Deslagging gasifiers by controlled heat and derivatization

Claim 2

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point; (3) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through an outlet; and (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet.

Claim 3

The process of claim 1 wherein the slag comprises metal compound which is derivatized to a metal derivative having a lower melting point than the metal compound.

Claim 4

The process of claim 2 wherein the metal compound is trivalent vanadium compounds and the metal derivative is pentavalent vanadium compounds.

Claim 5

The process of claim 1 wherein the reactor temperature is above the melting point of the derivatized slag.

Claim 6

The process of claim 4 wherein the reactor temperature is above about 700° C.

Claim 7

The process of claim 1 wherein the temperature at the inside surface of the reactor is less than the temperature that would produce significant loss of refractory material lining the reactor.

Claim 8

The process of claim 6 wherein the temperature at the inside surface is less than about 1,600° C.

Claim 9

The process of claim 7 wherein the temperature at the inside surface is from about 600° C. to about 1,500° C.

Claim 10

The process of claim 1 wherein the reactor outlet temperature is above the derivatized slag fluidizing point preventing slag from solidifying in and blocking the outlet.

Claim 11

The process of claim 1 wherein the reactor temperature is controlled by adding hot gas to the reactor.

Claim 12

The process of claim 1 wherein the reactor is heated by reacting an oxidant with a fuel in the reactor.

Claim 13

The process of claim 11 wherein the oxidant is the derivatizing agent and has a concentration in the reactor provided by adding more oxidant than is consumed by fuel combustion.

Claim 14

The process of claim 11 wherein the amount of fuel added is controlled to give a reactor outlet temperature above the derivatized slag fluidizing point preventing the slag from solidifying in and blocking the outlet.

Claim 15

The process of claim 1 wherein the fuel is fluid organic feedstock for partial oxidation.

Claim 16

The process of claim 1 wherein the amount of slag is monitored.

Claim 17

The process of claim 15 wherein slag in the outlet is monitored by observing with a borescope, fiber optics, nuclear or sonar means, or by measuring temperature or pressure.

Claim 18

A process for making synthesis gas which comprises: (1) adding free-oxygen-containing gas and fluid organic feedstock containing slag-depositing material to a reactor; (2) reacting the feedstock and gas through a partial oxidation reaction to make synthesis gas containing hydrogen and carbon monoxide gases, which leave the reactor through an outlet, and slag which collects in the reactor; (3) recovering the synthesis gas; and removing slag by: (4) stopping the partial oxidation reaction; (5) adding at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point; (6) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through the outlet; and (7) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet.

Claim 19

A process for making synthesis gas which comprises: (1) adding free-oxygen-containing gas and fluid organic feedstock containing slag-depositing material to a reactor; (2) reacting the feedstock and gas through a partial oxidation reaction to make synthesis gas containing hydrogen and carbon monoxide gases, which leave the reactor through an outlet, and slag which collects in the reactor; (3) recovering the synthesis gas; and removing slag by: (4) stopping the partial oxidation reaction; (5) adding at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point; (6) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through the outlet; and (7) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet.

Claim 20

The process of claim 17 wherein the feedstock is coke containing vanadium.

Claim 21

The process of claim 17 wherein the partial oxidation reaction is resumed after slag is removed from the reactor.

Claim 22

The process of claim 19 wherein slag removal is repeated periodically.

Claim 23

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding as excess amount of at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point and which amount increases the concentration of derivatizing agent in the reactor during the deslagging; (3) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through an outlet; and (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet.

Claim 24

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding as excess amount of at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point and which amount increases the concentration of derivatizing agent in the reactor during the deslagging; (3) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through an outlet; and (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet.

Claim 25

The process of claim 21 wherein the derivatizing agent concentration increases from initially about 0 up to a partial pressure of at least about 0.5 atmospheres.

Claim 26

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivated slag having a lower fluidizing point; (3) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through an outlet; (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet; and (5) maintaining a temperature lower at the outlet.

Claim 27

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding at least one derivatizing agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivated slag having a lower fluidizing point; (3) providing a temperature in the reactor at which derivatized slag fluidizes and leaves the reactor through an outlet; (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet; and (5) maintaining a temperature lower at the outlet.

Claim 28

The process of claim 23 wherein the outlet is at the base of the reactor and has a temperature which is from about 50° C. to about 500° C. less than the temperature near the top of the reactor.

Claim 29

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding at least one derivating agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point; (3) providing a temperature in the reactor at which derivated slag fluidizes and leaves the reactor through an outlet; and (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet by fluidizing slag at or near the outlet before other slag enters and fills the outlet.

Claim 30

A process for removing slag from partial oxidation reactors which comprises: (1) stopping a partial oxidation reaction which has deposited solid slag in a partial oxidation reactor; (2) adding at least one derivating agent, which is a free-oxygen-containing or -producing material, to the reactor which reacts with the slag to make derivatized slag having a lower fluidizing point; (3) providing a temperature in the reactor at which derivated slag fluidizes and leaves the reactor through an outlet; and (4) controlling the deslagging rate by regulating derivatizing agent and temperature levels in the reactor to prevent slag from filling the outlet by fluidizing slag at or near the outlet before other slag enters and fills the outlet.