Thermal and chemical utilization of carbonaceous materials, in particular for emission-free generation of energy

Abstract

A process for the generation of energy and/or hydrocarbons and other products utilizing carbonaceous materials. In a first process stage (P 1 ) the carbonaceous materials are supplied and are pyrolysed, wherein pyrolysis coke (M 21 ) and pyrolysis gas (M 22 ) are formed. In a second process stage (P 2 ), the pyrolysis coke (M 21 ) from the first process stage (P 1 ) is gasified, wherein synthesis gas (M 24 ) is formed, and slag and other residues (M 91 , M 92 , M 93 , M 94 ) are removed. In a third process stage (P 3 ), the synthesis gas (M 24 ) from the second process stage (P 2 ) is converted into hydrocarbons and/or other solid, liquid, and/or gaseous products (M 60 ), which are discharged. The three process stages (P 1 , P 2 , P 3 ) form a closed cycle. Surplus gas (M 25 ) from the third process stage (P 3 ) is passed as recycle gas into the first process stage (P 1 ), and/or the second process stage (P 2 ), and pyrolysis gas (M 22 ) from the first process stage (P 1 ) is passed into the second process stage (P 2 ), and/or the third process stage (P 3 ).

What is claimed is: 
     
         1 . A facility for emission-free generation of energy and/or hydrocarbons and/or other products by utilizing carbonaceous materials, with a utilization installation comprising a utilization unit with
 a first subunit for carrying out a pyrolysis of the carbonaceous materials to form pyrolysis coke and pyrolysis gas;   a second subunit for carrying out a gasification of the pyrolysis coke, to form synthesis gas and residues; and   a third subunit for carrying out a conversion of the synthesis gas into hydrocarbons and/or other solid, liquid and/or gaseous products, and a recycle gas comprising carbon dioxide, water vapor, and unreacted carbon monoxide and hydrogen, the third subunit of the utilization unit comprising a Fischer-Tropsch synthesis stage, and/or a liquid-phase methanol synthesis stage;   wherein the first subunit and the second subunit comprise a shared pressure reactor,   a transport pipe for the synthesis gas connects the second subunit pressure-tightly to the third subunit; and a transport pipe for the recycle gas connects the third subunit pressure-tightly to the first subunit, and   all three subunits of the utilization unit are pressure-tightly closed and form an essentially closed cycle.   
     
     
         2 . The facility according to  claim 1 , wherein at least one compressor is arranged along at least one of said transport pipes of the utilization unit. 
     
     
         3 . The facility according to  claim 1 , wherein the subunits of the utilization unit each comprise one or more pressure reactors. 
     
     
         4 . The facility according to  claim 1 , wherein the facility comprises an energy installation that is arranged for generating at least one of electrical energy, mechanical energy, and thermal energy, by using hydrocarbons and/or other products from the utilization installation as fuels. 
     
     
         5 . The facility according to  claim 4 , wherein the energy installation is provided with a drive device, for generating electrical and/or mechanical energy from the fuels, wherein said drive device obtains the energy necessary for operation from the oxidation of the fuels to an oxidation gas consisting essentially of carbon dioxide and water, and comprises a device for the compression and/or condensation of the oxidation gas. 
     
     
         6 . The facility according to  claim 5 , wherein the drive device of the energy installation is operable with pure oxygen as an oxidizing agent. 
     
     
         7 . The facility according to  claim 5 , wherein the drive device of the energy installation comprises a heat exchanger for cooling down a stream of the oxidation gas, upstream and/or downstream of the device for the compression and/or condensation of the oxidation gas. 
     
     
         8 . The facility according to  claim 5 , wherein the drive device of the energy installation comprises a device for condensation and/or separation of water from the oxidation gas. 
     
     
         9 . The facility according to  claim 5 , wherein the drive device of the energy installation is provided with a storage for collecting the oxidation gas, or the residual gas after compression and/or condensation, respectively, of the oxidation gas. 
     
