Conversion of synthesis gas to hydrocarbon mixtures utilizing dual reactors

Claim 1

In a processing combination comprising the steps of coal gasification to produce H 2 and CO, F-T hydrocarbon synthesis from said H 2 and CO and upgrading the product of F-T synthesis to produce more desirable gaseous hydrocarbon products, gasoline and distillate material wherein said coal gasification is carried out in a gasifier characterized by: (1) being capable of producing syngas with less than 30 lbs. of steam per MSCF of syngas, (2) producing a low ratio syngas with a H 2 /CO ratio of 0.4 to 1, and (3) a gasifier exit gas temperature of less than 2000° F., the improvement which comprises: charging said low ratio H 2 /CO syngas to an F-T syngas conversion zone comprising a catalyst providing water gas shift and CO reducing characteristics in a single or a combination of catalyst particles in direct contact with a suspending liquid medium providing temperature control of the exothermic syngas conversion reaction about the particle of catalyst, recovering heat from said F-T syngas conversion zone in the form of medium pressure steam and utilizing said steam in said coal gasifier or its associated oxygen generation plant; recovering a product of said Fischer-Tropsch syngas conversion comprising hydrocarbon in a range of C 1 to C 50 hydrocarbons and oxygenates, and converting hydrocarbons and oxygenates recovered from said F-T operation with a special crystalline zeolite catalyst providing a constraint index in the range of 1 to 12, a silica to alumina ratio of at least 12 and a dried crystal density of not less than about 1.6 grams per cubic centimeter to premium products comprising gaseous LPG products, gasoline and distillate material.