An improved continuous partial oxidation process for producing clean synthesis or fuel gas from a hydrocarbonaceous fuel feed is disclosed wherein the effluent gas stream from the reaction zone of the gas generator is simultaneously cooled and cleaned by first discharging the gas stream directly int
An improved continuous partial oxidation process for producing clean synthesis or fuel gas from a hydrocarbonaceous fuel feed is disclosed wherein the effluent gas stream from the reaction zone of the gas generator is simultaneously cooled and cleaned by first discharging the gas stream directly into a relatively large body of hot liquid hydrocarbon immersion fluid contained in an immersion vessel, and second by scrubbing with by-product water obtained subsequently in the process in a nozzle scrubber. The process gas stream is optionally cooled and passed into a gas-liquid separator where any condensed by-product noxious water and any C 5 -C 10 liquid hydrocarbons are separated from each other and from the clean product gas stream. By-product noxious water is disposed of without polluting the environment by recycling a portion of it to the gas generator as the temperature moderator. For example, the immersion fluid may be a dispersion of liquid hydrocarbonaceous fuel such as petroleum oil and particulate carbon which is contained in a separate immersion vessel. A portion of the hot immersion fluid is continuously removed from the immersion vessel and is cooled in an external gas cooler to a temperature in the range of about 300° to 850° F but above the dew point of the water in the process gas stream. Portions of the cooled immersion fluid are recycled to the immersion vessel, and optionally to the gas generator as at least a portion of the hydrocarbonaceous fuel feed. In another embodiment, a portion of the immersion fluid removed from the immersion vessel may be introduced into the gas generator as at least a portion of the feed without first being passed through a cooler. The clean product gas comprises H 2, CO, CO 2, H 2 O and, optionally at least one material from the group H 2 S, COS, N 2, A, and C 1 -C 4 hydrocarbons.
대표청구항▼
1. A continuous process for producing clean gaseous mixtures comprising H 2, CO, CO 2, H 2 O, and optionally at least one gas from the group H 2 S, COS, N 2, A, and C 1 -C 4 hydrocarbons, while simultaneously disposing of by-product water produced by the process comprising: 1. reacting in the rea
1. A continuous process for producing clean gaseous mixtures comprising H 2, CO, CO 2, H 2 O, and optionally at least one gas from the group H 2 S, COS, N 2, A, and C 1 -C 4 hydrocarbons, while simultaneously disposing of by-product water produced by the process comprising: 1. reacting in the reaction zone of a free-flow, unpacked gas generator as feed a dispersion of particulate carbon and liquid hydrocarbonaceous fuel, a stream of free-oxygen-containing gas selected from the group consisting of air, oxygen-enriched air i.e. at least 22 mole % oxygen, and substantially pure oxygen i.e. at least 95 mole % oxygen, wherein the ratio of free-oxygen in the free-oxygen containing gas to carbon in the feedstock (O/C atom/atom) is in the range of about 0.6 to 1.5; and a temperature moderator comprising at least a portion of the by-product water produced subsequently in step (3) (a), by partial oxidation at a temperature in the range of about 1300° to 3000° F and a pressure in the range of about 1 to 250 atmospheres thereby producing an effluent gas stream containing H 2, CO, CO 2, H 2 O, particulate carbon, and optionally at least one gas from the group H 2 S, COS, N 2, CH 4 and A; 2. cooling the effluent gas stream from (1) to a temperature in the range of about 300° to 900° F but above the dew point of the water in the gas and simultaneously removing said particulate carbon by discharging said effluent gas stream directly into a body of hot immersion fluid contained in a quench zone and comprising a dispersion of liquid hydrocarbonaceous fuel and particulate carbon, wherein said quench zone contains 30 to 60 gallons of immersion fluid maintained at a temperature in the range of about 300° to 850° F for each 1000 Standard Cubic Feet of effluent gas from the gas generator that is quenched therein, and removing from said quench zone a clean gaseous stream comprising H 2, CO, CO 2, H 2 O, particulate carbon and optionally at least one material from the group H 2 S, COS, N 2, A, and C 1 -C 10 hydrocarbons; 3. contacting the process gas stream leaving the quench zone in (2) in a gas-liquid contacting zone with a portion of by-product water and optionally cooling the gas stream in a cooling zone to condense out any entrained normally liquid C 5 -C 10 hydrocarbons and water, and separating the following streams in a gas-liquid separation zone: (a) by-product water, (b) any light liquid C 5 - C 10 hydrocarbons, and (c) clean product gas comprising H 2, CO, CO 2, and optionally at least one material from the group H 2 S, COS, N 2, A, and C 1 -C 4 hydrocarbons; 4. recycling separate portions of the by-product water (3) (a) optionally in admixture with make-up water, to the reaction zone of the gas generator in (1) and to the gas-liquid contacting zone in (3); 5. cooling at least a portion of the hot immersion fluid from (2) to a temperature in the range of about 300° to 850° F. in an external cooler, recycling at least a portion of said cooled immersion fluid to said quench zone; and 6. introducing a portion of said hot immersion fluid from (2) or a portion of said cooled immersion fluid from (5) into the reaction zone in (1) as at least a portion of said dispersion of particulate carbon in liquid hydrocarbonaceous fuel. 2. The process of claim 1 provided with the additional step of spraying the effluent gas stream from the gas generator with a portion of said immersion fluid prior to quenching said effluent gas stream in said quench zone. 3. The process of claim 1 wherein the clean product gas stream from step (3) contains from about nil to 40.0 mole percent of C 1 -C 4 hydrocarbons. 4. The process of claim 1 wherein said gas-liquid contacting zone in step (3) comprises a nozzle scrubber. 5. The process of claim 1 wherein said liquid hydrocarbonaceous fuel is selected from the group consisting of petroleum distillate and residua, gas oil, residual fuel, reduced crude, whole crude, asphalt, coal tar, coal oil, shale oil, tar sand oil, and mixtures thereof. 6. The process of claim 1 wherein said liquid hydrocarbonaceous fuel is a pumpable slurry of solid carbonaceous fuel. 7. The process of claim 1 wherein said free-oxygen containing gas is selected from the group air, oxygen-enriched air i.e. at least 22 mole % oxygen, and substantially pure oxygen i.e. at least 95 mole % oxygen. 8. The process of claim 1 wherein the weight ratio of temperature moderator to liquid hydrocarbonaceous fuel is in the range of about 0.0 to 3.0. 9. The process of claim 1 wherein the immersion fluid in step (2) is a pumpable dispersion of liquid hydrocarbonaceous fuel and carbon particles in which the solids content is in the range of about nil to 50 weight percent. 10. The process of claim 1 wherein said quench zone contains residual aromatic oil as the immersion fluid and said immersion fluid is maintained at a temperature in the range of about 300° to 500° F. and below the thermal cracking temperature, and at a pressure of at least 1500 psia; and wherein said clean product gas from step (3) contains up to 5 mole % C 1 -C 4 hydrocarbons. 11. The process of claim 1 wherein said product gas contains from 10 to 40 mole % of C 1 -C 4 hydrocarbons and has a gross heating value in the range of about 400 to 800 BTU per Standard Cubic Feet.
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