     
         10 . The facility according to  claim 5 , wherein the drive device of the energy installation is a combustion engine, with at least one combustion chamber for combustion of liquid or gaseous fuel with oxygen, with means for converting the resulting gas pressure or gas volume into mechanical work, with a feed device for introducing oxygen into the combustion chamber, and with a venting device for removing the oxidation gas from the combustion chamber. 
     
     
         11 . The facility according to  claim 10 , wherein the drive device of the energy installation is provided with a feed device for introducing water and/or steam into the combustion chamber, and/or into a stream of the oxidation gas after exit from the combustion chamber. 
     
     
         12 . The facility according to  claim 1 , wherein the utilization installation comprises an energy unit for generating electrical and/or mechanical energy, with at least one drive device for generating electrical and/or mechanical energy from steam and/or other hot gases that have been generated or superheated in the utilization unit. 
     
     
         13 . The facility according to  claim 12 , wherein the energy unit of the utilization installation comprises a drive device for generating electrical and/or mechanical energy from steam or other hot gases that have been generated or superheated in the utilization unit; and
 in that in the cycle of the utilization unit at least one heat exchanger is provided for heating steam and/or other gases, and/or for generating steam.   
     
     
         14 . The facility according to  claim 1 , wherein the facility comprises an installation for the production of hydrogen and means for supplying the hydrogen into the utilization unit. 
     
     
         15 . The facility according to  claim 1 , wherein in the shared pressure reactor of the first subunit and the second subunit, the pyrolysis coke is lying on a conveying means adapted for continuous horizontal transport of lumpy pyrolysis coke along a horizontal direction. 
     
     
         16 . The facility according to  claim 15 , wherein for carrying out a gasification of the pyrolysis coke in the second subunit in a fire bed, at a temperature above 850° C., to form synthesis gas and residues, the fire bed is formed by pyrolysis coke lying on the conveying means adapted for continuous horizontal transport of lumpy pyrolysis coke along a horizontal direction; a transport pipe for the pyrolysis gas connects the first subunit pressure-tightly to the second subunit, such that the point of entry of the pyrolysis gas into the second subunit is above the fire bed of the pyrolysis coke; and
 means are provided that allow blowing oxygen into the fire bed, spatially separated from the point of entry of the pyrolysis gas, such that the pyrolysis gases do not come into contact with oxygen. 
 
     
     
         17 . A process for the emission-free generation of energy and/or hydrocarbons and other products by utilization of carbonaceous materials, comprising:
 in a first process stage, supplying the carbonaceous materials to a first subunit;   pyrolyzing the carbonaceous materials in the first subunit to form pyrolysis coke and pyrolysis gas;   passing the pyrolysis coke and the pyrolysis gas into a second subunit;   in a second process stage, gasifying in the second subunit the pyrolysis coke from the first process stage, to form synthesis gas and slag and other residues;   removing said slag and other residues; and   passing the synthesis gas into a third subunit;   in a third process stage, converting in the third subunit the synthesis gas from the second process stage into hydrocarbons and/or other solid, liquid and/or gaseous products, and a recycle gas comprising carbon dioxide, water vapor, and unreacted carbon monoxide and hydrogen, by using Fischer-Tropsch synthesis or a liquid-phase methanol synthesis;   discharging said products; and   passing the recycle gas into the first subunit, thereby forming an essentially closed cycle from the first process stage to the second process stage to the third process stage and back to the first process stage;   wherein the first process stage and the second process stage are carried out in a pressure reactor, and wherein the same pressure reactor is used to carry out both the first and the second process stages.   
     
     
         18 . The process according to  claim 17 , wherein hydrogen is supplied in at least one of said process stages. 
     
     
         19 . The process according to  claim 18 , wherein the hydrogen is supplied in the third process stage. 
     
     
         20 . The process according to  claim 19 , wherein the carbon dioxide is supplied in the first process stage or the second process stage. 
     
     
         21 . The process according to  claim 17 , wherein carbon dioxide is supplied in at least one of said process stages. 
     
     
         22 . The process according to  claim 17 , wherein there is a pressure drop along the cycle. 
     
