Texaco Inc.

Texaco Development Corporation

Kay Anderson Johnson

Paul Steven Wallace

Delome D Fair

Janice L Kasbaum

Alma I Rodarte

Fred C Jahnke

Jacquelyn Gayle Niccum

Clint F Penrose

Jacqueline G Niccum

R Walter Barkley

The present invention relates to an integrated gasification and hydroprocessing process. A hydrocarbonaceous fuel is first gasified to produce syngas, and then a portion of the hydrogen is removed from the syngas. The hydrogen is compressed and used as an excess reactant in a hydroprocessing unit. Hydrogen gas is recovered from the hydroprocessing unit product, purified, compressed and recycled to the hydroprocessing unit. The hydrogen-poor syngas is expanded in an expander that drives the compressor that compresses the recycled hydrogen gas. The expanded syngas is then combined with light hydrocarbons removed from the recycle hydrogen gas stream, combusted in a gas turbine and used for power generation.

Recycle of hydrogen from hydroprocessing purge gas

The invention is a process to recover a high pressure hydrogen rich gas stream from synthesis gas. The synthesis gas is separated into a hydrogen-enriched permeate and a hydrogen-depleted non-permeate by use of a membrane. The permeate experiences a substantial pressure drop of between about 500 psi (23.9 KPa) to 700 psi (33.5 kPa) as it passes through the membrane. The pressure of the non-permeate gas is unchanged by the membrane. The non-permeate gas pressure is reduced to between about 200 and about 500 psi for use in a combustion turbine. The hydrogen-rich permeate is compressed to between about 800 and 3000 psi (143.6 kPa) for use in subsequent operations, i.e., for use in hydrotreating of crude oil. The non-permeate gas is expanded in a manner to provide energy which is used to compress the permeate gas.

Utilization of membranes and expander/compressors in gasification

The primary object of the present invention is to provide a process and an apparatus to recover heat from a combustion engine turbine exhaust that involves exchanging heat between the combustion engine turbine exhaust and both a heat transfer medium and water. The exhaust is cooled in a series of heat exchange steps that ultimately produces a heated heat transfer medium fluid and superheated steam.

Hot oil integrated with heat recovery steam generator and method of operation

Syngas for use, as fuel in the combustion turbine of an IGCC process is heated to a maximum temperature of about 350&deg; F. (177&deg; C.) prior to entering the combustor. Non-combustible diluent gas and additional fuel with a high heating value is also added to the syngas to increase the total heating value of the feed to the combustor of the gas turbine. The cooler temperature allows for more mass flow to the combustion turbine, allowing for greater sensible heat in the syngas to offset the latent heat loss due to the cooler temperature. Because the syngas/diluent feed steam is not heated to the high temperatures disclosed in the prior art, the steam that would otherwise heat the feed stream is available for power generation in the steam turbine, increasing its individual power output and the overall power output of the IGCC process.

Combustion turbine fuel inlet temperature management for maximum power outlet

A hydrotreated liquid contains volatile hydrocarbons, hydrogen, and contaminants such as hydrogen sulfide. An inert gas, preferably nitrogen, is used to strip volatiles from the hydrotreated liquid. This stripper gas is then added to fuel gas fed to a combustion turbine, where combustibles in the fuel gas and stripper gas are combusted. The stripping is at a pressure sufficient to allow the stripper gas, now containing hydrocarbons and hydrogen, to be added to the combustion turbine fuel without additional compression. This process allows for efficient use of the stripped combustibles, and the nitrogen added to the fuel, gas provides increased power generation from the combustion turbine and reduces NO emissions.

Nitrogen stripping of hydrotreater condensate

This invention involves heat integration of a solvent deasphalting process with a gasification process and an improved process for separating a resin phase from a solvent solution comprising a solvent, deasphalted oil (DAO) and resin. This improved process comprises heating the solvent solution so as to precipitate the resin from the solvent solution, and then separating the resin and some solvent from the solvent solution. This will produce a resin product and a mixture comprising the DAO and the remaining solvent. The DAO/solvent mixture is then boiled so as to vaporize a fraction of the solvent, with waste heat from a gasification unit providing the heat source for the boiling. The vaporized solvent is removed from the DAO/solvent mixture leaving a resin-free DAO product that contains any unvaporized solvent. The vaporized solvent is used for heating the aforementioned solvent solution and preheating the resin-free DAO/solvent mixture. The solvent solution heating and DAO/solvent mixture preheating steps are usually done in series, where the DAO/solvent mixture is first preheated prior to the boiling step leaving a cooled vaporized solvent fraction. The cooled vaporized solvent fraction is then used to provide the heat to the solvent solution prior to the resin separation step. The asphalt that is recovered in the deasphalting step is then used as feedstock in the gasification process.

Asphalt and resin production to integration of solvent deasphalting and gasification

The present invention is a process to recover a high purity, high pressure hydrogen gas stream from synthesis gas. The synthesis gas is contacted with a membrane that separates the synthesis gas into a hydrogen-enriched permeate and a hydrogen-depleted non-permeate. The permeate is conveyed to a carbon dioxide absorber. The carbon dioxide absorber removes carbon dioxide using a solvent. The carbon dioxide-rich solvent from the absorber is heated and sent to a gas-liquid contactor, where the solvent is regenerated by nitrogen stripping. A small recycle stream of a regenerating gas, i.e., hydrogen, is subsequently contacted with the solvent, stripping entrained and dissolved nitrogen from the solvent. This stripping gas, the regenerating gas, or preferably both, are then mixed with the non-permeate for combustion in a combustion turbine.

