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WO2006081661A1 - Procede et appareil de gazeification du charbon - Google Patents

Procede et appareil de gazeification du charbon Download PDF

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Publication number
WO2006081661A1
WO2006081661A1 PCT/CA2006/000134 CA2006000134W WO2006081661A1 WO 2006081661 A1 WO2006081661 A1 WO 2006081661A1 CA 2006000134 W CA2006000134 W CA 2006000134W WO 2006081661 A1 WO2006081661 A1 WO 2006081661A1
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WO
WIPO (PCT)
Prior art keywords
coal
reactor vessel
oxygen
synthesis gas
steam
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.)
Ceased
Application number
PCT/CA2006/000134
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English (en)
Inventor
Andreas V. Tsangaris
Kenneth C. Campbell
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Plasco Energy Group Inc
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Plasco Energy Group Inc
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Filing date
Publication date
Application filed by Plasco Energy Group Inc filed Critical Plasco Energy Group Inc
Publication of WO2006081661A1 publication Critical patent/WO2006081661A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • C10J3/723—Controlling or regulating the gasification process
    • 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
    • C10J3/463—Gasification of granular or pulverulent flues in suspension in stationary fluidised beds
    • 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
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
    • C10K3/001—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by thermal treatment
    • C10K3/003—Reducing the tar content
    • C10K3/006—Reducing the tar content by steam reforming
    • 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
    • C10J2300/093—Coal
    • 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
    • C10J2300/0959—Oxygen
    • 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
    • C10J2300/12—Heating the gasifier
    • C10J2300/123—Heating the gasifier by electromagnetic waves, e.g. microwaves
    • C10J2300/1238—Heating the gasifier by electromagnetic waves, e.g. microwaves by plasma
    • 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
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1625—Integration of gasification processes with another plant or parts within the plant with solids treatment
    • C10J2300/1628—Ash post-treatment
    • C10J2300/1634—Ash vitrification

Definitions

  • This invention relates to the gasification of coal, and in particular to a process and apparatus for the gasification of coal.
  • Coal can typically be gasified with oxygen and steam to produce so-called "synthesis gas" containing carbon monoxide, hydrogen, carbon dioxide, gaseous sulfur compounds and particulates.
  • the gasification step is usually carried out at a temperature in the range of about 65O 0 C to 1200 0 C, either at atmospheric pressure or, more commonly, at a high pressure of from about 20 to about 100 atmospheres.
  • Synthesis gas is produced according to the Haber Bosch Process, which was developed in 1917. This process operates on the basic reforming reaction that reacts carbon e.g., coal with steam in a primary reaction to produce hydrogen and carbon monoxide-
  • the hydrogen/carbon monoxide ratio of the synthesis gas varies widely depending on the nature of the coal feed. However, if one mol of methane was reformed with steam, it would produce a synthesis gas which is rich in hydrogen, e.g., three mols of hydrogen and one mol of carbon monoxide, i.e., a hydrogen/carbon monoxide ratio of 3/1.
  • a competing secondary reaction known as the water gas shift reaction also takes place wherein carbon monoxide reacts with steam to form carbon dioxide and additional hydrogen. This water gas shift reaction is a secondary reaction since high temperature and lower pressure favor the primary reaction.
  • coal often contains sulfur compounds
  • attempts have been made to provide processes for the gasification of coal to produce a clean product fuel gas wherein the sulfur is removed from the product fuel gas prior to its use, e.g., in gas turbines to generate electricity.
  • gases from the gasification zone may be purified to remove coal dust and fly ash and also many other impurities, e.g., vaporized ash, alkali, etc.
  • Plasma torch technology has also been employed in coal gasification processes. Plasma torch technology was substantially advanced through the 1960's when new plasma generators were developed to simulate the very high temperature conditions experienced by space vehicles re-entering the Earth's atmosphere. Unlike a combustion burner flame, a plasma arc torch can be operated in the absence of oxygen.
  • a plasma arc torch is created by the electrical dissociation and ionization of a working gas to establish high temperatures at the plasma arc centerline.
  • Commercially-available plasma torches can develop suitably high flame temperatures for sustained periods at the point of application and are available in sizes from about 100 Kw to over 6Mw in output power.
  • Plasma is a high temperature luminous gas that is at least partially ionized, and is made up of gas atoms, gas ions, and electrons. Plasma can be produced with any gas in this manner. This gives excellent control over chemical reactions in the plasma as the gas might be neutral (for example, argon, helium, neon), reductive (for example, hydrogen, methane, ammonia, carbon monoxide), or oxidative (for example, oxygen, nitrogen, carbon dioxide). In the bulk phase, a plasma is electrically neutral. Thermal plasma can be created by passing a gas through an electric arc. The electric arc will rapidly heat the gas by resistive and radiative heating to a very high temperature within microseconds of passing through the arc.
  • a typical plasma torch consists of an elongated tube through which the working gas is passed, with an electrode centered coaxially within the tube.
  • a high direct current voltage is applied across the gap between the end of the center electrode as anode, and an external electrode as cathode.
  • the current flowing through the gas ⁇ in the gap between the anode and the cathode causes the formation of an arc of high temperature electromagnetic wave energy that is comprised of ionized gas molecules.
  • Any gas or mixture of gases, including air, can be passed through the plasma torch.
