Lummus Technology Inc.

Conocophillips Company

Phillips 66 Company

Albert C Tsang

Max W Thompson

Chancelor L Williams

David L Breton

Joe D Allison

Steven E Lusk

Sourabh S Pansare

Shrinivas Lokare

Paul Edgar Michaud

Jayesh Shah

Philip Rodney Amick

Edward L Sughrue

Roland Schmidt

Joseph B Cross

Robert William Morton

Rick Q Honaker

Max Thompson

Edward L Ii Sughrue

Robert W Morton

A gasification process may include (a) introducing a liquid hydrocarbon feedstock and at least one of a dry feedstock or a first slurried feedstock into a reactor lower section, wherein the at least one dry feedstock or first slurried feedstock is introduced through two primary feed nozzles while the liquid hydrocarbon feedstock is introduced through at least two secondary feed nozzles; (b) partially combusting the feedstocks in the reactor lower section with a gas stream comprising an oxygen-containing gas or steam to evolve heat and form products comprising hot synthesis gas; (c) passing said hot synthesis gas from step (b) upward into a reactor upper section; (d) and introducing a second slurried feedstock into said reactor upper section, whereby heat from said hot synthesis gas supports reaction of the second slurried feedstock by pyrolysis and gasification reactions.

Two-stage gasifier and gasification process with feedstock flexibility

A two-stage gasification reactor may include a reactor lower section and a reactor upper section. The reactor lower section may include (a) a lower reactor body, (b) two primary feed nozzles, configured to introduce at least one of a dry feedstock or a first slurried feedstock and located on opposing terminal ends of the lower reactor body, and (c) at least two secondary feed nozzles, configured to introduce a liquid hydrocarbon feedstock, located on the lower reactor body. The reactor upper section may include (a) an upper reactor body, (b) at least one upper feed nozzle, configured to introduce at least one of a dry feedstock or a first slurried feedstock, located on the upper reactor body, and (c) an outlet.

A system for gasification of a carbonaceous material and recycling char or solids from a gasifier is disclosed. The recycling system may include a standpipe that receives a solids stream from a separator, the standpipe generating a pressure differential across a bed of accumulated char, thereby producing a bottoms stream having a greater pressure than the inlet solids stream. The recycling system may also include a holding vessel that receives the bottoms stream and a fluidized-bed distribution vessel that receives char from the holding vessel and is configured to provide a continuous and precise flow of recycled char to the gasification reactor.

Standpipe-fluid bed hybrid system for char collection, transport, and flow control

A catalyst comprising NiO, a metal mixture comprising at least one of MoOor WO, a mixture comprising at least one of SiOand AlO, and PO. In this embodiment the metal sites on the catalyst are sulfided and the catalyst is capable of removing tar from a synthesis gas while performing methanation and water gas shift reactions at a temperature range from 300&#xb0; C. to 600&#xb0; C.

Low temperature sulfur tolerant tar removal with concomitant synthesis gas conditioning

A catalyst comprising of NiO; AlO; and ZnO. The catalyst is capable of greater than 5% sulfur removal from a synthesis gas at a temperature range from 300&#xb0; C. to 600&#xb0; C.

Low temperature sulfur tolerant tar and sulfur removal with concomitant synthesis gas conditioning

The current invention discloses a novel process and system to improve the quality of the slag product from a gasification process, thereby producing low-carbon marketable aggregate product. The inventive processes and systems employ a hindered-bed settler in conjunction with optional disengager and de-watering devices. A slag slurry stream from a gasification process is de-watered and the solids content is increased from less than 5% to greater than 30% via the de-waterer before being conveyed to a hindered-bed settler, wherein the carbon content is reduced from as much as 70% to less than 5%. Particles with a high carbon content are conveyed to a gravity settler, whereby they are concentrated and then recycled to the gasification reactor.

Methods and systems for treating a gasification slag product

The present invention relates to a system and process for gasifying feedstock such as carbonaceous materials. The invention includes partial combustion of dry solids and pyrolysis of carbonaceous material slurry in two separate reactor sections and produce mixture products comprising synthesis gas. The invention employs one or more catalytic or sorbent bed for removing tar from the synthesis gas. The inventive system and process allow a gasification to be carried out under higher slurry feeding rate and lower temperature with the provision to manage the tar being produced, therefore to increase the conversion efficiency of the overall gasification.

Two stage entrained gasification system and process

A catalyst comprising NiO, a metal mixture comprising at least one of MoO3 or WO3, a mixture comprising at least one of SiOand AlO, and PO. In this embodiment the metal sites on the catalyst are sulfided and the catalyst is capable of removing tar from a synthesis gas while performing methanation and water gas shift reactions at a temperature range from 300&#xb0; C. to 600&#xb0; C.

A novel tar-free gasification process and system is disclosed that involves the partial combustion of recycled dry solids and the drying of a slurry feedstock comprising carbonaceous material in two separate reactor zones in a two stage gasifier, thereby producing mixture products comprising synthesis gas. The synthesis gas produced from the high temperature first stage reaction zone is then quenched in the second stage reaction zone of the gasifier prior to introduction of a slurry feedstock. The temperature of the final syngas exiting the second stage reaction zone of the gasifier is thereby moderated to be in the range of about 350-900&#xb0; F., which is below the temperature range at which tar is readily formed, depending upon the type of carbonaceous feedstock utilized.

Tar-free gasification system and process

A system and process for gasifying carbonaceous feedstock with staged slurry addition in order to prevent the formation of tar that causes deposition problems. Dry solid carbonaceous material is partially combusted, then pyrolyzed along with a first slurry stream comprising carbonaceous material in two separate reactor sections, thereby producing mixture products comprising synthesis gas. The second slurry stream comprising particulate carbonaceous material is fed to a drying unit downstream of a heat recovery zone along with the mixture product exiting the heat recovery zone The resulting final temperature of the second stage mixture products and dried particulate carbonaceous material is between 450&#xb0; F. and 550&#xb0; F., a temperature range that is typically not conducive to the emission of heavy molecular-weight tar species.

Gasification system and process with staged slurry addition

A system and process for gasifying carbonaceous feedstock with staged slurry addition in order to prevent the formation of tar that causes deposition problems. Dry solid carbonaceous material is partially combusted, then pyrolyzed along with a first slurry stream comprising carbonaceous material in two separate reactor sections, thereby producing mixture products comprising synthesis gas. The second slurry stream comprising particulate carbonaceous material is fed to a drying unit downstream of a heat recovery zone along with the mixture product exiting the heat recovery zone. The resulting final temperature of the second stage mixture products and dried particulate carbonaceous material is between 450&#xb0; F. and 550&#xb0; F., a temperature range that is typically not conducive to the emission of heavy molecular-weight tar species.

A system employing a regenerable zinc-oxide based sorbent to remove one or more contaminants from an incoming gas stream. The contaminant-depleted gas stream can then be used for any subsequent application, while at least a portion of the contaminant-laden sorbent can be regenerated via a step-wise regeneration process. In one embodiment, sorbent regenerated via the step-wise regeneration process can comprise less sorbent-damaging compounds than traditional sorbents exposed to conventional regeneration processes.

Growing community of inventors

Sugar Land, TX, United States of America

Albert C Tsang