Production of demercurized synthesis gas, reducing gas, or fuel gas

Claim 2

A process for the production of demercurized synthesis gas, reducing gas, or fuel gas comprising: (1) reacting a mercury-containing fossil fuel feed by partial oxidation with a free-oxygen containing gas with or without a temperature moderator in a reaction zone provided with a reducing atmosphere at a temperature in the range of about 1800° F. to 3000° F. and a pressure in the range of about 10 atmospheres or higher to produce a raw effluent gas stream comprising H 2 , CO, H 2 O, CO 2 , H 2 S, COS, entrained slag and/or ash, and optionally CH 4 , NH 3 , N 2 and Ar; and wherein substantially all of the mercury in the feed is converted into elemental mercury vapor which leaves the reaction zone entrained in the raw effluent gas stream; (2) cooling, cleaning, and demoisturizing the raw effluent gas stream from (1); (3) introducing the gas stream from (2) into a gas scrubbing zone where at a temperature in the range of about -50° C. to 80° C. and a pressure of about 10 atmospheres or higher, said gas stream is contacted by a stream of gas scrubbing solvent thereby condensing about 20 to 100 wt. % of the mercury vapor and removing from about 90 to 100 wt. % of the sulfur-containing gases; and (4) removing the following streams from the gas scrubbing zone: (a) a clean and demercurized stream of synthesis gas, reducing gas, or fuel gas containing about 0 to 80 wt. % of the mercury entering the gas scrubber, (b) rich gas scrubbing solvent containing a major portion of the remaining mercury entering the gas scrubber entrained in condensed form; and (c) sludge or drainage containing the remainder of the mercury or its compounds in condensed form entering the gas scrubber.

Claim 3

The process of claim 1 wherein said reaction zone is a vertical downflowing free-flow refractory lined chamber with the reactants being introduced at the top by way of a burner, and with the raw effluent gas stream removed from the bottom of said chamber.

Claim 4

The process of claim 1 where in (2) the raw effluent gas stream from (1) is cooled to a temperature in the range of about -50° C. to 80° C. by heat exchange with at least one coolant.

Claim 5

The process of claim 1 wherein the raw effluent gas stream from (1) is cooled and cleaned by direct contact with water.

Claim 6

The process of claim 1 wherein the cooling, cleaning, and demoisturizing in (2) includes the steps of: (a) passing the raw effluent gas stream from (1) through a radiant cooler where at least a portion of the entrained slag and/or ash separate out, and the effluent gas stream is cooled to a temperature in the range of about 500° C. to 800° C., by noncontact heat exchange with H 2 O; (b) scrubbing the cooled gas stream from (a) with water to remove particulate matter; and (c) cooling the partially cooled gas stream from (b) in at least one convection cooler to a temperature below the dew point, separating out water, and adjusting the temperature of the gas stream to about -50° C. to 80° C.

Claim 7

The process of claim 1 provided with the step of contacting the demercurized gas stream from (4)(a) with activated carbon sorbent, thereby removing substantially all of any remaining mercury vapor and sulfur-containing gas in the process gas stream.

Claim 8

The process of claim 1 wherein said gas scrubbing solvent is selected from the group consisting of methanol, N-methyl-pyrrolidone, di and triethanolamine, and methyl diethanolamine.

Claim 9

The process of claim 1 provided with the step of regenerating said stream of rich gas scrubbing solvent (4)(b) by at least one of the following process steps: flashing, stripping with steam or an inert gas, and heating and refluxing at reduced pressure to produce a sulfur-containing off-gas stream comprising H 2 S, COS, CO 2 , and mercury vapor; and a stream of lean gas scrubbing solvent; and recycling said stream of lean gas scrubbing solvent to the gas scrubbing zone in (3).

Claim 10

The process of claim 8 provided with the steps of: (a) burning said sulfur-containing off-gas stream in an elemental sulfur recovery unit along with a recycle stream of H 2 S-containing gas produced by regenerating the rich gas scrubbing solvent from a tail gas volatile sulfur recovery unit, and optionally a stream of flash gases, thereby producing in said elemental sulfur recovery unit elemental sulfur containing substantially no mercury, and a separate tail gas stream comprising SO 2 , CO 2 , H 2 S, COS and; (b) feeding said tail gas stream from the elemental sulfur recovery unit to said tail gas volatile sulfur recovery; (c) withdrawing from said tail gas volatile sulfur recovery unit a solvent scrubbed gas stream comprising CO 2 , N 2 , and mercury vapor; and (d) contacting said exit gas stream from (c) with activated carbon to remove substantially all of said mercury vapor.

