Production of purified synthesis gas H2 -rich gas, and by-product CO2 -rich gas

Claim 2

A process of purifying a raw synthesis gas stream comprising H 2 , CO, H 2 O, CO 2 , H 2 S, COS, particulate carbon, and optionally CH 4 , N 2 and A and producing a by-product stream of CO 2 -rich gas for injection into an underground oil reservoir to effect secondary or tertiary recovery of oil comprising: 1. cooling said raw synthesis gas stream and removing said particulate carbon therefrom by contacting with water; 2. introducing the clean gas stream from (1) into a water-gas shift conversion zone in admixture with supplemental H 2 O and reacting together a portion of the CO and H 2 O in said shift conversion zone to produce additional H 2 and CO 2 ;

Claim 3

drying the process gas stream, cooling, and separating from said process gas stream about 0 to 70 volume % of the CO 2 , H 2 S, and COS; 4. contacting the process gas stream from (3) in an acid-gas absorption zone with a first liquid solvent absorbent to produce a rich first liquid solvent absorbent containing substantially all of the remaining CO 2 , H 2 S, and COS, and a product stream of purified synthesis gas comprising H 2 , CO, and optionally CH 4 , N 2 and A; 5. regenerating said rich first liquid solvent absorbent in a first absorbent regeneration zone by removing a CO 2 -rich gas stream by the combination of stripping with a stripping gas selected from the group consisting of: (a) a portion of said raw synthesis gas, (b) a portion of the product stream of purified synthesis gas from (4), (c) a portion of a H 2 -rich gas stream, and (d) mixtures of (a), (b) and (c); and at least one of the following: flashing, heating; 6. introducing at least a portion of said CO 2 -rich gas stream in admixture with said stripping gas from (5) into a subterranean formation to effect secondary or tertiary recovery of oil.

Claim 4

drying the process gas stream, cooling, and separating from said process gas stream about 0 to 70 volume % of the CO 2 , H 2 S, and COS; 4. contacting the process gas stream from (3) in an acid-gas absorption zone with a first liquid solvent absorbent to produce a rich first liquid solvent absorbent containing substantially all of the remaining CO 2 , H 2 S, and COS, and a product stream of purified synthesis gas comprising H 2 , CO, and optionally CH 4 , N 2 and A; 5. regenerating said rich first liquid solvent absorbent in a first absorbent regeneration zone by removing a CO 2 -rich gas stream by the combination of stripping with a stripping gas selected from the group consisting of: (a) a portion of said raw synthesis gas, (b) a portion of the product stream of purified synthesis gas from (4), (c) a portion of a H 2 -rich gas stream, and (d) mixtures of (a), (b) and (c); and at least one of the following: flashing, heating; 6. introducing at least a portion of said CO 2 -rich gas stream in admixture with said stripping gas from (5) into a subterranean formation to effect secondary or tertiary recovery of oil.

Claim 5

The process of claim 1 wherein said stripping gas comprises a portion of the purified synthesis gas from step (4) and is introduced into said first absorbent regeneration zone; and said stripping gas in admixture with said CO 2 -rich gas stream is removed from said first absorbent regeneration zone and is introduced into said subterranean formation in step (6).

Claim 6

The process of claim 1 wherein H 2 S-rich gas and stripping gas are removed in admixture with said CO 2 -rich gas from the first absorbent regenerating zone in step (5).

Claim 7

The process of claim 1 provided with the added steps of heating said first liquid solvent absorbent from step (5) in a second absorbent regeneration zone; removing an H 2 S-rich gas stream; and producing a clean first liquid solvent absorbent which is recycled to said acid-gas absorption zone in (4) as at least a portion of said first liquid solvent absorbent.

Claim 8

The process of claim 4 with the added step of introducing said H 2 S-rich gas stream into a Claus Unit to produce elemental sulfur.

Claim 9

The process of claim 1 provided with the additional steps of contacting purified synthesis gas stream from step (4) with a lean second liquid solvent absorbent in a second solvent absorption zone; removing a stream of H 2 -rich gas, and a stream of rich second liquid solvent absorbent from said second absorption zone; regenerating said rich second liquid solvent absorbent in a second solvent regeneration zone; removing a stream of CO-rich gas and a stream of lean second liquid solvent absorbent from said second solvent regeneration zone; and recycling said stream of lean second liquid solvent absorbent to said second absorption zone.

