Partial oxidation process

Abstract

Synthesis gas is produced by the partial oxidation of a feedstock comprising petroleum coke and/or heavy liquid hydrocarbonaceous fuel containing sulfur and having an ash that contains nickel, vanadium and a low content of silicon. An iron-containing additive is introduced into the vertical free-flow unobstructed refractory lined reaction zone along with the feed to produce first and second types of liquid phase washing agents which collect and transport at least a portion of the vanadium-containing oxide laths and spinels and other ash components out of the reaction zone. The refractory lining of the reaction zone comprises in wt. %: MgO 85 to 98, Fe.sub.2 O.sub.3 0.03 to 3.0, Al.sub.2 O.sub.3 0.02 to 2.0, CaO 0.01 to 10, and SiO.sub.2 0.02 to 2.0. Elemental iron may be prevented from forming in the reaction zone by introducing sufficient supplemental oxygen-containing material and/or sulfur-containing material into the reaction zone so as to keep the partial pressure of oxygen and/or S.sub.2 gas in the reaction zone slightly above that calculated from Formulae I and/or II. The refractory substantially resists corrosion, erosion, and chemical attack by the molten slag. The life of the refractory is extended. Further, the molten slag is modified by contact with the refractory so that it runs more freely from the gasifier. By this method molten slag having a reduced viscosity and containing the nickel and vanadium-containing impurities from the feedstock and refractory components is readily removed from the gas generator.