Process and apparatus for the production of synthesis gas

Abstract

Reactive diluent fluid (22) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“POX”) reactor (12) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted (26) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit (30) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

1 . A process for the production of syngas comprising carbon monoxide and molecular hydrogen, said process comprising: exothermically reacting hydrocarbon-containing fuel with an oxidant gas comprising molecular oxygen in a first reactor to produce an exothermically-generated syngas product, the exothermically-generated syngas product having a first concentration of carbon monoxide; combining an effluent stream of the exothermically-generated syngas product with reactive diluent fluid with to produce a mixture comprising cooled exothermically-generated syngas product and reactive diluent fluid, the mixture including carbon dioxide, molecular hydrogen and solid carbon particles; reacting the carbon dioxide and the molecular hydrogen in the mixture over a catalyst in a second reactor to produce reacted syngas product having a second concentration of carbon monoxide greater than the first concentration; and gasifying solid carbon particles in the mixture with at least one other component in the mixture to produce reacted syngas product. 
     
     
         2 . The process of  claim 1 , further comprising endothermically reforming hydrocarbon-containing fuel gas with steam over a catalyst in a heat exchange reformer to produce heat exchange-reformed syngas product wherein at least a portion of the heat generated in the exothermic reaction drives at least a portion of the endothermic reforming reaction. 
     
     
         3 . The process of  claim 1 , wherein the first reactor comprises a partial oxidation reactor. 
     
     
         4 . The process of  claim 1 , wherein the reactive diluent fluid comprises carbon dioxide.