CA2624626A1 - Catalytic steam gasification of petroleum coke to methane - Google Patents
Catalytic steam gasification of petroleum coke to methane Download PDFInfo
- Publication number
- CA2624626A1 CA2624626A1 CA002624626A CA2624626A CA2624626A1 CA 2624626 A1 CA2624626 A1 CA 2624626A1 CA 002624626 A CA002624626 A CA 002624626A CA 2624626 A CA2624626 A CA 2624626A CA 2624626 A1 CA2624626 A1 CA 2624626A1
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- CA
- Canada
- Prior art keywords
- steam
- catalyst
- petroleum coke
- methane
- raw product
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/82—Gas withdrawal means
- C10J3/84—Gas withdrawal means with means for removing dust or tar from the gas
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C1/00—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/46—Gasification of granular or pulverulent flues in suspension
- C10J3/48—Apparatus; Plants
- C10J3/482—Gasifiers with stationary fluidised bed
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
- C07C2523/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the alkali- or alkaline earth metals or beryllium
- C07C2523/04—Alkali metals
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2527/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- C07C2527/20—Carbon compounds
- C07C2527/232—Carbonates
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0903—Feed preparation
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0913—Carbonaceous raw material
- C10J2300/0943—Coke
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0953—Gasifying agents
- C10J2300/0973—Water
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
- C10J2300/0983—Additives
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
- C10J2300/1823—Recycle loops, e.g. gas, solids, heating medium, water for synthesis gas
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/584—Recycling of catalysts
Abstract
The present invention provides a catalyticsteam gasification process of gasifiying petrolelum coke. The solids composition within the gasification reactor of the disclosed invention is maintained by controlling the catalyst composition of the feed. The process utilizes sour water from the raw gasification product gases to recover and recycle catalyst. Fine particles generated in the handling of coke are advantageously utilized to increase the efficiency of the process.
Claims (18)
1. A process for converting petroleum coke to methane, comprising:
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles with said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
recovering methane from said raw product gas; and controlling the concentration of catalyst in said aqueous medium based on the amount of ash in said petroleum coke.
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles with said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
recovering methane from said raw product gas; and controlling the concentration of catalyst in said aqueous medium based on the amount of ash in said petroleum coke.
2. The process of Claim 1 wherein said catalyst having steam gasification activity comprises one or more from the group consisting of alkali metals and alkali metal compounds.
3. The process of Claim 2 wherein said alkali metal compounds are selected from the group consisting of alkali metal carbonates, alkali metal bicarbonates, alkali metal formates, alkali metal oxalates, alkali metal amides, alkali metal hydroxides, alkali metal acetates, and alkali metal sulfides.
4. The process of Claim 2 wherein said catalyst comprises one or more alkali metal compounds selected from the group consisting of Na2CO3, K2CO3, Rb2CO3, Li2CO3, Cs2CO3, NaOH, KOH, RbOH and CsOH.
5. The process of Claim 2 wherein said catalyst comprises potassium carbonate or potassium hydroxide.
6. The process of Claim 5 wherein said potassium carbonate concentration in said aqueous medium is in the range of about 0.9 to 10 wt%.
7. A process for converting petroleum coke to methane, comprising:
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles and said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
recovering methane from said raw product gas;
contacting said solid purge with said sour water to dissolve said incorporated catalyst to form a dilute aqueous catalyst solution, and returning said dilute aqueous catalyst solution to said feed slurry.
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles and said net steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
recovering methane from said raw product gas;
contacting said solid purge with said sour water to dissolve said incorporated catalyst to form a dilute aqueous catalyst solution, and returning said dilute aqueous catalyst solution to said feed slurry.
8. The process of Claim 7 wherein the solid purge from the gasification reactor is contacted with said sour water in a slurry vessel, and ammonia vapor is recovered from said slurry vessel.
9. The process of Claim 7 wherein said dilute catalyst solution is contacted with a gas containing CO2 before returning to said feed slurry.
10. The process of Claim 7 wherein said dilute catalyst solution is stripped with said cooled raw product gas before returning to said feed slurry.
11. A process for gasifying petroleum coke comprising:
crushing petroleum coke to produce petroleum coke particles having a mesh size larger than about 325 mesh on the U.S. Standard Sieve Scale and a stream of petroleum coke fines;
combining said petroleum coke particles and at least part of said petroleum coke fines with a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles and said net steam in a gasification reactor.
crushing petroleum coke to produce petroleum coke particles having a mesh size larger than about 325 mesh on the U.S. Standard Sieve Scale and a stream of petroleum coke fines;
combining said petroleum coke particles and at least part of said petroleum coke fines with a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
introducing said feed slurry and superheated steam into a slurry drier to produce net steam and substantially dry solid particles of petroleum coke impregnated with catalyst;
reacting said dry solid particles and said net steam in a gasification reactor.
