Gasification System And Process For Maximizing Production Of Syngas and Syngas-Derived Products

A method for producing a syngas product, comprising:

• gasifying a hydrocarbon in a gasifier to produce a raw syngas;
• purifying the raw syngas in a purification unit to produce a syngas product and a waste gas;
• reforming a first portion of the waste gas in a first reformer to produce a first reformed hydrocarbon;
• introducing the reformed hydrocarbon to a second reformer to provide heat to the second reformer;
• reforming a second portion of the waste gas in the second reformer to form a second reformed hydrocarbon;
• mixing the first and second reformed hydrocarbons to form a recovered raw syngas;
• and
• introducing the recovered raw syngas to the purification unit.

A system for gasifying a hydrocarbon, comprising:

• a gasifier that receives the hydrocarbon and produces a raw syngas;
• an acid gas removal unit fluidly coupled to the gasifier, wherein the acid gas removal unit receives the raw syngas from the gasifier;
• a purification unit fluidly coupled to the acid gas removal unit, wherein the purification unit receives the raw syngas from the acid gas removal unit and produces a waste gas and a syngas product;
• a compressor fluidly coupled to the purification unit, wherein the compressor receives the waste gas from the purification unit and produces a compressed waste gas;
• an autothermal reformer fluidly coupled to the compressor, wherein the autothermal reformer receives a first portion of the compressed waste gas and at least a portion of the oxidant from the air separation unit, and produces a reformed hydrocarbon;
• and
• a shell-and-tube reformer fluidly coupled to the compressor, the autothermal reformer, and the acid gas removal unit, wherein the shell-and-tube reformer receives the reformed hydrocarbon from the autothermal reformer and a second portion of the compressed waste gas from the compressor and produces a recovered raw syngas that is directed to the acid gas removal unit.