Gasification of carbonaceous materials and gas to liquid processes

Abstract

Herein disclosed is a system for producing an organic, the system including at least one high shear mixing device having at least one rotor and at least one stator separated by a shear gap, wherein the shear gap is the minimum distance between the at least one rotor and the at least one stator; a pump configured for delivering a fluid stream comprising liquid medium and light gas to the at least one high shear mixing device, wherein the at least one high shear mixing device is configured to form a dispersion of the light gas in the liquid medium; and a reactor comprising at least one inlet and at least one outlet, wherein the at least one inlet of the reactor is fluidly connected to the at least one high shear mixing device, and wherein the at least one outlet is configured for extracting the organic therefrom.

What is claimed is: 
     
         1 . A method of producing synthesis gas from carbonaceous material, the method comprising:
 (a) providing a mixture comprising carbonaceous material and a liquid medium;   (b) subjecting the mixture to high shear under gasification conditions whereby a high shear-treated stream comprising synthesis gas is produced; and   (c) separating a product comprising synthesis gas from the high shear-treated stream.   
     
     
         2 . The method of  claim 1  wherein (b) subjecting the mixture to high shear to produce a high shear-treated stream comprising synthesis gas further comprises contacting the mixture with at least one gas or vapor selected from the group consisting of steam, hydrogen, air, oxygen, and associated gas. 
     
     
         3 . The method of  claim 2  further comprising contacting the mixture with a catalyst that promotes the formation of synthesis gas. 
     
     
         4 . The method of  claim 1  further comprising recycling separated unreacted carbonaceous material, separated liquid medium or both from (c) to (a). 
     
     
         5 . The method of  claim 1  wherein the carbonaceous material comprises coke, coal, peat, natural gas, or a combination thereof. 
     
     
         6 . The method of  claim 5  wherein the coal is selected from the group consisting of bituminous, anthracite, and lignite. 
     
     
         7 . The method of  claim 1  wherein the carbonaceous material comprises powdered coal or coalbed methane. 
     
     
         8 . The method of  claim 1  further comprising utilizing at least a portion of the synthesis gas to produce a liquid product comprising forming a dispersion of synthesis gas in a liquid phase. 
     
     
         9 . The method of  claim 8  wherein utilizing at least a portion of the synthesis gas to produce a liquid product comprises catalytically reacting the at least a portion of the synthesis gas to produce Fischer-Tropsch hydrocarbons. 
     
     
         10 . The method of  claim 8  wherein the liquid product comprises liquid hydrocarbons and alcohols. 
     
     
         11 . The method of  claim 8  wherein the liquid product comprises primarily liquid hydrocarbons, primarily alcohols, or substantially equivalent amounts of alcohols and liquid hydrocarbons. 
     
     
         12 . The method of  claim 8  wherein the liquid phase comprises one or more liquid hydrocarbon produced by Fischer-Tropsch, one or more alcohol, or a combination thereof. 
     
     
         13 . The method of  claim 8  wherein forming a dispersion comprises introducing the synthesis gas and liquid carrier into a high shear device comprising at least one rotor and at least one stator and providing a tip speed of at least about 23 m/sec, wherein the tip speed is defined as πDn, where D is the diameter of the at least one rotor and n is the frequency of revolution. 
     
     
         14 . The method of  claim 8  further comprising introducing the dispersion into a reactor comprising a fixed bed of catalyst or a fluidized bed of catalyst. 
     
     
         15 . A system for producing synthesis gas from carbonaceous material, the system comprising:
 apparatus for providing a mixture comprising carbonaceous material and a liquid medium; at least one high shear device comprising at least one rotor and at least one complementarily-shaped stator and configured to subject the mixture to high shear and produce a high shear-treated stream comprising synthesis gas, wherein the at least one rotor is configured to provide a tip speed of at least about 23 m/sec, wherein the tip speed is defined as πDn, where D is the diameter of the at least one rotor and n is the frequency of revolution; and a pump configured for delivering the mixture to the at least one high shear device.   
     
     
         16 . The system of  claim 15  further comprising a vessel coupled to the at least one high shear device, the vessel configured for receiving a high shear-treated stream from the at least one high shear device. 
     
     
         17 . The system of  claim 15  wherein the at least one rotor is separated from the at least one stator by a shear gap in the range of from in the range of from about 0.02 mm to about 5 mm, wherein the shear gap is the minimum distance between the at least one rotor and the at least one stator. 
     
     
         18 . The system of  claim 15  further comprising a line for introducing a dispersible gas or vapor into the mixture upstream of the at least one high shear device or into the at least one high shear device. 
     
     
         19 . The system of  claim 15  comprising more than one high shear device. 
     
     
         20 . The system of  claim 15  wherein the at least one high shear device comprises at least two generators, wherein each generator comprises a rotor and a complementarily-shaped stator. 
     
     
         21 . The system of  claim 15  further comprising apparatus for the production of liquid hydrocarbons, alcohols or a combination thereof wherein the apparatus for producing liquid hydrocarbons, alcohols or a combination thereof is fluidly connected with an outlet of the at least one high shear device.