Claim 10

The process of claim 6 wherein at least a portion of said CO-rich gas stream is introduced into said water-gas shift conversion zone.

Claim 11

The process of claim 6 wherein said second liquid solvent absorbent is an aqueous solution of copper ammonium acetate.

Claim 12

The process of claim 1 provided with the additional step of introducing a portion of the recovered oil into a partial oxidation generator as at least a portion of the hydrocarbonaceous feed to produce said raw synthesis gas.

Claim 13

The process of claim 1 wherein said first liquid solvent absorbent is selected from the group consisting of methanol, N-methyl-pyrrolidone, and dimethyl ether of polyethylene glycol.

Claim 14

The process of claim 1 wherein said raw feed gas is produced by the partial oxidation of a hydrocarbonaceous feed at a temperature in the range of about 1300° to 3500° F and a pressure in the range of about 3 to 250 atomspheres absolute.

Claim 15

The process of claim 11 wherein at least a portion of said hydrocarbonaceous feed is selected from the group consisting of petroleum distillate and residua, gas oil, fuel oil, residual fuel, reduced crude, whole crude, asphalt, coal tar, coal oil, shale oil, tar sand oil, and mixtures thereof.

Claim 16

The process of claim 11 wherein at least a portion of said hydrocarbonaceous feed comprises a pumpable slurry of solid carbonaceous fuels selected from the group consisting of coal, coal char, particulate carbon, petroleum coke, and mixtures thereof, in H 2 O or in a liquid hydrocarbonaceous fuel.

Claim 17

The process of claim 11 wherein at least a portion of said hydrocarbonaceous feed comprises a liquid hydrocarbon material containing combined oxygen selected from the group consisting of alcohols, ketones, aldehydes, organic acids, esters, ethers, and mixtures thereof, optionally in admixture with a liquid petroleum material.

Claim 18

A process for producing a hydrogen-rich gas stream comprising: 1. reacting a hydrocarbonaceous feed by partial oxidation with a free-oxygen containing gas in the presence of a temperature moderator in the reaction zone of a free-flow synthesis gas generator at a temperature in the range of about 1300° to 3500° F and a pressure in the range of about 3 to 250 atmospheres to produce a raw feed gas stream comprising H 2 , CO, CO 2 , H 2 O, H 2 S, COS, particulate carbon, and optionally CH 4 , N 2 and A; 2. removing said particulate carbon from said raw feed gas stream in a gas scrubbing zone; 3. mixing supplemental H 2 O and a by-product CO-rich gas stream as produced subsequently in the process with the clean feed gas stream from (2) and introducing the mixture into a water-gas shift conversion zone, and reacting CO and H 2 O in said shift conversion zone to produce H 2 and CO 2 ; 4. drying and cooling the process gas stream from (3) to condense out and separate a portion of the H 2 O, CO 2 , H 2 S, and COS;

Claim 19

A process for producing a hydrogen-rich gas stream comprising: 1. reacting a hydrocarbonaceous feed by partial oxidation with a free-oxygen containing gas in the presence of a temperature moderator in the reaction zone of a free-flow synthesis gas generator at a temperature in the range of about 1300° to 3500° F and a pressure in the range of about 3 to 250 atmospheres to produce a raw feed gas stream comprising H 2 , CO, CO 2 , H 2 O, H 2 S, COS, particulate carbon, and optionally CH 4 , N 2 and A; 2. removing said particulate carbon from said raw feed gas stream in a gas scrubbing zone; 3. mixing supplemental H 2 O and a by-product CO-rich gas stream as produced subsequently in the process with the clean feed gas stream from (2) and introducing the mixture into a water-gas shift conversion zone, and reacting CO and H 2 O in said shift conversion zone to produce H 2 and CO 2 ; 4. drying and cooling the process gas stream from (3) to condense out and separate a portion of the H 2 O, CO 2 , H 2 S, and COS;

