Production of cleaned and purified synthesis gas and carbon monoxide

Claim 2

Process for the simultaneous production of a product stream of cleaned and purified synthesis gas and a CO-rich product-gas stream comprising: (1) reacting a hydrocarbonaceous or oxygenated hydrocarbonaceous organic material with a free-oxygen containing gas, optionally in the presence of a temperature moderator in the reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300° to 3000° F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H 2 , CO, H 2 O, solid particles of carbon and ash and at least one gas from the group consisting of CO 2 , H 2 S, COS, Ch 4 , NH 3 , N 2 , and A;

Claim 3

(2) splitting the effluent gas stream from (1) into first and second gas streams, and simultaneously processing said first and second gas streams in separate first and second trains;

Claim 4

(2) splitting the effluent gas stream from (1) into first and second gas streams, and simultaneously processing said first and second gas streams in separate first and second trains;

Claim 5

(3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone; cleaning to remove any entrained solids, and removing water;

Claim 6

(3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone; cleaning to remove any entrained solids, and removing water;

Claim 7

(4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur compounds;

Claim 8

(4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur compounds;

Claim 9

(5) dividing the cleaned and purified stream of synthesis gas from (4) into two streams and introducing the first of these streams into a CO-separation zone from which said product stream of CO-rich gas and a separte stream of H 2 -rich gas are removed;

Claim 10

(5) dividing the cleaned and purified stream of synthesis gas from (4) into two streams and introducing the first of these streams into a CO-separation zone from which said product stream of CO-rich gas and a separte stream of H 2 -rich gas are removed;

Claim 11

(6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5;

Claim 12

(6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5;

Claim 13

(7) reacting together CO and H 2 O in the gas streams from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream;

Claim 14

(7) reacting together CO and H 2 O in the gas streams from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream;

Claim 15

(8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at lest one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas stream free from gaseous sulfur compounds; and

Claim 16

(8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at lest one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas stream free from gaseous sulfur compounds; and

Claim 17

(9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and pruified H 2 -rich gas stream from (8) to produce said product stream of cleaned and purified synthesis gas.

Claim 18

(9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and pruified H 2 -rich gas stream from (8) to produce said product stream of cleaned and purified synthesis gas.

Claim 19

The process of claim 1 in which the effluent gas stream from the reaction zone in step (1) and the cleaned and purified stream of synthesis gas from step (4) have a mole ratio H 2 /CO in the range of about 0.5 to 1.9, and the product stream of cleaned and purified synthesis gas has a mole ratio H 2 /CO in the range of about 2 to 12.

Claim 20

The process of claim 2 in which said product stream of cleaned and purified synthesis gas is methanol synthesis gas having a H 2 /CO mole ratio in the range of about 2-4.

Claim 21

The process of claim 1 in which said product stream of cleaned and purified synthesis gas is delivered at a pressure which is about that in the synthesis gas generator less ordinary drop in the lines and equipment.

Claim 22

The process of claim 1 in which the following gas streams contain substantially no water: (a) the purified stream of synthesis gas from step (4), (b) the cleaned and purified H 2 -rich gas streams from steps (5) and (8), and (c) the CO-rich gas stream from step (5).

Claim 23

The process of claim 1 in which said product stream of CO-rich gas is substantially pure CO containing about 95-99 mole percent CO.

Claim 24

The process of claim 1 in which said second split stream from step (2) contains about 20 to 70 volume percent of the effluent gas stream from step (1), the remainder of which comprising said first split stream.

Claim 25

The process of claim 1 in which the cleaned and purified stream of synthesis gas is divided in step (5) into said first stream containing 5 to 50 volume percent and into said second divided stream contaning the remainder of said cleaned and purified stream of synthesis gas.

Claim 26

The process of claim 1 provided with the additional step of preheating the second gas stream from step (6) to a temperature in the range of about 600° to 850° F. and reacting said gas stream in step (7) while in contact with a water-gas shift catalyst comprising iron oxide -- chromium oxide promoted by 1 to 15 weight percent of an oxide of a metal selected from the group, K, Th, U, Be, and Sb.

Claim 27

The process of claim 1 in which said second gas stream from step (6) is reacted in step (7) while in contact with a water-gas shift catalyst which comprises a Co-Mo catalyst comprising in weight percent CoO 2-5, MoO 3 8-16, MgO nil-20, and Al 2 O 3 59-85.

Claim 28

The process of claim 1 in which said second gas stream from step (6) is reacted in step (7) while in contact with a water-gas shift catalyst which comprises copper and zinc salts or oxides in the weight ratio of about 3 parts by weight zinc and 1 part copper.

Claim 29

The process of claim 1 in which said free-oxygen containing gas is substantially pure oxygen (95 mole percent O 2 or more).