  • U.S. Patent Nos. 4,141,694 and 4,181,504 describe a process for the gasification of coal in which plasma torches were employed as a bank of long arc columns which devolatilized crushed coal in a matter of milliseconds. Steam was continuously injected to produce carbon-rich gases. The process described in these patents, however, is likely expensive to implement as most of the necessary heat for the process is supplied by the plasma arc.
  • U.S. Patent No. 4,208,191 describes a process for the production of pipeline gas from goal that employs an additional catalytic process and to gasify coal and produce a synthesis gas containing carbon monoxide, hydrogen, gaseous sulfur compounds, methane and carbon dioxide.
  • Gaseous sulfur compounds and carbon dioxide were removed from the gas in an acid gas removal system, followed by contacting the gas with a reduced iron catalyst at conditions to produce methane, and small amounts of olefins. This was followed by separation of carbon dioxide byproduct and methanation with a nickel catalyst to produce additional methane and to convert olefins to alkanes.
  • U.S. Patent No. 4,410,336 also describes a process for the production of pipeline gas from coal that requires several independent sequential processes to be employed.
  • the coal was gasified at a relatively low pressure, typically less than about 5 atmospheres, to produce a raw synthesis gas containing carbon monoxide, hydrogen, carbon dioxide, gaseous sulfur compounds and particulates.
  • the so-produced raw synthesis gas was cooled to a temperature range of about 200 0 C to about 400 0 C and was purified to remove substantially all of the sulfur compounds and particulates contained therein.
  • the clean raw synthesis gas was enriched in a first step by converting the carbon monoxide and hydrogen contained therein to yield a gas containing methane and carbon dioxide.
  • the enriched gas was further enriched in a second step by removing carbon dioxide there from to yield a gas consisting essentially of methane.
  • U.S. Patent No. 4,472,172 describes the gasification of the crushed coal by way of a free-burning arc discharge that produced a highly reactive carbonaceous fume which was subjected to a second independent steam treatment step. This process, however, produced byproduct ash and did not provide secondarily-useful molten slag.
  • U.S. Patent No. 5,331,906 describes a coal combuster that comprises a slag exhausting device and maintains a combustion capability in a combustion furnace for coal gasification by exhausting molten slag produced within the furnace without the slag stagnating by including a special slag exit construction.
  • the slag exhausting device was configured in such a way that the cooling of the molten slag being exhausted from the furnace was minimized to prevent the slag from solidifying, and causing other slag to stagnate. This was achieved by way of a disposing the slag exhausting device at the center of the bottom wall of the furnace and providing such exhaust device with particular dimensional characteristics.
  • U.S. Patent No. 5,486,269 describes the gasification of carbonaceous material in a reactor having a gasification zone and a combustion zone.
  • the gasification zone is described as generally being at super-atmospheric pressure up to 150 bar.
  • the thermal energy which is necessary to maintain the first endothermic reaction is supplied by combustion of a fuel with added oxygen-containing gas. Again, the commercial viability of this process, however, may be compromised by the expense of such a two- stage process.
  • U.S. Patent No. 6,200,430 describes a process whereby coal was subjected to an electric arc-activated, non-catalytic burner at high pressure in the absence of oxygen. Considerable expense would likely be involved in providing a high pressure reactor with attendant apparatus to provide the high pressure, which may impact the commercial viability of this process.
  • An object of the present invention is to provide a coal gasification process and apparatus.
  • a process for producing synthesis gas and vitreous slag from coal comprising the steps of: passing coal into a gasification zone at a coal input rate; passing oxygen, into said gasification zone at an oxygen input rate; subjecting said coal to the heating effect of a first plasma torch configuration in the presence of the oxygen to provide a first gaseous product and by-product ash; passing the first gaseous product to a reforming zone; adding steam to said first gaseous product at a steam input rate to convert the first gaseous product to a synthesis gas; .
  • an apparatus for producing synthesis gas and vitreous slag from coal by the process of the present invention comprising: a gasification zone; one or more coal input in operative communication with said gasification zone for passing coal into said gasification zone; one or more oxygen inlets in operative communication with said gasification zone for passing oxygen into said gasification zone; a first plasma torch configuration positioned to provide a first plasma discharge into said gasification zone and thereby convert said coal and said oxygen into a gaseous product and by-product ash; a reforming zone in operative communication with said gasification zone whereby the first gaseous product passes from said gasification zone into said reformation zone; one or more steam inlets positioned to add steam into said reformation zone and thereby convert said gaseous product into synthesis gas; a synthesis gas outlet in operative communication with said reforming zone for exhausting said synthesis gas from the reformation zone; a melting zone in operative communication with said gasification zone whereby said by-product slag passes from said gasification zone
  • an apparatus for producing synthesis gas and vitreous slag from coal comprising: a refractory-lined reactor vessel; a slag reservoir located at a bottom end of the reactor vessel; an axial synthesis gas outlet associated with the reactor vessel for exhausting said synthesis gasl; a first plasma torch configuration for generating a first plasma discharge, said first plasma torch configuration associated with said reactor vessel and positioned to direct the first plasma discharge into the reaction vessel; a second plasma torch configuration for generating a second plasma discharge, said second plasma torch configuration associated with said reactor vessel and positioned to direct the second plasma discharge towards the slag reservoir; a slag outlet associated with said reactor vessel and positioned to exhaust molten slag from the slag reservoir; one or more coal inlets associated with said reactor vessel and positioned to inject coal into the first plasma discharge; one or more oxygen inlets associated with said reactor vessel and positioned to inject oxygen into the first plasma discharge; and one or more steam inlets associated with said reactor vessel to inject
  • Figure 1 is a central longitudinal cross-section through a reactor vessel in one embodiment of the present invention
  • FIG. 2 is a block diagram of reactor controls in one embodiment of the present invention.