12. The process of Claim 11 wherein said petroleum coke particles range in size from 33 to 100 mesh.
13. The process of Claim 11 wherein said reactor comprises a fluidized bed.
14. The process of Claim 13 wherein said reactor has an upper fluidized bed and a lower fluidized bed.
15. A process for converting petroleum coke to methane, comprising:
introducing dry petroleum coke, catalyst having steam gasification activity, and superheated steam to a gasification reactor;
reacting said coke, catalyst, and steam to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
contacting said solid purge with said sour water in a slurry vessel;
recovering ammonia vapor from said slurry vessel; and recovering methane from said raw product gas.
introducing dry petroleum coke, catalyst having steam gasification activity, and superheated steam to a gasification reactor;
reacting said coke, catalyst, and steam to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
contacting said solid purge with said sour water in a slurry vessel;
recovering ammonia vapor from said slurry vessel; and recovering methane from said raw product gas.
16. A process for producing methane from petroleum coke comprising:
introducing to a gasification reactor petroleum coke containing an ash mass fraction (dry basis), catalyst containing a mass fraction of alkali, and superheated steam, whereby the ratio of alkali to ash introduced to said reactor is between 3 and 10;
reacting said coke, catalyst, and steam to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; and recovering methane from said raw product gas.
introducing to a gasification reactor petroleum coke containing an ash mass fraction (dry basis), catalyst containing a mass fraction of alkali, and superheated steam, whereby the ratio of alkali to ash introduced to said reactor is between 3 and 10;
reacting said coke, catalyst, and steam to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; and recovering methane from said raw product gas.
17. A process for converting petroleum coke to methane, comprising:
reacting petroleum coke with steam in a gasification reactor in the presence of a catalyst having steam gasification activity to form a product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; and controlling the ratio of said catalyst to said petroleum coke based on the amount of ash in said petroleum coke.
reacting petroleum coke with steam in a gasification reactor in the presence of a catalyst having steam gasification activity to form a product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide; and controlling the ratio of said catalyst to said petroleum coke based on the amount of ash in said petroleum coke.
18. A process for converting petroleum coke to methane, comprising:
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
recovering dry solids from said feed slurry;
reacting said dry solids and steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
contacting said solid purge with said sour water to dissolve said incorporated catalyst to form a dilute aqueous catalyst solution, and returning said dilute aqueous catalyst solution to said feed slurry.
combining petroleum coke and a catalyst having steam gasification activity in an aqueous medium to form a feed slurry;
recovering dry solids from said feed slurry;
reacting said dry solids and steam in a gasification reactor to form a raw product gas comprised of unreacted steam, methane, carbon dioxide, hydrogen, and carbon monoxide;
withdrawing a solid purge from said reactor, said solid purge comprising coke material and having catalyst incorporated therewith;
cooling said raw product stream to condense unreacted steam to form sour water and a stream of cooled raw product gas;
contacting said solid purge with said sour water to dissolve said incorporated catalyst to form a dilute aqueous catalyst solution, and returning said dilute aqueous catalyst solution to said feed slurry.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/249,814 | 2005-10-12 | ||
| US11/249,814 US8114176B2 (en) | 2005-10-12 | 2005-10-12 | Catalytic steam gasification of petroleum coke to methane |
| PCT/US2006/039431 WO2007047210A1 (en) | 2005-10-12 | 2006-10-05 | Catalytic steam gasification of petroleum coke to methane |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2624626A1 true CA2624626A1 (en) | 2007-04-26 |
| CA2624626C CA2624626C (en) | 2012-02-28 |
Family
ID=37911761
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2624626A Expired - Fee Related CA2624626C (en) | 2005-10-12 | 2006-10-05 | Catalytic steam gasification of petroleum coke to methane |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US8114176B2 (en) |
| CN (1) | CN101356254A (en) |
| AU (1) | AU2006304019A1 (en) |
| CA (1) | CA2624626C (en) |
| DE (1) | DE112006002722T5 (en) |
| EA (1) | EA012999B1 (en) |
| WO (1) | WO2007047210A1 (en) |
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2005
- 2005-10-12 US US11/249,814 patent/US8114176B2/en active Active
-
2006
- 2006-10-05 WO PCT/US2006/039431 patent/WO2007047210A1/en active Application Filing
- 2006-10-05 CN CNA2006800379897A patent/CN101356254A/en active Pending
- 2006-10-05 CA CA2624626A patent/CA2624626C/en not_active Expired - Fee Related
- 2006-10-05 DE DE112006002722T patent/DE112006002722T5/en not_active Ceased
- 2006-10-05 EA EA200801062A patent/EA012999B1/en not_active IP Right Cessation
- 2006-10-05 AU AU2006304019A patent/AU2006304019A1/en not_active Abandoned
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|---|---|
| WO2007047210A1 (en) | 2007-04-26 |
| DE112006002722T5 (en) | 2008-08-07 |
| US8114176B2 (en) | 2012-02-14 |
| AU2006304019A1 (en) | 2007-04-26 |
| US20070083072A1 (en) | 2007-04-12 |
| CA2624626C (en) | 2012-02-28 |
| CN101356254A (en) | 2009-01-28 |
| EA200801062A1 (en) | 2008-08-29 |
| EA012999B1 (en) | 2010-02-26 |
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