Claim 30

The process of claim 1 in which said hydrocarbonaceous feedstock is selected from the group consisting of liquified petroleum gas, petroleum distillates and residua, naphtha, gas oil, residual fuel, reduced crude, whole crude, asphalt, coal tar, coal-derived oil, shale oil, tarsand oil, and pumpable slurries of coal, particulate carbon, and petroleum cole in water or in liquid hydrocarbon fuel, and mixtures thereof.

Claim 31

The process of claim 1 in which said hydrocarbonaceous feedstock is selected from the group consisting of methane, propane, natural gas, water-gas, coke-oven gas, synthesis gas, refinery gas, and mixtures thereof.

Claim 32

The process of claim 1 in which said hydrocarbonaceous feedstocks are organic materials selected from the group consisting of carbohydrates, cellulosic materials, aldehydes, organic acids, alcohols, ketones, oxygenated fuel oil, waste liquids, and by-products from chemical processes containing oxygenated hydrocabonaceous organic materials, and mixtures thereof.

Claim 33

The process of claim 1 in which a portion of the gas stream from step (3), or a portion of the H 2 -rich gas stream from step (7) after removal of water, or a portion of each of said gas streams by-pass said first and second gas purification zones in their respective lines; and mixing separately each by-pass gas stream with its related purified gas stream.

Claim 34

The process of claim 1 in which a portion of the H 2 -rich gas stream from step (8), or a portion of the product stream of cleaned and purified synthesis gas from step (9), or a portion of each of said gas streams are recycled to the gas generator in step (1).

Claim 35

A process for producing substantially pure methanol and a by-product stream of CO-rich gas comprising: (1) reacting a hydrocarbonaceous and oxygen-containing hydrocarbonaceous organic material with substantially pure oxygen optionally in the presence of H 2 O in a reaction zone of a free-flow noncatalytic partial oxidation gas generator at a temperature in the range of about 1300° to 3000° F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H 2 , CO, H 2 O, solid particles of carbon and ash and at least one gas from the group consisting of CO 2 , H 2 S, COS, CH 4 , NH 3 , N 2 , and A; and wherein said effluent gas stream has a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (2) splitting the efflucent gas stream from (1) into first and second gas streams, wherein said second split stream contains about 20 to 70 volume % of the effluent gas stream from (1), and the remainder of which comprising said first split stream, and simultaneously processing said first and second gas streams in separate first and second trains; (3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone, cleaning to remove any entrained solids, and removing water; (4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur-compounds and having a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (5) dividing the cleaned and purified stream of synthesis gas from (4) into a first stream containing 5 to 50 volume percent and into a second stream containing the remainder of said cleaned and purified stream of synthesis gas, and introducing the first of these streams into a CO-separation zone from which said by-product stream of CO-rich gas and a separate stream of H 2 -rich gas are removed; (6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5; (7) reacting together CO and H 2 O in the gas stream from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream; (8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas steam freefrom gaseous sulfur-compounds; (9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and purified H 2 -rich gas stream from (8) to produce a stream of cleaned and purified methanol synthesis gas having a mole ratio H 2 /CO in the range of about 2-4; (10) reacting at least a portion of said methanol synthesis gas in the presence of a methanol catalyst in a methanol-synthesis zone at a temperature in the range of about 400° to 750° F and at a pressure in the range of about 40 to 350 atm. to produce crude methanol, and purifying said crude methanol to oxygen-containing substantially pure methanol and by-product oxygen-contaning organic materials; and (11) introducing at least a portion of said by-product oxygen-containing organic materials into the reaction zone of the partial oxidation gas generator in (1) as at least a portion of said oxygen-containing hydrocarbonaceous organic material.