  • FIG. 3 is block diagram of process logic in one embodiment of the present invention.
  • the present invention provides for a process for the gasification of coal and an apparatus suitable for use to carry out the process.
  • the process of the present invention efficiently gasifies coal, while converting the ash content of the coal to a vitreous slag.
  • the process utilises plasma torches to generate high temperature heat to gasify the coal and to melt the coal ash and convert it to a glass-like product with commercial value.
  • the use of plasma torches improves the slag quality and, in conjunction with the input of steam and gaseous oxygen, helps in controlling the gas composition.
  • the input of power required for the plasma torches is less than the potential power production of the process.
  • the power input required for the plasma torches is less than the potential power production of the process is due to the relatively homogeneous quality of the coal feedstock.
  • the process can further comprise a corrective feedback procedure in which one or more of the flow rate, temperature and composition of the synthesis gas are monitored and corrections made to one or more of the coal input rate, the oxygen input rate, the steam input rate and the amount of power supplied to the plasma torches based on changes in the flow rate, temperature and/or composition of the synthesis gas in order to ensure that these remain within acceptable ranges.
  • the ranges for the flow rate, temperature and/or composition of the synthesis gas are selected to optimise the synthesis gas for a particular downstream application, such as gas turbines for electricity generation,
  • the process of the present invention simultaneously uses the controllability of plasma heat to drive the gasification process, and to ensure that the gas flow and composition from the process remains within an acceptable range even if the composition of the coal exhibits natural variability.
  • the process allows for the total amount of carbon processed per unit time to be held as constant as possible, and utilizes the plasma torches to ensure that the total heat that enters and leaves the reactor vessel per unit time is kept within process limits.
  • the apparatus of the present invention is of a simple construction and can be utilized without the requirement for pressure equipment, such as compressors.
  • the term "about” refers to a +/-10% variation from the nominal value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.
  • plasma torch configuration refers to one or more plasma torches.
  • the plasma torches can be provided in a variety of configurations, for example, in parallel, in series, at opposite sides of the reactor vessel, the same side of the reactor vessel, adjacent to each other either vertically or horizontally, spatially separated from each other, and the like.
  • the plasma torches in the plasma torch configuration can receive power from the same source or from different sources.
  • One or more of the plasma torches in a plasma torch configuration can be moveable.
  • composition of the synthesis gas refers to the amount of carbon monoxide, carbon dioxide and/or hydrogen in the synthesis gas. Composition of the synthesis gas is generally monitored immediately upon, or shortly after, leaving the reactor vessel, i.e. proximal to the synthesis gas outlet.
  • the process for gasification of coal generally comprises the steps of:
  • the process can further comprise a corrective feedback procedure in which adjustments are made to one or more of the coal input rate, the oxygen input rate, the steam input rate and the amount of power supplied to the plasma torche configurations based on changes in the flow rate, temperature and/or composition of the synthesis gas.
  • the corrective feedback procedure thus allows the flow rate, temperature and/or composition of the synthesis gas to be maintained within acceptable ranges.
  • the coal gasification process comprises a specified sequence of steps that are conducted in a single reactor vessel and converts coal, steam and oxygen to a synthesis gas comprising gaseous carbon monoxide, carbon dioxide, and hydrogen.
  • the process further comprises the step of pre-heating one or more of the coal, oxygen and steam prior to adding the respective gasification and reformation zones.
  • the process of the present invention is conducted by feeding coal along with oxygen into a gasification zone within a reactor vessel where the coal is subjected to the heat of a first plasma torch configuration which allows the gasification reaction to take place.
  • Extra oxygen may be injected to initiate or to increase the exothermic reactions that produce carbon monoxide, carbon dioxide and carbon particles.
  • the flow is upwardly and the pulverized coal is entrained in the oxygen and in the preliminary gasification products that are formed in the gasification zone.
  • the exothermic reactions along with the heat provided by the first plasma torch configuration increase the processing temperature.
  • the processing temperature is between about 1200 0 C to about 1400 0 C, although lower and higher temperatures are also contemplated.
  • the process employs an average gasification temperature within the reactor vessel is about 1300 0 C +/- 100 0 C. The heat so produced provides the heat required for the en ⁇ othermic reactions that are carried out in the reforming zone.
  • Coal of varying grades- can be used as the feedstock, including low grade, high sulfur coal.
  • feedstock including low grade, high sulfur coal.
  • Peat is the layer of vegetable material directly underlying the growing zone of a coal-forming environment. The vegetable material shows very little alternation and contains the roots of living plants.
  • Lignite is geologically very young (less than 40,000 years) and can be soft and fibrous. Lignite generally contains large amounts of moisture (typically around 70%) and has a low energy content (8 - 10 MJ/kg).
  • Black coal ranges from 65-105 million years old to up to 260 million years old and is harder and shinier than lignite and contains less than 3% moisture.
  • the energy content of black coal is up to about 24 - 28 MJ/kg.
  • Anthracite contains virtually no moisture and very low volatile content, so it burns with little or no smoke.
  • Anthracite can have energy contents up to about 32MJ7kg.
  • Peat, lignite, black coal and anthracite are all considered to be "coal feedstock" in the context of the present invention.