Claim 20

contacting the process gas stream from (4) in an acid-gas absorption zone with a first liquid solvent absorbent which absorbs the remaining portion of said H 2 O, CO 2 , H 2 S, and COS, thereby producing a rich first liquid solvent absorbent and a dry gas stream free from acid gas; 6. contacting the dry acid gas-free process gas stream leaving (5) in a CO-absorption zone with a second liquid solvent absorbent which absorbs substantially all of the remaining CO in said process gas stream and producing said H 2 -rich product gas stream; 7. regenerating said second liquid solvent absorbent to produce a lean solution of said second liquid solvent absorbent and said by-product CO-rich gas stream; 8. recycling said CO-rich gas stream to (3) as previously described; and 9. recycling said lean solution of second liquid solvent absorbent to the CO absorption zone in (6).

Claim 21

contacting the process gas stream from (4) in an acid-gas absorption zone with a first liquid solvent absorbent which absorbs the remaining portion of said H 2 O, CO 2 , H 2 S, and COS, thereby producing a rich first liquid solvent absorbent and a dry gas stream free from acid gas; 6. contacting the dry acid gas-free process gas stream leaving (5) in a CO-absorption zone with a second liquid solvent absorbent which absorbs substantially all of the remaining CO in said process gas stream and producing said H 2 -rich product gas stream; 7. regenerating said second liquid solvent absorbent to produce a lean solution of said second liquid solvent absorbent and said by-product CO-rich gas stream; 8. recycling said CO-rich gas stream to (3) as previously described; and 9. recycling said lean solution of second liquid solvent absorbent to the CO absorption zone in (6).

Claim 22

The process of claim 15 provided with the additional steps of regenerating said rich first liquid solvent absorbent from step (5) in a regeneration zone by flashing plus stripping with a portion of said dry acid gas-free gas stream from step (5), thereby producing a first liquid solvent absorbent containing H 2 S and optionally COS, and a gaseous stream comprising CO 2 -rich gas in admixture with said stripping gas; regenerating said first liquid solvent absorbent by boiling to produce an H 2 S-rich stream and a lean first liquid solvent absorbent stream; recycling said lean first liquid solvent stream to step (5), and introducing said H 2 S-rich stream into a sulfur recovery zone; introducing said gaseous stream comprising CO 2 -rich gas in admixture with stripping gas into a subterranean formation to facilitate the secondary recovery of oil; and introducing a portion of said recovered oil into the reaction zone of said gas generator as at least a portion of said hydrocarbonaceous feed.

Claim 23

The process of claim 15 provided with the additional steps of regenerating said rich first liquid solvent from step (5) in a regeneration zone by a combination of flashing plus reboiling, thereby producing a gaseous stream comprising a CO 2 -rich gas, a separate gaseous stream comprising an H 2 S-rich gas, and a lean first liquid solvent stream; recycling said lean first liquid solvent to said acid-gas absorption zone; introducing said CO 2 -rich gas into a subterranean formation to facilitate the secondary recovery of a hydrocarbonaceous material; and introducing said recovered hydrocarbonaceous material into the reaction zone of said gas generator as at least a portion of said hydrocarbonaceous feed.

Claim 24

The process of claim 15 wherein a gaseous stream comprising a mixture of CO 2 -rich gas and H 2 S-rich gas is produced by regenerating said rich first liquid solvent; and said gaseous stream is introduced into said subterranean formation to facilitate the secondary recovery of said hydrocarbonaceous material.

