Fuel gas from solid carbonaceous fuels

Claim 2

IN THE CONTINUOUS MANUFACTURE OF GASEOUS MIXTURES PRINCIPALLY COMPRISING H2 AND CO, AND OPTIONALLY CONTAINING AT LEAST ONE MEMBER OF THE GROUP CO2, H2O, CH4, N2, A, COS, AND H2S BY THE PARTIAL OXIDATION OF A HYDROCARBONACEOUS FUEL WITH A FREE-OXYGEN CONTAINING GAS IN THE PRESENCE OF A TEMPERATURE MODERATOR IN A REACTION ZONE FREE FROM PACKING AND CATALYST OF A FREE-FLOWING GAS GENERATOR, THE IMPROVEMENT WHICH COMPRISES INTRODUCING INTO SAID REACTION ZONE A CONTINUOUS FIRST SLURRY FEEDSTREAM COMPRISING A GROUND SOLID CARBONACEOUS FUEL AND A LIQUID HYDROCARBON FUEL AT A VELOCITY IN THE RANGE OF ABOUT 1 TO 500 FEET PER SECOND; SIMULTANEOUSLY INTRODUCING INTO SAID REACTION ZONE SO AS TO CONTACT SAID FIRST SLURRY FEEDSTREAM A CONTINUOUS SEPARATE SECOND SLURRY FEEDSTREAM COMPRISING A GROUND SOLID CARBONACEOUS FUEL AND WATER AT A VELOCITY IN THE RANGE OF ABOUT 1 TO 500 FEET PER SECOND; SIMULTANEOUSLY INTRODUCING INTO SAID REACTION ZONE A CONTINUOUS SEPARATE THIRD STREAM COMPRISING A FREE-OXYGEN CONTAINING GAS INTERPOSED BETWEEN SAID FIRST AND SECOND SLURRY FEEDSTREAMS; AND CONTACTING AND MIXING SAID THREE STREAMS TOGETHER TO FORM AN ATOMIZED DISPERSION IN WHICH THE RATIO OF ATOMS OF OXYGEN TO ATOMS OF CARBON IN THE TOTAL FUEL IS IN THE RANGE OF ABOUT 0.6 TO 1.6, THE WEIGHT RATIO OF H2O TO FUEL IS IN THE RANGE OF ABOUT 0.10 TO 1.3, AND THE WEIGHT RATIO OF TOTAL SOLID CARBONACEOUS FUEL TO LIQUID HYDROCARBON FUEL IS IN THE RANGE OF ABOUT 0.8 TO 12, AND REACTING SAID ATOMIZED DISPERSION IN SAID REACTION ZONE AT A TEMPERATURE IN THE RANGE OF ABOUT 1,500* TO 3,500*F., AND A PRESSURE IN THE RANGE OF ABOUT 1 TO 250 ATMOSPHERES.

Claim 3

The process of claim 1 wherein said first slurry stream comprises 0.30 to 0.65 parts by weight of a ground solid carbonaceous fuel selected from the group consisting of petroleum coke, coal, particulate carbon, coal char, coke from coal, oil shale, tar sands, pitch and mixtures thereof for each part by weight of liquid hydrocarbon fuel selected from the group consisting of fuel oil, residual fuel oil, reduced crude oil, whole crude oil, coal oil, shale oil, gasoline, kerosene, naphtha, gas oil fractions of petroleum distillate, benzene, toluene, hexane, heptane cyclohexane, tetralin, decalin and mixtures thereof; and wherein said second slurry stream comprises 0.30 to 0.65 parts by weight of said solid carbonaceous fuel for each part by weight of water.