  • the coal is pulverized prior to addition to the reactor vessel, hi general, when pulverized coal is used, it is of an appropriate size to provide the necessary rapid reaction.
  • the coal is of a particle size of 0.75 inches or smaller. Suitable examples of particle size include, but are not limited to, particle sizes of 30 mesh, or -100 mesh or the size recognized in the coal industry as "Buckwheat No. 1".
  • the coal and oxygen are fed via inlets into the lower part of the reactor vessel (i.e. the gasification zone is located in the lower portion of the reactor vessel), hi another embodiment, the oxygen is provided in the form of air, oxygen or oxygen enriched air.
  • the gases which are formed in the gasification zone are treated with steam in the reforming zone. These reactions are mainly endothermic.
  • the temperature is maintained in a range that is high enough to keep the reactions at an appropriate level to minimise pollution production, while being low enough to minimize the energy which is expelled as sensible heat.
  • An added benefit of minimizing the sensible heat in this manner is that the gas chemical heat increases accordingly (gas quality/heating value). Appropriate temperature ranges can readily be determined by the skilled worker.
  • the steam that is added in the reformation step acts to reduce the exit temperature of the synthesis gas. hi one embodiment, the exit temperature of the synthesis gas is reduced to between about 900 0 C and about 1200 0 C. hi another embodiment, the exit temperature is reduced to an average temperature of about 900 0 C +/- 100 0 C.
  • Inorganic particles produced in the gasification and reformation reactions melt and fall into the slag pool. Enough time is allowed when the particles are entrained in the slag pool so that volatiles and carbon are removed. As would be appreciated by a worked skilled in the art, the residence time is a function of the particle size.
  • the heat produced by the second plasma torch configuration homogenizes the slag and allows it to be extracted while hot.
  • the plasma torch configuration heats the slag to a temperature between about 1400 0 C and about 1800 0 C. In one embodiment, to a temperature between about 1400 0 C and about 1650 0 C. This manipulation of the temperature profiles can help to avoid wasting heat and later water to quench the slag in the bottom of the reactor vessel.
  • the process of the present invention thus efficiently gasifies coal, while converting the ash content of the coal to a vitreous slag, hi one embodiment, the process uses the high temperature heat that the plasma torches provide to melt the coal ash, and to convert it to a glass-like product with commercial value.
  • the coal gasification process efficiently melts, homogenizes and exhausts slag from the combustion vessel.
  • the heating is achieved by means of a plasma torch.
  • the process can further comprise a corrective feedback control procedure which includes the steps of monitoring one or more of the synthesis gas flow rate, the synthesis gas temperature and the synthesis gas composition and correcting, via a simple feedback procedure, one or more of the rate of coal input, the rate of oxygen- input, the rate of steam input and the power to the plasma torch configurations.
  • the feedback control procedure is described in more detail below.
  • the process of the present invention utilizes controlled amounts of oxygen and steam to produce optimum high quality, stable synthesis gas from coal.
  • the present invention further provides for an apparatus suitable for carrying out the above-described process.
  • the apparatus is of a simple construction and in one embodiment generally comprises
  • refractory-lined reactor vessel having one or more coal inlets, one or more oxygen inlets and one or more steam inlets;
  • a first plasma torch configuration located within the reactor vessel and disposed such that coal entering the reactor vessel through the coal inlet(s) enters into the path of the plasma discharge of this first plasma torch configuration;
  • a second plasma torch configuration disposed adjacent to the slag reservoir and positioned such that the plasma discharge from the second plasma torch configuration is directed towards the slag reservoir;
  • the reactor vessel can be one of a number of standard reaction vessels known in the art.
  • the reactor vessel can be vertically or horizontally oriented and may include internal components, such as baffles, to promote back mixing and turbulence if desired.
  • the plasma torches in each of the first and second plasma torch configurations can be mounted within the reactor vessel to provide axial, radial, tangential or other promoted flow direction for the plasma gas, with plasma sources providing upward or downward gas flow.
  • One or more inlets are incorporated to allow concurrent, countercurrent, radial, tangential, or other feedstock flow directions.
  • the coal and oxygen inlets are located in close proximity to the first plasma torch configuration.
  • Reactor vessels generally comprise an outlet located near the top of the vessel to enable the reformed product gas to exit the reactor vessel.
  • reactor vessels known in the art include entrained flow reactor vessels that can accept feedstock in the form of solids, particulates, slurry, liquids, gases, or a combination thereof.
  • the feedstock is injected through one or more inlets, which are disposed close to the first plasma torch configuration.
  • Product synthesis gas exits the reaction vessel via a gas outlet, while slag exits via a slag outlet.
  • the reactor vessel can have a wide range of length-to-diameter ratios and can be oriented either vertically or horizontally, as long as the slag outlet is disposed at the bottom to enable the slag to be removed by gravity flow.
  • the reactor vessel wall can be lined with refractory material and/or a water jacket can encapsulate the reactor vessel for cooling and/or generation of steam.
  • a suitable reactor vessel is a down-fired reactor vessel.
  • the first plasma torch configuration is positioned at the top of the reactor vessel, with the plasma jet directed inwardly and downwardly.
  • One or more feed inlets are disposed adjacent to the first plasma torch configuration, so that as soon as the feedstock enters the reaction vessel it encounters the plasma to begin the process.
  • a plurality of inlets are provided to inject oxygen and steam.