Claim 25

In a process for producing synthesis gas, hydrogen-rich gas, and by-product CO 2 -rich gas by reacting a hydrocarbonaceous feed by partial oxidation with a free-oxygen containing gas optionally in the presence of a temperature moderator in the reaction zone of a free-flow gas generator at a temperature in the range of about 1300° to 3500° F. and a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream; cooling said effluent gas stream and removing particulate carbon therefrom thereby producing a clean process gas stream comprising H 2 , CO, CO 2 , H 2 O, H 2 S, COS and optionally CH 4 , N 2 , and A; introducing said clean, feed gas stream containing supplemental water into a water-gas shift reaction zone and reacting CO and H 2 O to produce H 2 and CO 2 ; and removing CO 2 , H 2 S and COS in an acid-gas absorption zone with a first liquid solvent absorbent, thereby producing a rich first liquid solvent absorbent and a dry product gas stream free from acid gas; the improvement comprising: 1. contacting at least a portion of said dry acid gas-free product gas in a CO-absorption zone with a second solvent absorbent which absorbs substantially all of the remaining CO in said process gas stream, and thereby producing said H 2 -rich product gas stream; 2. regenerating said second liquid solvent absorbent to produce a lean solution of said second liquid solvent absorbent and a by-product CO-rich gas stream; 3. recycling said CO-rich gas stream to said water-gas shift conversion zone to produce additional hydrogen; 4. recycling at least a portion of said lean solution of second liquid solvent absorbent to the CO absorption zone in (1); 5. regenerating a portion of said first liquid solvent absorbent in a regeneration zone by flashing, boiling, and stripping with a stripping gas obtained from within the process and selected from the group consisting of a portion of said clean process gas stream, a portion of said dry product gas stream free from acid gas, and a portion of said H 2 -rich product gas stream, thereby producing a gaseous by-product stream comprising CO 2 -rich gas in admixture with said stripping gas, and a first liquid absorbent containing H 2 S and optionally COS; 6. boiling the first liquid solvent absorbent leaving (5) to produce an H 2 S-rich stream and a lean first liquid solvent absorbent stream;

Claim 26

In a process for producing synthesis gas, hydrogen-rich gas, and by-product CO 2 -rich gas by reacting a hydrocarbonaceous feed by partial oxidation with a free-oxygen containing gas optionally in the presence of a temperature moderator in the reaction zone of a free-flow gas generator at a temperature in the range of about 1300° to 3500° F. and a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream; cooling said effluent gas stream and removing particulate carbon therefrom thereby producing a clean process gas stream comprising H 2 , CO, CO 2 , H 2 O, H 2 S, COS and optionally CH 4 , N 2 , and A; introducing said clean, feed gas stream containing supplemental water into a water-gas shift reaction zone and reacting CO and H 2 O to produce H 2 and CO 2 ; and removing CO 2 , H 2 S and COS in an acid-gas absorption zone with a first liquid solvent absorbent, thereby producing a rich first liquid solvent absorbent and a dry product gas stream free from acid gas; the improvement comprising: 1. contacting at least a portion of said dry acid gas-free product gas in a CO-absorption zone with a second solvent absorbent which absorbs substantially all of the remaining CO in said process gas stream, and thereby producing said H 2 -rich product gas stream; 2. regenerating said second liquid solvent absorbent to produce a lean solution of said second liquid solvent absorbent and a by-product CO-rich gas stream; 3. recycling said CO-rich gas stream to said water-gas shift conversion zone to produce additional hydrogen; 4. recycling at least a portion of said lean solution of second liquid solvent absorbent to the CO absorption zone in (1); 5. regenerating a portion of said first liquid solvent absorbent in a regeneration zone by flashing, boiling, and stripping with a stripping gas obtained from within the process and selected from the group consisting of a portion of said clean process gas stream, a portion of said dry product gas stream free from acid gas, and a portion of said H 2 -rich product gas stream, thereby producing a gaseous by-product stream comprising CO 2 -rich gas in admixture with said stripping gas, and a first liquid absorbent containing H 2 S and optionally COS; 6. boiling the first liquid solvent absorbent leaving (5) to produce an H 2 S-rich stream and a lean first liquid solvent absorbent stream;

Claim 27

recycling said lean first liquid solvent stream to said acid-gas absorption zone; and introducing said H 2 S-rich stream into a sulfur recovery zone; 8. introducing said gaseous by-product stream comprising CO 2 -rich gas in admixture with stripping gas from (5) into a subterranean formation to facilitate the recovery of oil; and 9. introducing a portion of said recovered oil into the reaction zone of said gas generator as at least a portion of said hydrocarbonaceous feed.

Claim 28

recycling said lean first liquid solvent stream to said acid-gas absorption zone; and introducing said H 2 S-rich stream into a sulfur recovery zone; 8. introducing said gaseous by-product stream comprising CO 2 -rich gas in admixture with stripping gas from (5) into a subterranean formation to facilitate the recovery of oil; and 9. introducing a portion of said recovered oil into the reaction zone of said gas generator as at least a portion of said hydrocarbonaceous feed.