Claim 36

A process for producing substantially pure methanol and a by-product stream of CO-rich gas comprising: (1) reacting a hydrocarbonaceous and oxygen-containing hydrocarbonaceous organic material with substantially pure oxygen optionally in the presence of H 2 O in a reaction zone of a free-flow noncatalytic partial oxidation gas generator at a temperature in the range of about 1300° to 3000° F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H 2 , CO, H 2 O, solid particles of carbon and ash and at least one gas from the group consisting of CO 2 , H 2 S, COS, CH 4 , NH 3 , N 2 , and A; and wherein said effluent gas stream has a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (2) splitting the efflucent gas stream from (1) into first and second gas streams, wherein said second split stream contains about 20 to 70 volume % of the effluent gas stream from (1), and the remainder of which comprising said first split stream, and simultaneously processing said first and second gas streams in separate first and second trains; (3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone, cleaning to remove any entrained solids, and removing water; (4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur-compounds and having a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (5) dividing the cleaned and purified stream of synthesis gas from (4) into a first stream containing 5 to 50 volume percent and into a second stream containing the remainder of said cleaned and purified stream of synthesis gas, and introducing the first of these streams into a CO-separation zone from which said by-product stream of CO-rich gas and a separate stream of H 2 -rich gas are removed; (6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5; (7) reacting together CO and H 2 O in the gas stream from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream; (8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas steam freefrom gaseous sulfur-compounds; (9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and purified H 2 -rich gas stream from (8) to produce a stream of cleaned and purified methanol synthesis gas having a mole ratio H 2 /CO in the range of about 2-4; (10) reacting at least a portion of said methanol synthesis gas in the presence of a methanol catalyst in a methanol-synthesis zone at a temperature in the range of about 400° to 750° F and at a pressure in the range of about 40 to 350 atm. to produce crude methanol, and purifying said crude methanol to oxygen-containing substantially pure methanol and by-product oxygen-contaning organic materials; and (11) introducing at least a portion of said by-product oxygen-containing organic materials into the reaction zone of the partial oxidation gas generator in (1) as at least a portion of said oxygen-containing hydrocarbonaceous organic material.

Claim 37

The process of claim 18 in which said methanol catalyst comprises zinc oxide and chromium oxide, the temperature in said methanol-synthesis zone is in the range of about 650° to 750° F., and the pressure is in the range of about 250 to 350 atm.

Claim 38

The process of claim 18 in which said methanol catalyst comprises copper oxide, zinc oxide, chromium oxide or aluminum oxide, the temperature in said methanol-synthesis zone is in the range of about 400° to 660° F., and the pressure is in the range of about 40 to 250 atm.

Claim 39

The process of claim 18 in which the pressure in said methanol-synthesis zone is the same as that in the synthesis-gas generator less ordinary pressure drop in the lines and equipment.

Claim 40

The process of claim 18 in which at least a portion of said substantially pure methanol is used in said first and second gas-purification zones to absorb gaseous impurities from the gas streams.

Claim 41

The process of claim 18 in which the mole ratio H 2 12CO+3CO 2 of the cleaned and purified methanol synthesis gas from step 9 is in the range of less than 1.05 and greater than 1.01.

Claim 42

A process for producing acetic acid comprising: (1) reacting hydrocarbonaceous and oxygen-containing hydrocarbonaceous organic material with substantially pure oxygen optionally in the presence of H 2 O in a reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300° to 3000° F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H 2 , CO, H 2 O, solid particles of carbon and ash and at least one gas from the group consisting of CO 2 , H 2 S, COS, CH 4 , NH 3 , N 2 , and A; and wherein said effluent gas stream has a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (2) splitting the effluent gas stream from (1) into first and second gas streams, wherein said second split stream contains about 20 to 70 volume % of the effluent gas stream from (1), and the remainder of which comprising said first split stream, and simultaneously processing said first and second gas streams in separate first and second trains; (3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone, cleaning to remove any entrained solids, and removing water; (4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur-compounds and having a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (5) dividing the cleaned and purified stream of synthesis gas from (4) into a first stream containing 5 to 50 volume percent and into a second stream containing the remainder of said cleaned and purified stream of synthesis gas, and introducing the first of these stream into a CO-separation zone from which a stream of substantially pure CO gas and a separate stream of H 2 -rich gas are removed; (6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5; (7) reacting together CO and H 2 O in the gas stream from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream; (8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas stream free-form gaseous sulfur-compunds; (9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and purified H 2 -rich gas stream from (8) to produce a stream of cleaned and purified methanol synthesis gas having a mole ratio H 2 /CO in the range of about 2-4; (10) reacting at least a portion of said methanol synthesis gas in the presence of a methanol catalyst in a methanol-synthesis zone at a temperature in the range of about 400° to 750° F and at a pressure in the range of about 40 to 350 atm. to produce crude methanol, and purifying said crude methanol to produce substantially pure methanol and by-product oxygen-containing organic materials; (11) reacting at least a portion of said substantially pure methanol with at least a portion of said substantially pure carbon monoxide in the presence of a carbonylation catalyst in an acetic acid-synthesis zone at a temperature in the range of about 302° to 608° F and at a pressure in the range of about 1 to 700 atmospheres to produce impure acetic acid, and purifying said impure acetic acid to produce substantially pure acetic acid and by-product oxygen-containing organic materials; and (12) introducing at least a portion of said by-product oxygen-containing organic materials from (10), or (11), or both into the reaction zone of the partial oxidation gas generator in (1) as at least a portion of said oxygen-containing hydrocarbonaceous organic material.

