In-situ gasification of soot contained in exothermically generated syngas stream

Abstract

A system is set forth for the exothermic generation of soot depleted syngas comprising (i) reacting a hydrocarbon-containing fuel with an oxygen containing gas in a first reactor to produce the syngas and byproducts comprising CO 2 , H 2 O and soot; and (ii) introducing the syngas and byproducts into a second reactor containing a non-carbonaceous material that traps the soot for a sufficient time such that the majority of the byproduct soot is gasified via reaction with the byproduct CO 2 and/or H 2 O to produce a syngas stream that is depleted in the soot. The system is particularly suitable for the practice of heat exchange reforming therein a portion of the heat is recovered from the soot depleted syngas stream and used as at least a portion of the heat to facilitate the additional production of syngas via the (endothermic) catalytic reforming of natural gas and steam.

1 . A process for the exothermic generation of syngas by the partial oxidation of a hydrocarbon-containing fuel comprising:
 (i) reacting the hydrocarbon-containing fuel with an oxygen containing gas in a first reactor to produce the syngas and byproducts comprising CO 2 , H 2 O and soot; and   (ii) introducing the syngas and byproducts into a second reactor containing a non-carbonaceous material that traps the soot for a sufficient time such that the majority of the byproduct sect is gasified via reaction with the byproduct CO 2  and/or H 2 O to produce a syngas stream that is depleted in the soot.   
     
     
         2 . The process of  claim 1  which further comprises:
 (iii) recovering a portion of the heat from the soot depleted syngas stream and using at least a portion of the recovered heat to facilitate the additional production of syngas via the (endothermic) catalytic reforming of natural gas and steam. 
 
     
     
         3 . The process of  claim 1  wherein substantially all of the byproduct soot is gasified in step (ii). 
     
     
         4 . The process of  claim 1  wherein the non-carbonaceous material comprises alumina. 
     
     
         5 . The process of  claim 1  wherein the non-carbonaceous material contained in the second reactor is in the term of spherical particles. 
     
     
         6 . The process of  claim 1  wherein the non-carbonaceous material contained in the second reactor is in the form of rings. 
     
     
         7 . The process of  claim 1  wherein the non-carbonaceous material contained in the second reactor has a catalytic functionality to facilitate the gasification of the soot. 
     
     
         8 . The process of  claim 1  wherein first and second reactors are operated in a temperature range from 2100F to 2800F. 
     
     
         9 . The process of  claim 1  wherein a fluid is added to the syngas and byproducts produced by the first reactor prior to introducing the syngas and byproducts into the second reactor. 
     
     
         10 . In an apparatus for the exothermic generation of syngas by the partial oxidation of a hydrocarbon-containing fuel comprising:
 (i) a first reactor for reacting the hydrocarbon-containing fuel with an oxygen containing gas to produce the syngas and byproducts comprising CO 2 , H 2 O and soot; and   (ii) a second reactor for receiving the syngas and byproducts containing a non-carbonaceous material that traps the soot for a sufficient time such that the majority of the byproduct soot is gasified via reaction with the byproduct CO 2  and/or H 2 O to produce a syngas stream that is depleted in the soot.   
     
     
         11 . The apparatus of  claim 10  which further comprises:
 (iii) a heat exchange reformer for recovering a portion of the heat from the soot depleted syngas stream and using at least a portion of the recovered heat to facilitate the additional production of syngas via the (endothermic) catalytic reforming of natural gas and steam. 
 
     
     
         12 . The apparatus of  claim 10  wherein substantially all of the byproduct soot is gasified in the second reactor. 
     
     
         13 . The apparatus of  claim 10  wherein the non-carbonaceous material comprises alumina. 
     
     
         14 . The apparatus of  claim 10  wherein the non-carbonaceous material contained in the second reactor is in the form of spherical particles. 
     
     
         15 . The apparatus of  claim 10  wherein the non-carbonaceous material contained in the second reactor is in the form of rings. 
     
     
         16 . The apparatus of  claim 10  to wherein the non-carbonaceous material contained In the second reactor has a catalytic functionality to facilitate the gasification of the soot. 
     
     
         17 . The apparatus of  claim 10  wherein first and second reactors are operated in a temperature range from 2100F to 2800F. 
     
     
         18 . The apparatus of  claim 10  further comprising a means to add a fluid to the syngas and byproducts produced by the first reactor prior to the second reactor receiving the syngas and byproducts.