Claim 4

The process of claim 1 provided with the additional steps of (1) splitting the effluent gas stream from said reaction zone into first and second process gas streams; (2) cooling said first process gas stream from (1) by indirect heat exchange with water to produce steam in a waste heat boiler; (3) simultaneously cooling and scrubbing said second process gas stream from (1) to remove entrained solids by immersion in water in a quench tank; (4) scrubbing the effluent gas stream from the waste-heat boiler in (2) with scrubbing oil to remove entrained solids and to produce a product gas stream principally comprising H2 and CO and containing less than 10 mole % H2O; and (5) removing the effluent gas stream from the quench tank in (3) to produce a product gas stream saturated with water and principally comprising H2 and CO.

Claim 5

A process for the production of fuel gas or synthesis gas comprising introducing into the reaction zone free from packing and catalyst of a free-flow gas generator a continuous first slurry feedstream comprising a solid carbonaceous fuel and a liquid hydrocarbon fuel at a velocity in the range of about 1 to 500 feet per second, wherein said first slurry stream comprises 0.30 to 0.65 parts by weight of a ground solid carbonaceous fuel selected from the group consisting of petroluem coke, coal, particulate carbon, coal char, coke from coal, oil shale, tar sands, pitch, and mixtures thereof for each part by weight of liquid hydrocarbon fuel selected from the group consisting of fuel oil, residual fuel oil, reduced crude oil, whole crude oil, coal oil, shale oil, gasoline, kerosene, naphtha, gas oil fractions of petroleum distillate, benzene, toluene, hexane, heptane, cyclohexane, tetralin, decalin and mixtures thereof; simultaneously introducing into said reaction zone so as to contact said first slurry feedstream a continuous separate second slurry feedstream comprising a solid carbonaceous fuel and water at a velocity in the range of about 1 to 500 feet per second, and wherein said second slurry stream comprises 0.3 to 0.65 parts by weight of said ground solid carboniferous fuel for each part by weight of water; simultaneously introducing into said reaction zone a continuous separate third feedstream comprising a free-oxygen containing gas interposed between said first and second slurry feedstreams, and contacting and mixing said three feedstreams together to form an atomized dispersion in which the ratio of atoms of oxygen to atoms of carbon in the total fuel is in the range of about 0.6 to 1.6, the weight ratio of H2O to fuel is in the range of about 0.10 to 1.3, and the weight ratio of total solid carbonaceous fuel to liquid hydrocarbon fuel is in the range of about 0.8 to 12, and reacting said atomized dispersion in said reaction zone at a temperature in the range of about 1,500* to 3,500*F., a pressure in the range of about 1 to 250 atmospheres, and for a residence time of 1 to 10 seconds; splitting the effluent gaseous stream from said reaction zone into first and second split process gas streams; cooling said first split process gas stream by indirect heat exchange with water in a waste heat boiler to produce steam; scrubbing with liquid hydrocarbon fuel or a dispersion of particulate carbon and liquid hydrocarbon fuel the effluent gas stream from said waste heat boiler to remove entrained solid particles, separating a dispersion of particulate carbon and liquid hydrocarbon fuel, and separating a first product gas stream principally comprising H2 and CO and containing at least one member of the group CO2, H2O, CH4, N2, A, COS, and H2S; mixing a portion of said dispersion of particulate carbon and liquid hydrocarbon fuel with make-up solid carboniferous fuel to produce said first slurry feedstream to the gas generator; separating at least one member of the group CO2, H2O, CH4, N2, A, COS, and H2S from said first product gas stream in a gas purification zone; and simultaneously cooling and scrubbing to remove entrained solid particles from said second split process gas stream by immersion in water in a quench zone, removing a second product gas stream from said quench zone similar to said first product gas stream but saturated with H2O and substantially free from entrained solid particles; removing a dispersion of solid particles and water from said quench zone and separating therefrom a concentrated particulate carbon-water dispersion, and mixing said ground solid carbonaceous fuel with said concentrated dispersion of particulate carbon-water to produce said second slurry feedstream to the gas generator.