  • the product synthesis gas exits via a gas outlet (disposed in a lower portion of the reaction vessel), while slag drops downwardly through the reactor vessel and exits through the bottom of the vessel via a slag outlet.
  • the interior surfaces of the reactor vessel can be lined with refractory material, and the reactor vessel can be partially covered with a water jacket to produce steam.
  • a plurality of baffles oriented at a slight downward angle can be included if desired to help direct the flow of slag towards the outlet. The angles of these baffles can be varied to optimize this function. Again, different length- to-diameter ratios can be used to vary the size and volume of the reaction vessel.
  • the refractory material used to line the reactor vessel can be one, or a combination of, conventional refractory materials known in the art which are suitable for use as a vessel for a high temperature, e.g., a temperature of about 1100 0 C to 1400 0 C, un- pressurized reaction.
  • refractory materials include, but are not limited to, high temperature fired ceramics (such as aluminum oxide, aluminum nitride, aluminum silicate, boron nitride, zirconium phosphate), glass ceramics and high alumina brick containing principally, silica, alumina and titania.
  • a variety of commercially-available plasma torches which can develop suitably high flame temperatures for sustained periods at the point of application can be utilized in the apparatus.
  • plasma torches are available in sizes from about 100 Kw to over 6 Mw in output power.
  • the plasma torch can employ one, or a combination, of suitable gases. Examples include, but are not limited to; argon, helium, neon, hydrogen, methane, ammonia, carbon monoxide, oxygen, nitrogen, and carbon dioxide, hi one embodiment of the present invention, the first plasma torch configuration is continuously operating so as to produce a temperature in the reactor vessel in excess of about 1100 0 C.
  • the second plasma torch configuration is employed to melt the coal ash.
  • the molten slag at a temperature of, for example, about 1400 0 C to about 1800 0 C; is periodically exhausted from the reactor vessel and is thereafter cooled to form a solid slag material.
  • Such slag material may be intended for landfill disposal.
  • the molten slag can be poured into containers to form ingots, bricks tiles or similar construction material.
  • the solid product may further be broken into aggregates for conventional uses.
  • the first plasma torch configuration is disposed adjacent to, but spaced from, the bottom of the reaction vessel and extending a downward angle towards the core of the reaction vessel.
  • the second plasma torch configuration is disposed closely adjacent to the bottom of the reaction vessel and extending at an upward angle towards the core of the reaction vessel.
  • the one or more oxygen inlets comprise a pair of. oxygen inlets to inject oxygen into the path of the plasma discharge of the first plasma torch configuration.
  • the one or more oxygen inlets inject oxygen into the path of the plasma discharge of the first plasma torch configuration from below and above.
  • the one or more steam inlets comprise a pair of steam inlets.
  • the one or more steam inlets are disposed above the pulverized coal and oxygen inlets.
  • the reactor vessel is a vertically oriented reactor vessel • having longitudinally-spaced-apart, bottom radial and upper, axial outlet ends.
  • the reactor vessel When the reactor vessel is a vertically oriented vessel, it generally has a predetermined length which is sufficient to effect the desired heating of the contents of the reactor vessel to a selected equilibrium temperature.
  • the apparatus may further comprise means for monitoring one or more of synthesis gas flow rate, synthesis gas temperature, synthesis gas composition, coal input rate, oxygen input rate, steam input rate and power supply to the plasma torches in order to provide the necessary information to implement the corrective feedback procedure described below.
  • Various monitoring means are know in the art and can be employed in the apparatus of the present invention.
  • Monitoring of the exit synthesis gas can be achieved, for example, by means of a gas monitor and gas flow meter.
  • the gas monitor is used to determine the hydrogen, carbon monoxide and carbon dioxide content of the synthesis gas.
  • Synthesis gas composition, flow rate and/or temperature are generally measured at a position proximal to the upper gas outlet vent.
  • a plurality of thermocouples can be used to monitor the temperature at critical points around the reactor vessel.
  • Figure 1 presents an example of an apparatus in accordance with one embodiment of the present invention.
  • One skilled in the are will appreciate that a number of variations can be made to the reactor vessel depicted in Figure 1 without detracting from its suitability to be used to carry out the process of the invention, for example, similarly configures horizontally-oriented reactor vessels could be employed.
  • the reactor vessel 10 is a refractory-lined vessel.
  • a pair of vertically-spaced-apart, radial oxygen inlets 12, 14 is provided to admit oxygen to the reactor vessel 10.
  • a first plasma torch 16 is disposed above the oxygen inlet 12, and extends upwardly towards the core 18 of the reactor vessel 10.
  • First plasma torch 16 is longitudinally movable towards and away from the core 18, as shown by the two- ended arrow.
  • a second plasma torch 20 is disposed below the oxygen inlet 14, and extends downwardly towards the core 18 of the reactor vessel 10, and towards a slag reservoir 22.
  • Second plasma torch 18 is both longitudinally movable towards and away from the slag reservoir 22, and slewable as shown by the two-ended arcuate arrow.
  • Slag reservoir 22 leads to a radial outlet 24 from the reactor vessel.
  • a radial, pulverized coal inlet 26 is provided above first plasma torch 16 to discharge the pulverized coal into the path of the plasma arc of first plasma torch 16.
  • a pair of vertically-spaced-apart, radial steam inlets 28, 30, is provided above the pulverized coal inlet 24.
  • a central, axial gas outlet vent 32 is provided at the upper end 34 of the reactor vessel 10.
