shell 90 and an internal refractory liner 91 (or multiple liners) around an enclosed gasification zone 93.
  • Projecting outwardly from the shell wall is an injector mounting neck 94 for supporting an elongated fuel injection injector assembly 95 within the gasifier vessel.
  • the injector assembly 95 is aligned and positioned so that the face 96 of the injector nozzle 97 is substantially flush with the inner surface of the refractory liner 91.
  • An injector mounting flange 96 secures the injector assembly 95 to a mounting neck flange 97 of the gasifier vessel to prevent the injector assembly 95 from becoming ejected during operation.
  • a feed of oxygen flows into a central inner nozzle through conduit 98.
  • the feedstock stream is fed to the injector assembly through line 99 into an annular space around the central oxidant nozzle.
  • a cooling jacket surrounding the injector assembly 95 above the injector mounting flange 96 is fed with cooling water 100 to prevent the injector assembly from overheating.
  • An optional second feed of oxidant flows through line 101 into an annular space around at least a portion of the outer surface of the shell defining the feedstock annulus.
  • FIG. 4 A more detailed view of the injector is shown in Figure 4.
  • the injector assembly 80 includes an injector nozzle assembly 125 comprising three concentric nozzle shells and an outer cooling water jacket 1 10.
  • the inner nozzle shell 1 1 1 discharges from an axial bore opening 1 12 the oxidizer gas that is delivered along upper assembly axis conduit 98 in Figure 3.
  • Intermediate nozzle shell 1 13 guides the feedstock stream into the gasification zone 93.
  • this size reduced textile/coal slurry is ejected from the annular space 1 14 defined by the inner shell wall 1 11 and the intermediate shell wall 1 13.
  • the outer, oxidizer gas nozzle shell 1 15 surrounds the outer nozzle discharge annulus 1 16.
  • the upper assembly port 101 as shown in Figure 3, supplies the outer nozzle discharge annulus with an additional stream of oxidizing gas.
  • Centralizing fins Centralizing fins
  • 1 17 and 1 18 extend laterally from the outer surface of the inner and
  • 1 18 form discontinuous bands about the inner and intermediate shells and offer small resistance to fluid flow within the respective annular spaces.
  • the internal nozzle shell 1 1 1 and intermediate nozzle shell 1 13 can both be axially adjustable relative to the outer nozzle shell 115 for the purpose flow capacity variation.
  • intermediate nozzle 1 13 is axially displaced from the conically tapered internal surface of outer nozzle 1 15, the outer discharge annulus 1 16 is enlarged to permit a greater oxygen gas flow.
  • the feedstock slurry discharge area 1 14 is reduced.
  • a coolant fluid jacket 1 10 Surrounding the outer nozzle shell 1 15 is a coolant fluid jacket 1 10 having an annular end closure 1 19.
  • a coolant fluid conduit 120 delivers a coolant, such as water, from the upper assembly supply port 100 in Figure 3 directly to the inside surface of the end closure plate 119.
  • Flow channeling baffles 121 control the path of coolant flow around the outer nozzle shell to assure a substantially uniform heat extraction and to prevent the coolant from channeling and producing localized hot spots.
  • the end closure 1 19 includes a nozzle lip 122 that defines an exit orifice or discharge opening for the feeding of reaction materials into the injection injector assembly.
  • the planar end of the cooling jacket 1 19 includes an annular surface 123 which is disposed facing the combustion chamber.
  • the annular surface 123 of cooling jacket is composed of cobalt base metal alloy materials.
  • cobalt is the preferred material of construction for the nozzle assembly 125, other high temperature melting point alloys, such as molybdenum or tantalum may also be used.
  • the heat shield 124 is formed from a high temperature melting point material such as silicon nitride, silicon carbide, zirconia, molybdenum, tungsten or tantalum.
  • the injector may consist of only two passages for introducing and injecting the oxidant and feedstock stream, and they may be in any order with the feedstock stream passing through the central axial bore opening while the feedstock is fed through an annulus surrounding at least a portion of the central oxidant conduit, or the order may be reversed as described above.

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Abstract

Des textiles à taille réduite sont co-alimentés avec un combustible dans un gazéifieur à oxydation partielle. Des concentrations élevées de matières solides dans la composition de charge peuvent être obtenues sans impact significatif sur la stabilité de la composition de charge et la pompabilité. Une qualité constante de gaz de synthèse peut être produite en continu, comprenant la génération de dioxyde de carbone et un rapport monoxyde de carbone/hydrogène tout en faisant fonctionner de manière stable le gazéifieur et en évitant la génération élevée de goudron de gazéifieurs à déchets à lits fluidisés ou à lits fixes et sans affecter le fonctionnement du gazéifieur. La qualité, la composition et le débit de gaz de synthèse sont appropriés pour produire une large gamme de produits chimiques.
PCT/US2020/024833 2019-03-29 2020-03-26 Gazéification de textiles à taille réduite et combustibles fossiles solides WO2020205392A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
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