Claim 11

The process of claim 1 provided with the steps of cleaning the raw effluent gas stream from the reaction zone in (1) by direct contact with water to produce a water dispersion comprising H 2 S, NH 3 , Hg, and ash and particulate solids; flashing and stripping said water dispersion to produce a flash gas stream comprising H 2 S, NH 3 and a trace of Hg vapor, and introducing said stream of flash gas into said elemental sulfur recovery unit along with said other feedstreams.

Claim 12

The process of claim 8 wherein said gas scrubbing solvent is regenerated in a stripping vessel being operated at a temperature of about 40° C. to 100° C. above the absorption temperature range and at a pressure in the range of about 1 to 2 atmospheres.

Claim 13

The process of claim 1 wherein said mercury-containing fossil fuel contains about 0.01 to 1000 ppm (parts per million) of mercury.

Claim 14

The process of claim 6 wherein said activated carbon treated process gas stream contains less than 0.004 mg/M 3 of mercury.

Claim 15

The process of claim 6 wherein said activated carbon is impregnated with highly dispersed gold to provide a wt. ratio of gold to carbon in the range of about 0.005 to 0.20.

Claim 16

The process of claim 6 wherein said carbon sorbent is regenerated by removal of mercury by heating to a temperature in the range of about 150° C. to 500° C. while stripping the sorbent with an inert gas e.g. nitrogen.

Claim 17

The process of claim 6 wherein said demercurized gas stream from (4)(a) is passed through a series of sorbent beds moving counter flow to the gas.

Claim 18

The process of claim 6 provided with the step of regenerating a sorbent bed by stripping mercury from the bed by passing steam through the sorbent bed, cooling the gaseous mixtures of H 2 O and mercury vapor and separating condensed mercury from condensed steam, and drying the sorbent before reuse.

Claim 19

The process of claim 1 wherein said mercury-containing fossil fuel is a solid carbonaceous fuel containing about 0.01 to 1000 parts per million of mercury.

Claim 20

The process of claim 18 wherein said solid carbonaceous fuel is selected from the group consisting of coal, coke from coal and mixtures thereof.

Claim 21

The process of claim 19 wherein said coal is selected from the group consisting of anthracite, bituminous, lignite, and mixtures thereof.

Claim 22

The process of claim 1 wherein a waste material-containing mercury is in admixture with said fossil fuel.

Claim 23

The process of claim 21 wherein said waste material-containing mercury is a mercury-containing inorganic and/or organic sludge from an industrial process.

Claim 24

The process of claim 1 wherein said partial oxidation reaction zone in (1) is operated at a pressure of at least 10 atmospheres, and the gas scrubbing zone in (3) is operated at substantially the same pressure as the reaction zone in (1) less ordinary pressure drop in the lines, and at a maximum temperature of about 20° C.

Claim 25

A process for the production of demercurized synthesis gas, reducing gas, or fuel gas comprising: (1) reacting a mercury-containing fossil fuel feed comprising solid carbonaceous fuel containing about 0.01 to 1000 ppm (parts per million) of mercury by partial oxidation with a free-oxygen containing gas with or without a temperature moderator in a reaction zone provided with a reducing atmosphere at a temperature in the range of about 1800° F. to 3000° F. and a pressure in the range of about 10 atmospheres or higher to produce a raw effluent gas stream comprising H 2 , CO, H 2 O, CO 2 , H 2 S, COS, entrained slag and/or ash, and optionally CH 4 , NH 3 , N 2 and Ar; and wherein substantially all of the mercury in the feed is converted into elemental mercury vapor which leaves the reaction zone entrained in the raw effluent gas stream; (2) cooling, cleaning, and demoisturizing the raw effluent gas stream from (1); wherein said cooling, cleaning and demoisturizing includes the steps of: (a) passing the raw effluent gas stream from (1) through a radiant cooler where at least a portion of the entrained slag and/or ash separate out, and the effluent gas stream is cooled to a temperature in the range of about 500° C. to 800° C., by noncontact heat exchange with H 2 O; (b) cooling further the partially cooled gas stream from (a) in at least one convection cooler and scrubbing gas stream with water to remove entrained particulate matter; (c) demoisturizing the cooled and cleaned gas stream from (b); (3) introducing the gas stream from (2)(c) into a solvent gas scrubbing zone where at a temperature in the range of about -50° C. to 80° C. and a pressure of about 10 atmospheres or higher, said gas stream is contacted by a stream of gas scrubbing solvent thereby condensing about 20 to 100 wt. % of the mercury vapor and removing from about 90 to 100 wt. % of the sulfur-containing gases; and (4) removing the following streams from the solvent gas scrubbing zone: (a) a clean and demercurized stream of synthesis gas, reducing gas, or fuel gas containing about 0 to 80 wt. % of the mercury entering the gas scrubber, and contacting said demercurized gas stream with activated carbon sorbent, thereby removing substantially all of any remaining mercury vapor and sulfur-containing gas in the process gas stream; (b) rich gas scrubbing solvent containing a major portion of the remaining mercury entering the gas scrubber entrained in condensed form, and regenerating said stream of rich gas scrubbing solvent by at least one of the following process steps: flashing, stripping with steam or an inert gas, or heating and refluxing at a temperature in the range of about 40° C. to 100° C. above the absorption temperature range and at a pressure in the range of about 1 to 2 atmospheres to produce a sulfur-containing off-gas stream comprising H 2 S, COS, CO 2 , and mercury vapor; and a stream of lean gas scrubbing solvent; and recycling said stream of lean gas scrubbing solvent to the gas scrubbing zone in (3); and (c) sludge or drainage containing the remainder of the mercury or its compounds in condensed form entering the gas scrubber.

