Texaco Development Corporation

Texaco Inc.

James R Muenger

Edward T Child

Albert Brent

Everett M Barber

David L Alexander

Frederick C Jahnke

John Saunders Stevenson

Peter L Paull

Warren G Schlinger

Michael W Becker

William N Gilmer

Frank E Guptill, Jr

Americo R Catena

John M Veillon

Anthony E Bergin

An assembly of a quench liquid distribution ring and dip-tube with or without a draft tube for use in a hot effluent gas quench cooling zone containing a pool of quench liquid in the bottom in combination with a vertical cylindrical free-flow refractory lined reaction zone of a partial oxidation gas generator. The hot effluent gas from the reaction zone passes through a bottom central discharge outlet and passage and then through a coaxial vertical dip-tube that extends down into a pool of quench liquid. A quench liquid distribution ring that includes an annular rectangular shaped bottom feed quench liquid distribution channel, surrounds the outside diameter of the dip-tube at its upstream end. A quench ring face and cover is provided that comprises a vertical cylindrical shaped leg portion and a top horizontal flat ring plate portion that extends perpendicularly outward from the upstream end of the leg portion. The cylindrical shaped leg portion extends downward and overlaps the inside surface of the inner wall of said annular rectangular shaped quench liquid distribution channel thereby providing an annular shaped gap therebetween. The top horizontal flat ring plate portion provides a gas and liquid tight cover with the annular quench liquid distribution channel when the two parts are bolted to a floor flange connected to the support floor for the refractory that lines the reaction zone of the gas generator. A plurality of slot orifices pass through the inner wall of said annular distribution channel to provide free passage for the quench liquid between the distribution channel and the annular gap. The annular gap may be kept full of quench liquid and free from gas and vapor pockets, thereby avoiding poor heat transfer. A spiralling layer of quench liquid may be supplied to and distributed over the inside surfaces of the inner wall of the quench liquid distribution channel and the cylindrically shaped dip-tube.

Quench ring and dip-tube assembly

A gas cooler and process are provided for the efficient extraction of heat from a hot raw gas stream containing entrained matter from the partial oxidation of a hydrocarbonaceous or carbonaceous fuel, and the simultaneous production of a separate stream of superheated steam. The gas cooler comprises a closed vertical pressure vessel with an upper central outlet through which the superheated steam is removed. A refractory lined hot gas inlet chamber is attached to the bottom of the pressure vessel. A plurality of bundles of helical tubes through which the hot gas flows are spaced in the vessel. The hot gas enters at the bottom of the vessel and the cooled gas leaves at the bottom of the helical coil. A portion of the vessel is filled with boiler feed water so that the bundles of helical tubes are partially submerged. Concurrent and countercurrent indirect heat exchange between boiler feed water and the gas stream takes place in the evaporator section to produce saturated steam. Concurrent and countercurrent indirect heat exchange between the saturated steam and the partially cooled gas stream then takes place in the superheater section to produce superheated steam. Advantageously, the gas cooler may be easily turned up or down with load by opening or closing off at least one of the helical tubes. This may be done by valving located downstream from the gas cooler at the cold end of the gas path.

Gas cooler for production of superheated steam

A gas cooler and process are provided for extracting heat from the hot raw gas stream from the partial oxidation of a hydrocarbonaceous or carbonaceous fuel, and the simultaneous production of a separate stream of saturated or superheated steam, or separate streams of both. The gas cooler comprises a vertical pressure vessel with an upper central outlet through which saturated steam may be removed and a closed bottom. A refractory lined hot gas inlet chamber is attached to the bottom of the pressure vessel. A coaxial vertical water-tight cylindrically shaped central chamber is supported within the vessel and defines an annular elongated passage with the inside walls of the vessel. A plurality of bundles of helical tubes through which the hot gas flows are spaced in the annular passage and are serially connected to a helical bundle of gas tubes that is supported in the central chamber. Concurrent indirect heat exchange between boiler feed water and the hot gas takes place in the annular passage or evaporative section to produce saturated steam. Countercurrent indirect heat exchange between saturated steam and partially cooled gas takes place in the central chamber to produce superheated steam. Advantageously, the gas cooler may be easily turned up or down with load by closing off one or more of the helical tubes. Further, along with the efficient cooling of a hot gas stream containing entrained matter, saturated or superheated steam, or both may be simultaneousy produced in the same vessel.

