Hydromethanation of a carbonaceous feedstock

Abstract

The present invention relates to processes for hydromethanating a carbonaceous feedstock to a fines-depleted methane-enriched synthesis gas, with recycle of recovered particulate fines back into a specified portion of a hydromethanation reactor.

We claim: 
     
         1 . A process for generating a fines-depleted methane-enriched raw product gas stream from a non-gaseous carbonaceous material, the process comprising the steps of:
 (a) supplying to a hydromethanation reactor
 (1) a carbonaceous feedstock derived from the non-gaseous carbonaceous material, 
 (2) a hydromethanation catalyst, 
 (3) a superheated steam stream and 
 (4) an oxygen-rich gas stream, 
   
       wherein the hydromethanation reactor comprises a fluidized bed having a upper portion above a lower portion, and wherein the superheated steam stream and the oxygen-rich gas stream are introduced into the lower portion of the fluidized bed;
 (b) reacting a portion of the carbonaceous feedstock in the hydromethanation reactor in the presence of hydromethanation catalyst, carbon monoxide, hydrogen and steam at a target operating temperature to produce a methane-enriched raw gas and a solid by-product char, wherein the methane-enriched raw gas comprises methane, carbon monoxide, hydrogen, carbon dioxide, hydrogen sulfide, steam, heat energy and entrained fines; 
 (c) treating the methane-enriched raw gas to remove a substantial portion of the entrained fines to generated a fines-depleted methane-enriched raw product gas stream and a recovered fines stream; and 
 (d) reacting a portion of the carbonaceous feedstock with oxygen to produce carbon monoxide, hydrogen and heat energy; 
 wherein:
 (i) the reaction of step (b) predominates in the upper portion of the fluidized bed; 
 (ii) the reaction of step (d) predominates in the lower portion of the fluidized bed; and 
 (iii) at least a portion of the fines stream is fed into the lower portion of the fluidized bed. 
 
 
     
     
         2 . The process of  claim 1 , wherein the reaction of step (b) has a syngas demand and a heat demand, and the heat demand and syngas demand are substantially satisfied by the reaction of step (d). 
     
     
         3 . The process of  claim 2 , wherein the syngas demand and the heat demand are satisfied by the reaction of step (d). 
     
     
         4 . The process of  claim 1 , wherein the reaction of step (b) has a steam demand, and the steam demand is substantially satisfied by steam in the superheated steam stream, the oxygen-rich gas stream and the fines stream fed into the lower portion of the fluidized bed, and steam generated from the carbonaceous feedstock. 
     
     
         5 . The process of  claim 4 , wherein the steam demand is satisfied by steam in the superheated steam stream and the oxygen-rich gas stream, and steam generated from the carbonaceous feedstock. 
     
     
         6 . The process of  claim 1 , wherein the superheated steam stream, the oxygen-rich gas stream, the carbonaceous feedstock and the hydromethanation catalyst are introduced into the hydromethanation reactor at a temperature below the target operating temperature of the reaction of step (b). 
     
     
         7 . The process of  claim 1 , wherein the target operating temperature is at least about at least about 1000° F. (about 538° C.) to about 1500° F. (about 816° C.). 
     
     
         8 . The process of  claim 1 , wherein the superheated steam stream is fed to the hydromethanation reactor at a temperature of from about 500° F. (about 260° C.) to about 950° F. (about 510° C.). 
     
     
         9 . The process of  claim 1 , wherein the superheated steam stream and the oxygen-rich stream are combined for feeding into the lower section of the fluidized bed of the hydromethanation reactor, and the temperature of the combined stream is from about from about 500° F. (about 260° C.) to about 900° F. (about 482° C.). 
     
     
         10 . The process of  claim 1 , wherein the methane-enriched raw product stream comprises at least about 15 mol % methane (based on the moles of methane, carbon dioxide, carbon monoxide and hydrogen in the methane-enriched raw product stream), and at least 50 mol % methane plus carbon dioxide (based on the moles of methane, carbon dioxide, carbon monoxide and hydrogen in the methane-enriched raw product stream). 
     
     
         11 . The process of  claim 1 , wherein the methane-enriched raw product stream is introduced into a first heat exchanger unit to recover heat energy and generate a cooled methane-enriched raw product stream, and wherein the heat energy recovered in the first heat exchanger unit is used to generate a first process steam stream, and superheat the first process steam stream for use as all or a part of the superheated steam stream for introduction into the hydromethanation reactor. 
     
     
         12 . The process of  claim 11 , wherein at least a portion of the carbon monoxide in the cooled methane-enriched raw product stream is steam shifted to generate heat energy and a hydrogen-enriched raw product stream. 
     
     
         13 . The process of  claim 12 , wherein heat energy is recovered from the steam shifting, and at least a portion of the recovered heat energy is utilized to preheat boiler feed water for use in generating process steam. 
     
     
         14 . The process of  claim 12 , wherein the hydrogen-enriched raw product stream is substantially dehydrated to generate a dehydrated hydrogen-enriched raw product stream. 
     
     
         15 . The process of  claim 14 , wherein a substantial portion of the carbon dioxide and a substantial portion of the hydrogen sulfide are removed from the dehydrated hydrogen-enriched raw product stream to produce a sweetened gas stream comprising a substantial portion of the hydrogen, carbon monoxide (if present in the dehydrated hydrogen-enriched raw product stream) and methane from the dehydrated hydrogen-enriched raw product stream. 
     
     
         16 . The process of  claim 15 , wherein carbon monoxide and hydrogen present in the sweetened gas stream (or hydrogen-depleted sweetened gas stream, if present) are reacted in a catalytic methanator in the presence of a methanation catalyst to produce heat energy and a methane-enriched sweetened gas stream. 
     
     
         17 . The process of  claim 16 , wherein methane-enriched sweetened gas stream is recovered as a methane product stream. 
     
     
         18 . The process of  claim 17 , wherein the methane product stream is a pipeline-quality natural gas. 
     
     
         19 . The process of  claim 16 , wherein heat energy from the catalytic methanation is recovered and at least a portion of the recovered heat energy is utilized to generate and superheat a second process steam stream. 
     
     
         20 . The process of  claim 19 , wherein the superheated steam stream substantially comprises steam from the first process steam stream and the second process steam stream.