Apparatus and Process for Gasification of Carbonaceous Materials to Produce Syngas

A process for gasification of a carbonaceous material to produce a hot syngas, said process comprising:

• (a) contacting said carbonaceous material with a first molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a gasification zone to gasify a portion of said carbonaceous material and to produce a first gaseous product;
• (b) contacting a remaining portion of said carbonaceous material with a second molecular oxygen-containing gas and optionally with one or more of steam and CO2 in a burn-up zone to gasify additional portion of said carbonaceous material and to produce a second gaseous product and a solid ash comprising carbon;
• (c) combining said first gaseous product and said second gaseous product to produce a raw syngas comprising carbon monoxide (CO), carbon dioxide (CO2) and tar;
• and
• (d) contacting said raw syngas with a third molecular oxygen containing gas in a tar destruction zone to produce said hot syngas,
• wherein a CO/CO2 molar ratio in said hot syngas is greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1.

A gasification apparatus comprising:

• a gasification zone that includes one or more hearths;
• a burn-up zone continuous with the gasification zone, the burn-up zone including one or more hearths, wherein the gasification and burn-up zones are effective for providing a raw syngas having a CO/CO2 molar ratio greater than about 0.75 and ratio of carbon content of solid ash to carbon content of carbonaceous material feed is less than about 0.1;
• and
• a tar destruction zone effective for receiving the raw syngas from the gasification and burn-up zones through a connecting zone.