Gas cooler for production of saturated or superheated steam, or both

An apparatus in which a downflowing high pressure stream of hot raw synthesis gas from the reaction zone of a free flow partial oxidation gas generator at a temperature in the range of about 1800.degree. to 3000.degree. F. is passed through a first gas diversion and residue separation chamber contained in a first pressure vessel where the velocity of the gas stream is reduced, solid material and molten slag are separated by gravity from the gas stream, and the direction is diverted into a thermally insulated side transfer line. The hot gas stream is then passed through a thermally insulated gas-solids impingement separation means contained in a second pressure vessel where its direction and velocity is changed and additional residue is separated. The hot gas stream is then passed upwardly through a radiant cooler where additional solid matter is removed by gravity and the gas temperature is reduced to a temperature in the range of about 900.degree. to 1800.degree. F. By the subject apparatus, combustion residue may be removed from the raw stream of synthesis gas, and its sensible heat may be extracted at maximum temperature to produce by-product steam.

Apparatus for the production of cleaned and cooled synthesis gas

An apparatus in which the hot raw synthesis gas stream leaving the reaction zone of a free flow partial oxidation gas generator at a temperature in the range of about 1800.degree. to 3000.degree. F. is passed through a first gas diversion and residue separation zone where the velocity of the gas stream is reduced and its direction is diverted into a side transfer line. Solid material and molten slag separate by gravity from the gas stream. The hot gas stream is then introduced into a second gas diversion and residue separation zone, which comprises a plurality of high temperature resistant, thermally insulated cyclones, where the direction and velocity is changed and additional residue is separated. About 0.5 to 20 vol. % of the hot gas stream may be passed through bottom outlets in said first and second gas diversion zones in order to prevent bridging. The hot gas stream from the second gas diversion zone is passed upwardly through a radiant cooler where additional solid matter is removed by gravity and the gas temperature is reduced to a temperature in the range of about 900.degree. to 1800.degree. F.

The hot raw synthesis gas stream leaving the reaction zone of a free flow partial oxidation gas generator at a temperature in the range of about 1800.degree. to 3000.degree. F. is passed through a first gas diversion and residue separation zone where the velocity of the gas stream is reduced and its direction is diverted into a side transfer line. Solid material and molten slag separate by gravity from the gas stream. The hot gas stream is then introduced into a second gas diversion and residue separation zone where the direction and velocity is changed and additional residue is separated. About 0.5 to 20 vol. % of the hot gas stream may be passed through bottom outlets in said first and second gas diversion zones in order to prevent bridging. The hot gas stream from the second gas diversion zone is passed upwardly through a radiant cooler where additional solid matter is removed by gravity and the gas temperature is reduced to a temperature in the range of about 900.degree. to 1800.degree. F. In this embodiment, the second diversion and residue separation zone comprises a plurality of high temperature resistant thermally insulated cyclones connected in series or in parallel. Entrained solid matter and slag are removed from the gas stream by means of said cyclone separators without substantially reducing the temperature of the gas stream.

Method for the production of cleaned and cooled synthesis gas

The hot raw synthesis gas stream leaving the reaction zone of a free flow partial oxidation gas generator at a temperature in the range of about 1800.degree. to 3000.degree. F. is passed through a first gas diversion and residue separation chamber where the velocity of the gas stream is reduced and its direction is diverted into a side transfer line. Solid material and molten slag separate by gravity from the gas stream. The hot gas stream is then introduced into second gas diversion and residue separation zone comprising at least one thermally insulated gas-solids impingement separation means were additional solid matter and slag is separated. For example, from about 2 to 8 thermally insulated gas-solids impingement separators may be employed which are connected in parallel and/or series. In one embodiment, about 0 to 20 vol. % of the hot gas stream may be passed through bottom outlets in said first and second gas diversion zones in order to prevent bridging. The hot gas stream from the second gas diversion zone is passed upwardly through a radiant cooling zone where additional solid matter is removed by gravity and the gas temperature is reduced to a temperature in the range of about 900.degree. to 1800.degree. F.

Production of cleaned and cooled synthesis gas

The hot raw synthesis gas stream leaving the reaction zone of a free flow partial oxidation gas generator at a temperature in the range of about 1800.degree. to 3000.degree. F. is passed through a first gas diversion and residue separation zone where the velocity of the gas stream is reduced and its direction is diverted into a side transfer line. Solid material and molten slag separate by gravity from the gas stream. The hot gas stream is then introduced into a second gas diversion and residue separation zone where additional residue is separated. About 0.5 to 20 vol. % of the hot gas stream may be passed through bottom outlets in said first and second gas diversion zones in order to prevent bridging. The hot gas stream from the second gas diversion zone is passed upwardly through a radiant cooler where additional solid matter is removed by gravity and the gas temperature is reduced to a temperature in the range of about 900.degree. to 1800.degree. F. In one embodiment, the second diversion and residue separation zone is a thermally insulated cyclone. By the subject process, 70 to 95 wt. % of the combustion residue is removed from the raw stream of synthesis gas, and the temperature of the gas stream is reduced below the maximum safe operating temperature for downstream devices used to recover energy from the hot gas stream, such as a conventional convection type gas cooler.