  • the main components of the synthesis gas as it leaves the reactor vessel are carbon monoxide, carbon dioxide, hydrogen, and steam, with lesser amounts of nitrogen. Much smaller amounts of methane, acetylene and hydrogen sulfide are also present.
  • an example of a baseline composition for the synthesis gas as it exits the reactor vessel is as follows:
  • the composition of the synthesis gas can be optimized for a specific application (e.g., gas turbines for electricity generation) by adjusting the balance between applied plasma heat, oxygen and steam that is used in the above-described process via a corrective feedback procedure based on the monitored composition, flow rate and/or temperature of the synthesis gas being produced by the process.
  • the product synthesis gas can be tailored for particular energy conversions (e.g., for specific gas engines or gas turbines) and for the conventional well-known particular grades of coal for best overall conversion efficiency.
  • the corrective feedback procedure included in the process of the present invention employs one or more of the following corrective steps:
  • the coal is quickly gasified, pyrolyzed, disassociated or oxidized.
  • a substantial amount of the coal is converted to carbon monoxide or carbon dioxide/ depending on the amount of oxygen that is fed into the reactor vessel.
  • the variable of carbon monoxide content of the synthesis gas can be monitored and the flow of oxygen controlled via corrective feedback so as to preclude the stoichiometric conversion of carbon to carbon dioxide, and the process is so operated to produce mainly carbon monoxide.
  • the composition and flow of synthesis gas from the reactor vessel is controlled within an acceptable range, e.g., by adjusting one or more of the input rate of coal, the input rate of oxygen, the input rate of steam and the power supply to the torches, as described above.
  • the temperature of the process is controlled at atmospheric pressure toiensure that the coal injected into the reactor vessel encounters as stable an environment as possible.
  • the process embodies corrective adjustment of the previously-defined total amounts of coal, steam and oxygen that are fed into the reactor vessel via the corrective feedback procedure.
  • the pulverized coal is fed continuously into the reactor vessel at a controlled rate.
  • the pulverized coal is fed continuously into the reactor vessel at a rate of between about 1.8 to about 2.8 Ib coal/min, for example, about 2.2 Ib coal/min.
  • this rate may be adjusted above or below this range in order to take into account the composition of the coal
  • the feed rate of the coal is correlated to the feed rate of steam
  • steam is injected at a rate between about 0.2 and about 0.8 lb/min, for example, about 0.5 lb/min.
  • coal is a complex material that exhibits substantial variability.
  • the gasification process of the present invention recognizes such variability and compensates for it in the following manner.
  • the parameters of the synthesis gas i.e.
  • the total amounts of coal which enter the reactor vessel per unit time and the vitrified slag which exits the reactor vessel are determined and maintained substantially constant.
  • the amount of carbon in the exit gas stream is estimated from the observed flow rate plus the percent of carbon monoxide and the percent of carbon dioxide. The above-described rate of feed of coal is adjusted to maintain the flow of carbon through the reactor vessel as constant as possible.
  • the above-described rates of injection of steam and oxygen are adjusted to account for any changes in the rate of feed of coal or changes in the composition of the coal, and to provide the desired synthesis gas composition.
  • the plasma torch power is adjusted to maintain the gasification temperature constant despite any fluctuations in the composition of the coal and corresponding above-described rates of feed of steam and oxygen.
  • the present invention also contemplates the substitution of conventional medium pressure steam for the conventional low pressure steam in the process.
  • One or more of the reactants that are fed into the process can be pre-heated.
  • feed temperatures for the process inputs are selected in order to take best advantage of waste heat from both the gasification equipment and the electrical generation system, ' in order to optimize system economics.
  • the process by employing the corrective feedback procedure, automatically adjusts the gas flow and the gas composition within specified limits as the composition of the coal undergoes its normal variation. As a result, the amount of coal that is gasified will vary with time.
  • FIG. 2 shows one embodiment of reactor controls contemplated by the present invention.
  • the reactor inputs of coal, steam and oxygen are preheated before they are fed into the reactor vessel 10.
  • water is fed to a first pre-heater 212 via water line 214 and steam at a temperature of about 100 0 C is fed into the reactor vessel 10 via steam line 216.
  • Pulverized coal of a size as previously defined is fed through pulverized coal line 218 to a second pre-heater 220 where it is heated to a temperature in excess of about 100 0 C.
  • Such pre-heated pulverized coal is fed to the reactor vessel 10 via heated coal line 222.
  • Oxygen is fed through oxygen line 224 to a third pre-heater 226, where it is heated to a temperature in excess of about 100 0 C. Such heated oxygen is fed to the reactor vessel 10 via heated oxygen line 228. The flow rate, the temperature, the percent carbon dioxide, the percent carbon monoxide and the percent hydrogen are all monitored at monitoring line 230.
  • Plasma heat to the reactor vessel 10 is generated by activating the plasma torches 16 and 18, and schematically enters the reactor vessel 10 via line 232, as input C4.
  • the heat for the pre-heaters 212, 220 and 226 can be provided by the heat that is generated from the gasification process.
  • the amounts of coal, oxygen, and steam and the power to the plasma torches are corrected on the basis of monitoring the flow rate of the exit synthesis gas, the exit temperature of the exit synthesis gas and the composition of the exit gas.
  • this monitoring employs the process logic shown in Figure 3.
  • the numerical value of the flow rate of carbon monoxide and carbon dioxide in the exit gases via lines 312, 314 is inputted into a first processor 316 along with the numerical value of the rate of feed of coal in line 318 (input Cl).
