Systems and methods for producing synthesis gas

Abstract

The present invention relates to a system for producing synthesis gas comprising CO and H 2 . The system comprises a first gasification reactor and a second gasification reactor. The first one has an inlet for a first oxygen containing stream, an inlet for a first carbonaceous stream, and an outlet for raw synthesis gas produced in the first gasification reactor. The second one has an inlet for a second oxygen containing stream, an inlet for a second carbonaceous stream, and an outlet for raw synthesis gas produced in the second gasification reactor. A source of an oxygen containing stream is selectively connected to the inlet for the first oxygen containing stream of the first gasification reactor and to the inlet for the second oxygen containing stream of the second gasification reactor via a distributor.

1 . A system for producing synthesis gas comprising CO and H 2 , the system comprising: 
 a first gasification reactor comprising a first-reactor oxygen inlet for a first oxygen-containing stream, a first-reactor fuel inlet for a first, carbonaceous stream, and a first-reactor outlet for raw synthesis gas produced in the first gasification reactor;    a second gasification reactor comprising a second-reactor oxygen inlet for a second oxygen-containing stream, a second-reactor fuel inlet for a second carbonaceous stream, and a second-reactor outlet for raw synthesis gas produced in the second gasification reactor;    an oxygen source of an oxygen containing stream; and    a distributor for fluidly connecting the oxygen source to the first-reactor oxygen inlet and to the second-reactor oxygen inlet, the distributor being arranged to selectively connect the oxygen source to the first or second gasification reactor.    
   
   
       2 . The system of  claim 1 , wherein the oxygen-containing stream comprises greater than 50 vol. % O 2 .  
   
   
       3 . The system of  claim 1 , wherein the oxygen-containing stream comprises greater than 99 vol. % O 2 .  
   
   
       4 . The system of  claim 1 , wherein the first carbonaceous stream is selected from the group consisting of a particulate and a liquid stream and the second carbonaceous stream is selected from a group consisting of a gaseous and liquid stream and a mixture thereof.  
   
   
       5 . The system of  claim 1 , wherein the first carbonaceous stream is a particulate stream.  
   
   
       6 . The system of  claim 5 , wherein the second carbonaceous stream is a gaseous stream.  
   
   
       7 . The system of  claim 1 , wherein the second carbonaceous stream is a gaseous stream.  
   
   
       8 . The system of  claim 7 , wherein the first carbonaceous stream is a liquid stream.  
   
   
       9 . The system of  claim 1 , wherein the oxygen source comprises an air separation unit having a maximum oxygen capacity of less than 80% of the sum of the oxygen requirements for the first and the second gasification reactors.  
   
   
       10 . The system of  claim 9 , wherein the maximum oxygen capacity of the air separation unit is less than 65% of the sum of the oxygen requirements for the first and the second gasification reactors.  
   
   
       11 . The system of  claim 1 , further comprising a second first gasification reactor.  
   
   
       12 . The system of  claim 1 , further comprising a shift converter being connected to the first-reactor outlet and the second-reactor outlet, in which shift converter at least a part of the CO in the synthesis gas may be reacted to produce CO 2  and H 2 .  
   
   
       13 . A method of producing synthesis gas comprising CO and H 2 , from a carbonaceous stream using an oxygen-containing stream, the method comprising the steps of: 
 (a) injecting a first carbonaceous stream and a first oxygen containing stream into a first gasification reactor, the first oxygen-containing stream originating from a source of oxygen;    (b) at least partially oxidising the first carbonaceous stream in the first gasification reactor, thereby obtaining a first raw synthesis gas;    (c) removing the first raw synthesis gas obtained in step (b) from the first gasification reactor;    (d) injecting a second carbonaceous stream and a second oxygen-containing stream into a second gasification reactor, and wherein the second oxygen containing stream originates from the source of oxygen used in step (a);    (e) at least partially oxidising the second carbonaceous stream in the second gasification reactor, thereby obtaining a second raw synthesis gas; and    (f) removing the second raw synthesis gas obtained in step (e) from the second gasification reactor;    wherein the first and second gasification reactors are used alternately.    
   
   
       14 . The method of  claim 13 , wherein the oxygen containing stream comprises greater than 50 vol. % O 2 .  
   
   
       15 . The method of  claim 13 , wherein the oxygen containing stream comprises greater than 99 vol. % O 2 .  
   
   
       16 . The method of  claim 13 , wherein the first carbonaceous stream is selected from a group consisting of a particulate and a liquid stream and the second carbonaceous stream is selected from a group consisting of a gaseous and liquid stream and a mixture thereof.  
   
   
       17 . The method of  claim 13 , wherein the first carbonaceous stream is a particulate stream.  
   
   
       18 . The method of  claim 17 , wherein the second carbonaceous stream is a gaseous stream.  
   
   
       19 . The method of  claim 13 , wherein the second carbonaceous stream is a gaseous stream.  
   
   
       20 . The method of  claim 19 , wherein the first carbonaceous stream is a liquid stream.  
   
   
       21 . The method of  claim 13 , further comprising the steps of: 
 (g) transporting at least one of the first synthesis gas removed in step (c) and the second synthesis gas removed in step (f) to a shift converter; and    (h) reacting at least a part of the CO comprised in the at least one of the first and second synthesis gas transported in step (g) to produce CO 2  and H 2 .    
   
   
       22 . A method using a spare gasification reactor in a process to generate power from a source of petroleum coke in one or more parallel operated gasification reactors, which spare reactor is capable of preparing a spare synthesis gas mixture comprising carbon monoxide and hydrogen by partial oxidation of at least one of a vacuum residue and natural gas, using up to a maximum first volume of oxygen per hour as obtained from an air separation unit, and wherein power is generated from the petroleum coke by 
 (aa) partial oxidation of the petroleum coke using up to a maximum second volume of oxygen per hour as obtained from the air separation unit, to yield a synthesis gas mixture,    (bb) using at least one of the synthesis gas mixture as obtained from step (aa) and the optional spare synthesis gas mixture to generate power wherein a maximum capacity of the air separation unit is less than the sum of the maximum first and second oxygen volumes per hour.    
   
   
       23 . The method of  claim 22 , further comprising a step of isolating carbon dioxide prior to the power generation.  
   
   
       24 . The method of  claim 23 , wherein the carbon dioxide is isolated in a gas turbine.  
   
   
       25 . The method of  claim 22  carried out in the system of  claim 1 .  
   
   
       26 . A process to prepare hydrogen from a source of petroleum coke in one or more parallel operated gasification reactors employing a spare gasification reactor, which spare reactor is capable of preparing an optional spare synthesis gas mixture comprising carbon monoxide and hydrogen, by partial oxidation of at least one of a vacuum residue and natural gas, using up to a maximum first volume of oxygen per hour as obtained from an air separation unit, and wherein hydrogen is prepared from the petroleum coke by 
 (aa1) partial oxidation of the petroleum coke using up to a maximum second volume of oxygen per hour as obtained from the air separation unit to yield a synthesis gas mixture,    (bb1) subjecting at least one of the synthesis gas mixture as obtained from step (aa1) and the optional spare synthesis gas mixture to a water gas shift step to obtain shifted gas,    (cc1) subjecting the shifted gas to a gas separation step to obtain a hydrogen enriched mixture,    wherein the maximum capacity of the air separation unit is less than the sum of the maximum first and second oxygen volumes per hour.    
   
   
       27 . The process of  claim 26 , wherein the gas separation step comprises a pressure swing absorbing process.  
   
   
       28 . The process of  claim 26  carried out in the system of  claim 1.