Partial oxidation process

Abstract

An ash fusion temperature reducing agent comprising a mixture of about 70-97 wt. % of an iron compound and the remainder comprising a silicon compound is mixed with an ash-containing fuel comprising liquid hydrocarbonaceous material and/or petroleum coke. The comminuted mixture is reacted in a free-flow partial oxidation reaction zone with a free-oxygen containing gas in the presence of a temperature moderator to produce a hot raw effluent gas stream comprising H.sub.2 +CO along with molten ash having a reduced initial deformation temperature. The weight ratio of ash fusion temperature reducing agent to ash in said ash-containing fuel is in the range of about 0.5 to 10, and the weight ratio of iron oxide to SiO.sub.2 in said molten ash is about 1.5, or more. The molten ash is then separated from the hot raw effluent gas stream. In another embodiment, the comminuted ash fusion temperature reducing agent is disseminated into an ash-containing heavy liquid hydrocarbonaceous material and the mixture is then coked to produce petroleum coke containing dispersed therein said ash fusion temperature reducing agent. The petroleum coke entrained in a liquid or gaseous carrier is then introduced into the partial oxidation reaction zone as at least a portion of the feedstock. The molten ash is readily separated from the effluent stream of raw synthesis gas. The gas generator may be operated at a lower temperature thereby extending the life of the refractory lined reaction zone.