Claim 43

A process for producing acetic acid comprising: (1) reacting hydrocarbonaceous and oxygen-containing hydrocarbonaceous organic material with substantially pure oxygen optionally in the presence of H 2 O in a reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300° to 3000° F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H 2 , CO, H 2 O, solid particles of carbon and ash and at least one gas from the group consisting of CO 2 , H 2 S, COS, CH 4 , NH 3 , N 2 , and A; and wherein said effluent gas stream has a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (2) splitting the effluent gas stream from (1) into first and second gas streams, wherein said second split stream contains about 20 to 70 volume % of the effluent gas stream from (1), and the remainder of which comprising said first split stream, and simultaneously processing said first and second gas streams in separate first and second trains; (3) cooling said first gas stream from (2) in said first train by indirect heat exchange in a separate heat-exchange zone, cleaning to remove any entrained solids, and removing water; (4) purifying at least a portion of the gas stream from (3) in a first gas-purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 , to produce a cleaned and purified stream of synthesis gas free-from gaseous sulfur-compounds and having a mole ratio H 2 /CO in the range of about 0.5 to 1.9; (5) dividing the cleaned and purified stream of synthesis gas from (4) into a first stream containing 5 to 50 volume percent and into a second stream containing the remainder of said cleaned and purified stream of synthesis gas, and introducing the first of these stream into a CO-separation zone from which a stream of substantially pure CO gas and a separate stream of H 2 -rich gas are removed; (6) cooling and cleaning said second gas stream from (2) by direct contact with water thereby removing the solid particles entrained therein and increasing the H 2 O/CO mole ratio of said gas stream to a value in the range of about 2 to 5; (7) reacting together CO and H 2 O in the gas stream from (6) in a water-gas shift conversion zone to produce a H 2 -rich gas stream; (8) removing H 2 O and purifying at least a portion of the H 2 -rich gas stream from (7) in a second-gas purification zone and separating therefrom at least one gas from the group CO 2 , H 2 S, COS, CH 4 , and NH 3 to produce a cleaned and purified H 2 -rich gas stream free-form gaseous sulfur-compunds; (9) mixing at least a portion of said second divided stream of cleaned and purified synthesis gas from (5) with from 0 to 100% of said H 2 -rich gas stream from (5) and at least a portion of said cleaned and purified H 2 -rich gas stream from (8) to produce a stream of cleaned and purified methanol synthesis gas having a mole ratio H 2 /CO in the range of about 2-4; (10) reacting at least a portion of said methanol synthesis gas in the presence of a methanol catalyst in a methanol-synthesis zone at a temperature in the range of about 400° to 750° F and at a pressure in the range of about 40 to 350 atm. to produce crude methanol, and purifying said crude methanol to produce substantially pure methanol and by-product oxygen-containing organic materials; (11) reacting at least a portion of said substantially pure methanol with at least a portion of said substantially pure carbon monoxide in the presence of a carbonylation catalyst in an acetic acid-synthesis zone at a temperature in the range of about 302° to 608° F and at a pressure in the range of about 1 to 700 atmospheres to produce impure acetic acid, and purifying said impure acetic acid to produce substantially pure acetic acid and by-product oxygen-containing organic materials; and (12) introducing at least a portion of said by-product oxygen-containing organic materials from (10), or (11), or both into the reaction zone of the partial oxidation gas generator in (1) as at least a portion of said oxygen-containing hydrocarbonaceous organic material.

Claim 44

The process of claim 24 in which said carbonylation catalyst comprises a carbonyl-forming metal selected from the group Fe, Co, and Ni in the form of a salt, and a halogen selected from the group I, Br, Cl in the form of a free halogen or halogen compound, and the temperature in said acetic acid-synthesis zone is in the range of about 338° to 608° F. and the pressure is in the range of about 15 to 700 atmospheres.

Claim 45

The process of claim 24 in which said carbonylation catalyst comprises in admixture (1) a noble metal from the group rhodium, palladium, platinum, iridium, osmium, and ruthenium in the form of an oxide, organometallic compound, salt, or coordination compound; (2) a halogen or halogen-compound promoter; and (3) a dispersant selected from the group, acetic acid and water, pumice, alumina, activated carbon, and silica; and the temperature in said acetic acid-synthesis zone is in the range of 302° to 392° F and the pressure is in the range of about 34 to 680 atm. for liquid-phase reaction.

Claim 46

The process of claim 24 in which the temperature in said acetic acid-synthesis zone is in the range of about 392° to 572° F and the pressure is in the range of about 1 to 10 atm. for vapor-phase reaction.

Claim 47

The process of claim 24 in which the pressure in said acetic acid-synthesis zone is the same as that in said synthesis-gas generator less ordinary pressure drop in the lines and equipment.