     
         23 . The process according to  claim 17 , wherein heat energy for the pyrolysis reactions in the first process stage is provided, at least in part by returning a part of hot synthesis gas from the second process stage into the first process stage, and/or by partial oxidation of the carbonaceous starting material and the resultant pyrolysis coke. 
     
     
         24 . The process according to  claim 17 , wherein the first process stage is carried out at a temperature between 300° C. and 800° C. 
     
     
         25 . The process according to  claim 24 , wherein the first process stage is carried out at a temperature between 450° C. and 700° C. 
     
     
         26 . The process according to  claim 24 , wherein the first process stage is carried out at a temperature between 500° C. and 600° C. 
     
     
         27 . The process according to  claim 17 , wherein for the gasification reaction in the second process stage oxygen and/or steam and/or carbon dioxide is used as a gasification agent. 
     
     
         28 . The process according to  claim 17 , wherein in the second process stage, the thermal energy required for the gasification reaction is supplied, at least in part from outside; and/or is generated by oxidizing a part of the pyrolysis coke with an oxidizing agent. 
     
     
         29 . The process according to  claim 28 , wherein the thermal energy required for the gasification reaction in the second process stage is supplied by heating devices and/or heat exchangers. 
     
     
         30 . The process according to  claim 28 , wherein the thermal energy required for the gasification reaction is generated by oxidizing a part of the pyrolysis coke using oxygen as the oxidizing agent. 
     
     
         31 . The process according to  claim 17 , wherein the second process stage is carried out at a temperature between 600° C. and 1600° C. 
     
     
         32 . The process according to  claim 31 , wherein the second process stage is carried out at a temperature between 700° C. and 1400° C. 
     
     
         33 . The process according to  claim 31 , wherein the second process stage is carried out at a temperature between 850° C. and 1000° C. 
     
     
         34 . The process according to  claim 17 , wherein the first process stage and/or the second process stage is carried out at a pressure between 1 and 60 bar. 
     
     
         35 . The process according to  claim 34 , wherein the pressure is between 5 bar and 25 bar. 
     
     
         36 . The process according to  claim 34 , wherein the pressure is between 10 bar and 15 bar. 
     
     
         37 . The process according to  claim 17 , wherein electrical and/or mechanical energy is generated by oxidation of the hydrocarbons and other solid, liquid, and/or gaseous products of the third process stage, to an oxidation gas, said oxidation gas consisting essentially of carbon dioxide and water. 
     
     
         38 . The process according to  claim 37 , wherein pure oxygen is used as an oxidizing agent. 
     
     
         39 . The process according to  claim 37 , wherein water is condensed out and/or separated from the oxidation gas. 
     
     
         40 . The process according to  claim 37 , wherein at least a part of the oxidation gas is fed back into at least one of the first process stage, the second process stage and the third process stage of the generation process. 
     
     
         41 . The process according to  claim 17 , wherein electrical and/or mechanical energy is generated by cooling the synthesis gas in a heat exchanger, wherein superheated steam and/or another hot gas are formed, from which electrical and/or mechanical energy is generated using a heat engine. 
     
     
         42 . The process according to  claim 41 , wherein the heat engine is a steam turbine. 
     
     
         43 . The process according to  claim 17 , wherein in the first process stage during the pyrolyzation of the carbonaceous materials in the first subunit, the pyrolysis coke is lying on a conveying means adapted for continuous horizontal transport of lumpy pyrolysis coke along a horizontal direction. 
     
     
         44 . The process according to  claim 17 , wherein in the second process stage, the pyrolysis coke from the first process stage is gasified in the in the second subunit in a fire bed that is formed by pyrolysis coke lying on a conveying means adapted for continuous horizontal transport of lumpy pyrolysis coke along a horizontal direction, at a temperature above 850° C., to form synthesis gas and slag and other residues, wherein a point of entry of the pyrolysis gas into the second subunit is above the fire bed of the pyrolysis coke, and wherein oxygen is blown into the fire bed, spatially separated from the point of entry of the pyrolysis gas, such that the pyrolysis gas does not come into contact with oxygen.