Claim 26

A process for the production of demercurized synthesis gas, reducing gas, or fuel gas comprising: (1) reacting a mercury-containing fossil fuel feed comprising solid carbonaceous fuel containing about 0.01 to 1000 ppm (parts per million) of mercury by partial oxidation with a free-oxygen containing gas with or without a temperature moderator in a reaction zone provided with a reducing atmosphere at a temperature in the range of about 1800° F. to 3000° F. and a pressure in the range of about 10 atmospheres or higher to produce a raw effluent gas stream comprising H 2 , CO, H 2 O, CO 2 , H 2 S, COS, entrained slag and/or ash, and optionally CH 4 , NH 3 , N 2 and Ar; and wherein substantially all of the mercury in the feed is converted into elemental mercury vapor which leaves the reaction zone entrained in the raw effluent gas stream; (2) cooling, cleaning, and demoisturizing the raw effluent gas stream from (1); wherein said cooling, cleaning and demoisturizing includes the steps of: (a) passing the raw effluent gas stream from (1) through a radiant cooler where at least a portion of the entrained slag and/or ash separate out, and the effluent gas stream is cooled to a temperature in the range of about 500° C. to 800° C., by noncontact heat exchange with H 2 O; (b) cooling further the partially cooled gas stream from (a) in at least one convection cooler and scrubbing gas stream with water to remove entrained particulate matter; (c) demoisturizing the cooled and cleaned gas stream from (b); (3) introducing the gas stream from (2)(c) into a solvent gas scrubbing zone where at a temperature in the range of about -50° C. to 80° C. and a pressure of about 10 atmospheres or higher, said gas stream is contacted by a stream of gas scrubbing solvent thereby condensing about 20 to 100 wt. % of the mercury vapor and removing from about 90 to 100 wt. % of the sulfur-containing gases; and (4) removing the following streams from the solvent gas scrubbing zone: (a) a clean and demercurized stream of synthesis gas, reducing gas, or fuel gas containing about 0 to 80 wt. % of the mercury entering the gas scrubber, and contacting said demercurized gas stream with activated carbon sorbent, thereby removing substantially all of any remaining mercury vapor and sulfur-containing gas in the process gas stream; (b) rich gas scrubbing solvent containing a major portion of the remaining mercury entering the gas scrubber entrained in condensed form, and regenerating said stream of rich gas scrubbing solvent by at least one of the following process steps: flashing, stripping with steam or an inert gas, or heating and refluxing at a temperature in the range of about 40° C. to 100° C. above the absorption temperature range and at a pressure in the range of about 1 to 2 atmospheres to produce a sulfur-containing off-gas stream comprising H 2 S, COS, CO 2 , and mercury vapor; and a stream of lean gas scrubbing solvent; and recycling said stream of lean gas scrubbing solvent to the gas scrubbing zone in (3); and (c) sludge or drainage containing the remainder of the mercury or its compounds in condensed form entering the gas scrubber.

Claim 27

The process of claim 24 wherein said solid carbonaceous fuel is selected from the group consisting of coal, coke from coal and mixtures thereof.

Claim 28

The process of claim 25 wherein said coal is selected from the group consisting of anthracite, bituminous, lignite, and mixtures thereof.

Claim 29

The process of claim 24 wherein said mercury-containing fossil fuel comprises a waste material-containing mercury in admixture with a fossil fuel.

Claim 30

The process of claim 27 wherein said waste material-containing mercury is a mercury-containing inorganic and/or organic sludge from an industrial process.

Claim 31

The process of claim 24 wherein said partial oxidation reaction zone in (1) is operated at a pressure of at least 10 atmospheres, and the gas scrubbing zone in (3) is operated at the same pressure as the reaction zone in (1) less ordinary pressure drop in the lines, and at a maximum temperature of about 20° C.