  • First processor 316 estimates the amount of carbon in the reactor vessel 10 and adjusts the coal feed rate accordingly.
  • Output from first processor 316, and which provides a measure of the numerical value of the percent carbon monoxide and the percent carbon dioxide (output Cl) is inputted via line 320 to second processor 322 along with the numerical value of the percent hydrogen via line 324, and the numerical values of steam (control input C2) and oxygen (control input C3) via line 326.
  • Second processor 322 estimates new oxygen and steam inputs to achieve the desired gas composition.
  • Output from second processor 322, i.e., output Cl, output C2 and output C3, are inputted into third processor 328 via line 330 along with an input representative of the numerical value of the exit gas temperature via line 332.
  • Third processor 328 computes new torch power which outputs as torch power (C4) via line 334.
  • a particular low-rank coal having a high heating value of about 22,360 MJ/metric tonne (about 9600 BTU) was used.
  • the elemental composition thereof was:
  • the gasification process is operated to provide a synthesis gas which exits the reactor vessel 10 at a temperature of about 900 0 C, has a flow rate (wet) of about 2817 NmVtonne of the above coal, and the following composition:
  • the process requires about 560.1 kg of oxygen plus 674.8 kg of steam per average tonne of coal. If the oxygen and coal are not pre- heated, and if the steam is supplied at 100 0 C and 1.01 bar, then the process will require an average of about 521.8MJ of plasma heat (about 193.3 KWh/tonne of electricity to the plasma torch, with normal efficiencies).
  • the amount ' of plasma heat that is required can be reduced if the process inputs are pre-heated. For example, if the oxygen is pre-heated to about 600 0 C, but the steam and coal are unchanged, and then the average plasma torch requirements are reduced to about 96 KWh/tonne. If the oxygen is pre-heated to about 600 0 C, and if the coal is pre-heated to about 55°C, then the torch power can be reduced to about 60 KWh/tonne.
  • the carbon-containing gases (carbon monoxide and carbon dioxide) are thus measured on exit. This dictates a lower or higher carbon input, as coal, to bring the carbon content to the desired level as designed.
  • the amounts of the hydrogen and steam are also measured.
  • the amount of the steam may be varied to bring the hydrogen to the desired level while simultaneously adjusting the oxygen level.
  • the gas temperature is also measured.
  • the power to the first plasma torch configuration(s) is varied to bring the temperature to the desired value.

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  • Combustion & Propulsion (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
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Abstract

L'invention concerne un procédé destiné à gazéifier efficacement le charbon en utilisant la chaleur d'une première configuration d'un chalumeau à plasma, tout en convertissant la teneur en cendres du charbon en un laitier vitreux au moyen d'une seconde configuration de chalumeau à plasma. Le procédé utilise simultanément la facilité de commande d'apport thermique fourni par ladite première configuration de chalumeau à plasma, en vue de commander le processus de gazéification, et de garantir que le flux et la composition du gaz issu du processus demeurent dans des limites acceptables, même si la composition du charbon présente une variabilité naturelle. L'invention concerne également un appareil approprié, destiné à la mise en oeuvre du procédé de gazéification du charbon. .
PCT/CA2006/000134 2005-02-04 2006-02-06 Procede et appareil de gazeification du charbon Ceased WO2006081661A1 (fr)

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WO2007068684A2 (fr) 2005-12-14 2007-06-21 Shell Internationale Research Maatschappij B.V. Procédé de fabrication d'un gaz de synthèse
EP1896553A4 (fr) * 2005-06-03 2010-09-01 Plascoenergy Ip Holdings Slb Systeme de conversion de charges d'alimentation carbonees en un gaz d'une composition specifique
EP1888717A4 (fr) * 2005-06-03 2010-09-01 Plascoenergy Ip Holdings Slb Systeme de conversion de charbon en un gaz d'une composition specifiee
CN102260537A (zh) * 2011-06-10 2011-11-30 杨清萍 一种等离子热解及富氧助燃物料制取可燃气的装置
GB2480752A (en) * 2010-05-28 2011-11-30 Gen Electric Sensing and control for plasma-assisted waste gasification
US8070863B2 (en) 2006-05-05 2011-12-06 Plasco Energy Group Inc. Gas conditioning system
US8128728B2 (en) 2006-05-05 2012-03-06 Plasco Energy Group, Inc. Gas homogenization system
CN102559272A (zh) * 2011-12-29 2012-07-11 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气流床气化炉及工艺
CN102559273A (zh) * 2011-12-29 2012-07-11 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气化固定床气化炉及工艺
US8306665B2 (en) 2006-05-05 2012-11-06 Plasco Energy Group Inc. Control system for the conversion of carbonaceous feedstock into gas
US8343241B2 (en) 2009-02-11 2013-01-01 Natural Energy Systems Inc. Process for the conversion of organic material to methane rich fuel gas