Hydrogen recycle and acid gas removal using a membrane

During the hydrotreating process, hydrogen sulfide and short chain hydrocarbons such as methane, ethane, propane, butane and pentane are formed. The separation of gas from hydrotreated liquid hydrocarbons is achieved using a stripper and a flash drum. High pressure steam or nitrogen is contacted with the hydrotreated liquid hydrocarbon material. This high pressure steam strips the volatiles, i.e., hydrogen, the volatile hydrocarbons, hydrogen sulfide, and the like, from the oil. The gaseous stream is then separated and cooled to remove condensables, including primarily water, short chain hydrocarbons, and hydrogen sulfide in the water. The condensables are advantageously sent to the gasifier, where the hydrocarbons are gasified, the water moderates the gasifier temperature and increases the yield of hydrogen, and where hydrogen sulfide is routed with the produced synthesis gas to the acid gas removal process.

Integration of solvent deasphalting, gasification, and hydrotreating

The invention is a process to recover a high pressure hydrogen-rich gas stream from a purge gas stream taken from a hydrotreater. This purge gas stream is admixed with synthesis gas that was the original source of the hydrogen to form a gaseous mixture. This mixed gas comprising purge gas and synthesis gas is advantageously treated to remove acid gases and possibly other impurities. The mixed gas is then treated to extract a hydrogen-rich gas and a hydrogen-depleted gas using, for example, a membrane. At least a portion of the hydrogen-rich gas is then heated and compressed as necessary and is recycled to the hydrotreater.

Reclaiming of purge gas from hydrotreaters and hydrocrackers

The invention provides an improved ammonium synthesis process. A synthesis gas is separated with a membrane into a hydrogen-rich gas and a hydrogen-depleted gas. The hydrogen rich gas is shifted with steam to convert carbon monoxide to carbon dioxide and hydrogen. Carbon dioxide is removed from the shifted gas, and remaining carbon oxides are methanized. This gas is admixed with nitrogen and with recycled ammonia synthesis feedstock gas. This ammonia synthesis feedstock gas is then cycled in an ammonia synthesis reactor. A purge gas stream is withdrawn from the ammonia synthesis feedstock gas and is admixed with the hydrogen-depleted gas. The hydrogen-depleted gas and the purge gas are combusted, usually in a combustion turbine, to generate heat or power. Lower purity hydrogen can therefore be used in the synthesis of the ammonia.

Method of utilizing purge gas from ammonia synthesis

The invention is a process of removing solids, particularly catalyst fines, from an asphaltene-containing hydrocarbon liquid. The process comprises contacting an asphaltene-containing hydrocarbon liquid with a solvent to create a mixture. The solvent is typically an alkane such as, propane to pentanes. Then, solids are removed from the mixture by any known process. Finally, additional solvent may be added, and the mixture heated until asphaltenes precipitate into a separate phase. The asphaltenes are removed from the mixture. The mixture is then further heated to recover the solvent from the deasphalted hydrocarbon liquid. The asphaltenes are advantageously gasified.

Filtration of feed to integration of solvent deasphalting and gasification

The invention is the integration of a process of gasifying asphaltenes in a gasification zone by partial oxidation and the process of asphaltene extraction with a solvent. The integration allows low level heat from the gasification reaction to be utilized in the recovery of solvent that was used to extract asphaltenes from an asphaltene-containing hydrocarbon material. Asphaltenes are extracted from an asphaltene-containing hydrocarbon material by mixing a solvent in quantities sufficient to precipitate at least a fraction of the asphaltenes. The precipitated asphaltenes are then gasified in a gasification zone to synthesis gas. The gasification process is very exothermic. The low level heat in the synthesis gas, either directly, or via an intermediate step of low pressure steam, is used to remove and recover the solvent from the deasphalted hydrocarbon material and from the asphaltenes prior to gasification.

Integration of solvent deasphalting and gasification

The invention is a process for separating acid gases from synthesis gas and treating the resulting solids. A mixture comprising synthesis gas and acid gas is contacted with a fluid that reacts with said acid gas to form a particulate solid dispersed in a fluid. The slurry comprising fluid and particulate solid is filtered to separate the particulate solid from the fluid by means of a regenerable filter. The particulate solids are removed from the regenerable filter by back-washing with a back-washing fluid to form a pumpable slurry comprising a mixture of particulate solids and back-washing fluid. The slurry is gasified to form synthesis gas and vitrified solids.

Acid gas solvent filtration system

An apparatus and a process for cooling a feed injector of a gasification reactor that produces synthesis gas is described. Cooling fluid is injected into a channel in the feed injector adapted for circulating the fluid. The injection pressure is maintained near or above the gasification reactor pressure. The fluid is withdrawn from the channel through an outlet at an outlet pressure between about 515 KPa above to about 1030 KPa below the gasification reactor pressure. The fluid is cooled, degassed, and injected back into the channel in the feed injector. The pressure on the cooling system is variable and tracks the gasification reactor pressure.

Floating pressure gasifier feed injector cooling water system

The system for controlling oxygen flow in a gasification process of the instant invention comprises a suction control valve located between the oxygen source and the oxygen compressor. The suction control valve is adapted in order to open to deliver oxygen from the source to the compressor through the first pipe and to move to a reduced flow position to prevent excess delivery of oxygen from the source to the compressor. The system also comprises a second pipe which operably connects the oxygen compressor to a port of a gasifier. The system comprises a normally closed vent valve located between the oxygen compressor and the port of a gasifier. The system comprises a means located in the gasifier or in the gasifier effluent for detecting when it is necessary to change the oxygen flow to the gasifier and to actuate the suction control valve sufficient to change the oxygen flow. Finally, the system comprises a means for a means of controlling the suction control valve and the vent valve to regulate the quantity of oxygen delivered to the gasifier.

Growing community of inventors

Missouri City, TX, United States of America

Kay Anderson Johnson