Claim 6

A process for the production of fuel gas or synthesis gas comprising introducing into the reaction zone free from packing and catalyst of a free-flow gas generator a continuous first slurry feedstream comprising a solid carbonaceous fuel and a liquid hydrocarbon fuel at a velocity in the range of about 1 to 500 feet per second, wherein said first slurry stream comprises 0.30 to 0.65 parts by weight of a ground solid carbonaceous fuel selected from the group consisting of petroluem coke, coal, particulate carbon, coal char, coke from coal, oil shale, tar sands, pitch, and mixtures thereof for each part by weight of liquid hydrocarbon fuel selected from the group consisting of fuel oil, residual fuel oil, reduced crude oil, whole crude oil, coal oil, shale oil, gasoline, kerosene, naphtha, gas oil fractions of petroleum distillate, benzene, toluene, hexane, heptane, cyclohexane, tetralin, decalin and mixtures thereof; simultaneously introducing into said reaction zone so as to contact said first slurry feedstream a continuous separate second slurry feedstream comprising a solid carbonaceous fuel and water at a velocity in the range of about 1 to 500 feet per second, and wherein said second slurry stream comprises 0.3 to 0.65 parts by weight of said ground solid carboniferous fuel for each part by weight of water; simultaneously introducing into said reaction zone a continuous separate third feedstream comprising a free-oxygen containing gas interposed between said first and second slurry feedstreams, and contacting and mixing said three feedstreams together to form an atomized dispersion in which the ratio of atoms of oxygen to atoms of carbon in the total fuel is in the range of about 0.6 to 1.6, the weight ratio of H2O to fuel is in the range of about 0.10 to 1.3, and the weight ratio of total solid carbonaceous fuel to liquid hydrocarbon fuel is in the range of about 0.8 to 12, and reacting said atomized dispersion in said reaction zone at a temperature in the range of about 1,500* to 3,500*F., a pressure in the range of about 1 to 250 atmospheres, and for a residence time of 1 to 10 seconds; splitting the effluent gaseous stream from said reaction zone into first and second split process gas streams; cooling said first split process gas stream by indirect heat exchange with water in a waste heat boiler to produce steam; scrubbing with liquid hydrocarbon fuel or a dispersion of particulate carbon and liquid hydrocarbon fuel the effluent gas stream from said waste heat boiler to remove entrained solid particles, separating a dispersion of particulate carbon and liquid hydrocarbon fuel, and separating a first product gas stream principally comprising H2 and CO and containing at least one member of the group CO2, H2O, CH4, N2, A, COS, and H2S; mixing a portion of said dispersion of particulate carbon and liquid hydrocarbon fuel with make-up solid carboniferous fuel to produce said first slurry feedstream to the gas generator; separating at least one member of the group CO2, H2O, CH4, N2, A, COS, and H2S from said first product gas stream in a gas purification zone; and simultaneously cooling and scrubbing to remove entrained solid particles from said second split process gas stream by immersion in water in a quench zone, removing a second product gas stream from said quench zone similar to said first product gas stream but saturated with H2O and substantially free from entrained solid particles; removing a dispersion of solid particles and water from said quench zone and separating therefrom a concentrated particulate carbon-water dispersion, and mixing said ground solid carbonaceous fuel with said concentrated dispersion of particulate carbon-water to produce said second slurry feedstream to the gas generator.

Claim 7

The process of cLaim 4 provided with the additional steps prior to said gas purification zone of scrubbing said first product gas stream with water to remove any remaining entrained solids; separating a clean first product gas stream, separating a dispersion of entrained solids and water and mixing said dispersion with said dispersion of solid particles and water from said quench zone.

Claim 8

The process of claim 5 provided with the additional steps of introducing said mixed dispersion of solid particles and water into a settling zone; withdrawing from said settling zone a separate stream of clear water and recycling same to said quench zone, and a separate stream of coarse ash, and a separate stream of particulate carbon and fine ash dispersed in water; introducing said water dispersion of particulate carbon and fine ash into a froth flotation zone and removing therefrom three separate streams comprising water, ash, and said concentrated dispersion of particulate carbon-water.