A chemical plant, wherein gaseous reactants are converted in an exothermic chemical reaction to a reaction product, is combined with a semi-closed Brayton-cycle power plant to utilize the heat of reaction to generate power. Specifically, in one embodiment, an ammonia synthesis plant, wherein gaseous nitrogen and hydrogen are catalytically converted to ammonia, is combined with a semi-closed Brayton-cycle power plant to utilize the heat of reaction of the ammonia synthesis reaction to generate power.

Combination chemical plant and Brayton-cycle power plant

A process for the efficient production of power from non-gaseous carbonaceous fuels, such as coal, or heavy fuel oil, in a steam power plant in which the carbonaceous fuel is first gasified at relatively high pressure and temperature by partial oxidation with oxygen to produce a fuel gas, the fuel gas from the partial oxidation reaction is expanded to a lower pressure in a turbine. Undesirable compounds, e.g., sulfur compounds, are removed from the fuel gas, and the fuel gas supplied to a steam boiler for the production of power. The process of this invention provides an effective means for conversion of gas-fired steam generation facilities to coal or heavy fuel oil while at the same time increasing the power generating capacity of the installation, all with minimal atmospheric pollution. The process is effective for the conversion of other types of gas-fired heaters and boilers to coal or heavy fuel oil.

Process for the generation of power from solid carbonaceous fuels

This is a continuous process for producing ammonia synthesis gas and includes the partial oxidation of particles of solid carboniferous fuels entrained in nitrogen. In the process, air is separated into high pressure nitrogen and substantially pure oxygen. A first stream of said nitrogen is used as a safe pneumatic vehicle in a grinding and transport operation which introduces ground, finely divided solid carbonaceous fuel into a venturi injector where the particles of solid fuel are dispersed in a second stream of said nitrogen. The solid fuel-nitrogen gaseous dispersion is then reacted with a free-oxygen containing gas preferably in the absence of supplemental H.sub.2 O, other than any moisture normally found in the reactants, in a freeflow partial oxidation synthesis gas generator. The nitrogen stream serves as a carrier for the particles of solid carbonaceous fuel and as a temperature moderator in the gas generator. After cleaning, shifting, and purifying the raw synthesis gas, a gaseous mixture of N.sub.2 and H.sub.2 is obtained having the proper stoichiometric proportions for ammonia synthesis. High pressure is preferably used in all of the steps of the process and in the catalytic ammonia synthesis which takes place subsequently. The high pressure is preferably the same as that produced in the gas generator less ordinary drop in the lines. Thus, expensive gas compressors may be avoided.

Production of ammonia synthesis gas from solid carbonaceous fuels

This invention relates to a process for the efficient production of power by the oxidation of carbonaceous or hydrocarbon fuels with minimal pollution of the atmosphere. In one of its more specific aspects, this object is accomplished by partial oxidation of the hydrocarbon or other carbon-containing fuels to produce a fuel gas, followed by partial oxidation of this fuel gas and finally complete combustion of the gaseous products of the second partial oxidation with the generation of power in stages following each of the oxidation steps such that the stack gas discharged to the atmosphere is low in oxides of nitrogen and is substantially free from sulfur compounds. The process is particularly suitable for use with sulfur-containing petroleum residua, shale oils and the like.

Process for the generation of power from carbonaceous fuels with minimal

Power is developed by an expansion turbine in which the working fluid is a gaseous mixture comprising all of the hot raw gas stream leaving an unpacked partial oxidation gas generator, after removing if present a portion of the entrained solids, in admixture with a temperature moderating stream. A molal increase is associated with the partial oxidation process. Power is obtained from this molal increase in addition to the power obtained from the elevated pressure and sensible heat in the hot raw partial oxidation product gas. The temperature moderating stream may comprise a recycle portion of the turbine exhaust gas stream after being cooled, cleaned, optionally water-gas shifted or purified, or both, and recompressed. Alternatively, the recycle gas stream may be mixed with water, steam, or both. In one embodiment the temperature moderating stream comprises liquid water or condensate produced in the process. Auxiliary gas compressors for recompressing said recycle gas, and optionally for compressing a free-oxygen containing gas for use in the gas generation zone may be driven by said expansion turbine. Similarly, an electric generator may be coupled to the turbine shaft.

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Beacon, NY, United States of America

James R Muenger