Two-stage integrated coking for chemicals and coke gasification process

Claim 2

In an integrated coking and gasification process comprising the steps of: (a) reacting a carbonaceous material having a Conradson carbon content of at least 10 weight percent in a coking zone containing a bed of fluidized solids maintained at fluid coking conditions including a temperature ranging from about 850° F. to about 1195° F., to form a vaporous coking zone conversion product and coke, said coke depositing on said fluidized solids; (b) introducing a portion of said solids with the coke deposition thereon into a heating zone operated at a temperature greater than said coking zone temperature to heat said portion of solids; (c) recycling a first portion of heated solids from said heating zone to said coking zone and introducing a second portion of said heated solids to a fluid bed gasification zone maintained at a temperature greater than the temperature of said heating zone, and (d) passing said vaporous coking zone conversion product with entrained solids to a gas-solids separation zone, the improvement which comprises withdrawing a portion of solids from the gasification zone and introducing said portion of solids into said gas-solids separation zone in an amount sufficient to maintain said gas-solids separation zone at a temperature in the range of about 1200 to about 1700 degrees Fahrenheit to convert at least 20 weight percent of the coking zone vaporous product to unsaturated hydrocarbons having less than 6 carbon atoms.

Claim 3

The process of claim 1 wherein said portion of gasification zone solids is introduced into said vaporous coking zone product passing into said gas-solids separation zone.

Claim 4

The process of claim 1 wherein said portion of gasification zone solids is introduced directly into said gas-solids separation zone.

Claim 5

The process of claim 1 wherein said coking zone is maintained at a temperature ranging from about 900° to about 1100° F.

Claim 6

The process of claim 1 wherein said gasification zone is maintained at a temperature ranging from about 1500° to about 2000° F.

Claim 7

The process of claim 1 wherein said gasification zone is maintained at a temperature ranging from about 1600° to about 2000° F.

Claim 8

The process of claim 1 wherein said coking zone and said gasification zone are each maintained at a pressure ranging from about 5 to about 150 psig.

Claim 9

In an integrated coking and gasification process comprising the steps of: (a) reacting a carbonaceous material having a Conradson carbon content of at least 10 weight percent in a coking zone containing a bed of fluidized solids maintained at a temperature ranging from about 900° to about 1100° F. to form a vaporous coking zone product and coke, said coke depositing on said fluidized solids; (b) introducing a portion of said solids with the coke deposition thereon into a heating zone operated at a temperature greater than said coking zone temperature to heat said portion of solids; (c) recycling a first portion of heated solids from said heating zone to said coking zone; (d) introducing a second portion of heated solids to a fluid bed gasification zone maintained at a temperature ranging from about 1500° to about 2000° F.; (e) reacting said portion of heated solids in said gasification zone with steam and an oxygen-containing gas to produce a hot gaseous stream containing hydrogen and carbon monoxide; (f) introducing said hot gaseous stream and entrained solids into said heating zone; (g) passing an additional stream of solids from said gasification zone to said heating zone, and (h) passing said vaporous coking zone conversion product with entrained solids to a gas-solids separation zone, the improvement which comprises passing a portion of solids from said gasification zone to said gas-solids separation zone in an amount sufficient to maintain said gas-solids separation zone at a temperature in the range of about 1200 to about 1700 degrees Fahrenheit, to convert at least 20 weight percent of said vaporous coking zone product to unsaturated hydrocarbons having less than 6 carbon atoms.

Claim 10

In an integrated coking and gasification process comprising the steps of: (a) reacting a carbonaceous material having a Conradson carbon content of at least 10 weight percent in a coking zone containing a bed of fluidized solids maintained at a temperature ranging from about 900° to about 1100° F. to form a vaporous coking zone product and coke, said coke depositing on said fluidized solids; (b) introducing a portion of said solids with the coke deposition thereon into a heating zone operated at a temperature greater than said coking zone temperature to heat said portion of solids; (c) recycling a first portion of heated solids from said heating zone to said coking zone; (d) introducing a second portion of heated solids to a fluid bed gasification zone maintained at a temperature ranging from about 1500° to about 2000° F.; (e) reacting said portion of heated solids in said gasification zone with steam and an oxygen-containing gas to produce a hot gaseous stream containing hydrogen and carbon monoxide; (f) introducing said hot gaseous stream and entrained solids into said heating zone; (g) passing an additional stream of solids from said gasification zone to said heating zone, and (h) passing said vaporous coking zone conversion product with entrained solids to a gas-solids separation zone, the improvement which comprises passing a portion of solids from said gasification zone to said gas-solids separation zone in an amount sufficient to maintain said gas-solids separation zone at a temperature in the range of about 1200 to about 1700 degrees Fahrenheit, to convert at least 20 weight percent of said vaporous coking zone product to unsaturated hydrocarbons having less than 6 carbon atoms.

Claim 11

The process of claim 8 wherein said gasification zone is maintained at a temperature ranging from about 1600° to about 2000° F.

Claim 12

The process of claim 8 wherein said portion of solids from said gasification zone is passed to said gas-solids separation zone in an amount sufficient to maintain said gas-solids separation zone at a temperature in the range of about 1300 to about 1500 degrees Fahrenheit.