DE102011051906A1 (de) 2011-07-18 2013-01-24 Technische Universität Bergakademie Freiberg Verfahren und Vorrichtung zur Vergasung kohlenstoffhaltiger fester Stoffe mit Wasserdampf und Kohlendioxid und deren Gemische
US8372169B2 (en) 2006-05-05 2013-02-12 Plasco Energy Group Inc. Low temperature gasification facility with a horizontally oriented gasifier
US8435315B2 (en) 2006-05-05 2013-05-07 Plasco Energy Group Inc. Horizontally-oriented gasifier with lateral transfer system
US8475551B2 (en) 2006-05-05 2013-07-02 Plasco Energy Group Inc. Gas reformulating system using plasma torch heat
US8946680B2 (en) 2010-05-11 2015-02-03 International Business Machines Corporation TFET with nanowire source
US9074152B2 (en) 2007-09-12 2015-07-07 General Electric Company Plasma-assisted waste gasification system
US9120985B2 (en) 2010-05-26 2015-09-01 Exxonmobil Research And Engineering Company Corrosion resistant gasifier components
US9416328B2 (en) 2010-01-06 2016-08-16 General Electric Company System and method for treatment of fine particulates separated from syngas produced by gasifier
CN114181741A (zh) * 2021-11-19 2022-03-15 新奥科技发展有限公司 煤加氢气化装置

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EP1896553A4 (fr) * 2005-06-03 2010-09-01 Plascoenergy Ip Holdings Slb Systeme de conversion de charges d'alimentation carbonees en un gaz d'une composition specifique
EP1888717A4 (fr) * 2005-06-03 2010-09-01 Plascoenergy Ip Holdings Slb Systeme de conversion de charbon en un gaz d'une composition specifiee
US8083818B2 (en) 2005-12-14 2011-12-27 Shell Oil Company Method and system for producing synthesis gas
AU2006325339B2 (en) * 2005-12-14 2010-04-22 Air Products And Chemicals, Inc. Method of controlling synthesis gas production
WO2007068684A3 (fr) * 2005-12-14 2007-08-02 Shell Int Research Procédé de fabrication d'un gaz de synthèse
WO2007068684A2 (fr) 2005-12-14 2007-06-21 Shell Internationale Research Maatschappij B.V. Procédé de fabrication d'un gaz de synthèse
US8128728B2 (en) 2006-05-05 2012-03-06 Plasco Energy Group, Inc. Gas homogenization system
US8070863B2 (en) 2006-05-05 2011-12-06 Plasco Energy Group Inc. Gas conditioning system
US8435315B2 (en) 2006-05-05 2013-05-07 Plasco Energy Group Inc. Horizontally-oriented gasifier with lateral transfer system
US9109172B2 (en) 2006-05-05 2015-08-18 Plasco Energy Group Inc. Low temperature gasification facility with a horizontally oriented gasifier
US8306665B2 (en) 2006-05-05 2012-11-06 Plasco Energy Group Inc. Control system for the conversion of carbonaceous feedstock into gas
US8475551B2 (en) 2006-05-05 2013-07-02 Plasco Energy Group Inc. Gas reformulating system using plasma torch heat
US8372169B2 (en) 2006-05-05 2013-02-12 Plasco Energy Group Inc. Low temperature gasification facility with a horizontally oriented gasifier
US9074152B2 (en) 2007-09-12 2015-07-07 General Electric Company Plasma-assisted waste gasification system
US8343241B2 (en) 2009-02-11 2013-01-01 Natural Energy Systems Inc. Process for the conversion of organic material to methane rich fuel gas
US9416328B2 (en) 2010-01-06 2016-08-16 General Electric Company System and method for treatment of fine particulates separated from syngas produced by gasifier
US8946680B2 (en) 2010-05-11 2015-02-03 International Business Machines Corporation TFET with nanowire source
US9120985B2 (en) 2010-05-26 2015-09-01 Exxonmobil Research And Engineering Company Corrosion resistant gasifier components
GB2480752A (en) * 2010-05-28 2011-11-30 Gen Electric Sensing and control for plasma-assisted waste gasification
CN102260537B (zh) * 2011-06-10 2014-01-22 阳光凯迪新能源集团有限公司 一种等离子热解及富氧助燃物料制取可燃气的装置
CN102260537A (zh) * 2011-06-10 2011-11-30 杨清萍 一种等离子热解及富氧助燃物料制取可燃气的装置
DE102011051906A1 (de) 2011-07-18 2013-01-24 Technische Universität Bergakademie Freiberg Verfahren und Vorrichtung zur Vergasung kohlenstoffhaltiger fester Stoffe mit Wasserdampf und Kohlendioxid und deren Gemische
DE102011051906B4 (de) * 2011-07-18 2015-06-11 Technische Universität Bergakademie Freiberg Verfahren und Vorrichtung zur Vergasung kohlenstoffhaltiger fester Stoffe mit Wasserdampf und Kohlendioxid und deren Gemische
CN102559272A (zh) * 2011-12-29 2012-07-11 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气流床气化炉及工艺
CN102559273A (zh) * 2011-12-29 2012-07-11 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气化固定床气化炉及工艺
CN102559272B (zh) * 2011-12-29 2014-05-14 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气流床气化炉及工艺
EP2799522A4 (fr) * 2011-12-29 2016-04-27 Wuhan Kaidi Eng Tech Res Inst Réacteur de gazéification de biomasse à lit entraîné à plasma micro-onde et procédé correspondant
AU2012362083B2 (en) * 2011-12-29 2016-06-09 Wuhan Kaidi General Research Institute Of Engineering & Technology Co., Ltd. Microwave plasma biomass entrained flow gasifier and process
CN102559273B (zh) * 2011-12-29 2014-03-05 武汉凯迪工程技术研究总院有限公司 一种微波等离子生物质气化固定床气化炉及工艺
CN114181741A (zh) * 2021-11-19 2022-03-15 新奥科技发展有限公司 煤加氢气化装置

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