US 4,081,253 A · Production of purified synthesis gas and carbon monoxide

Abstract

A continuous process for simultaneously producing (1) a stream of purified synthesis gas having a controlled mole ratio H.sub.2 /CO, and (2) a separate stream of CO-rich gas. Methanol may be synthesized from the purified synthesis gas and reacted with CO to produce acetic acid. In the process, raw synthesis gas from a noncatalytic partial-oxidation gas generator is cleaned (if necessary), cooled, and dehumidified. At least a portion of the resulting gas stream is then partially purified by removing H.sub.2 S and COS if present, and at least a portion of the CO.sub.2 in a first gas purification zone. The remainder of the clean dehumidified gas stream if any, by-passes the first gas purification zone. Partially purified gas from the first gas purification zone is introduced into a second gas-purification or separation zone and at least a portion of the remainder if any, by-passes the second gas purification zone. A product stream of CO-rich gas and a separate stream of H.sub.2 -rich gas is removed from the second gas purification zone. The product stream of purified synthesis gas may then be produced by mixing together at least a portion of said H.sub.2 -rich gas stream with at least a portion of at least one of the following by-pass gas streams; (a) gas processed in the first gas purification zone that by-passes the second gas purification zone; (b) clean dehumidified gas that by-passes the first gas purification zone.

Claims37

Dependent claims

Process for simultaneous production of a product stream of purified synthesis gas and a product stream of CO-rich gas, comprising:

(1) reacting a hydrocarbonaceous feedstock with a free-oxygen-containing gas, optionally in the presence of a temperature moderator, in the reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300.degree. to 3000.degree. F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H.sub.2, CO, H.sub.2 O, CO.sub.2, and optionally at least one material from the group H.sub.2 S, COS, CH.sub.4, N.sub.2 A.sub.r, and solid particles;
(2) removing a portion of said solid particles if present, cooling the effluent gas stream by indirect heat exchange in a separate heat-exchange zone, removing any remaining entrained solid particles, and dehumidifying the cooled gas stream;
(3) introducing at least a portion of the clean dehumidified gas stream from (2) into a first gas-purification zone and by-passing said first gas-purification zone with the remainder if any;
removing from the gas stream in said first gas-purification zone any H.sub.2 S, COS, and at least a portion of the CO.sub.2 ;
(4) introducing partially purified gas from the first gas purification zone in (3) into a second gas-purification zone and by-passing said second gas-purification zone with at least a portion of the remainder, if any, and removing from said second gas-purification zone said product stream of CO-rich gas and a separate stream of H.sub.2 -rich gas;
and
(5) mixing together at least a portion of the H.sub.2 -rich gas from (4) with at least a portion of at least one of the following:
(a) gas processed in the first gas purification zone that by-passes the second gas purification zone in (4);
(b) soot-free dehumidified gas that by-passes the first gas-purification zone in (3);
producing said product stream of purified synthesis gas having a controlled H.sub.2 /CO mole ratio.

7 more elements

Process for the production of methanol, comprising:

(1) reacting a substantially sulfur-free hydrocarbonaceous feedstock with substantially pure oxygen, optionally in the presence of a temperature moderator, in the reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300.degree. to 3000.degree. F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H.sub.2, CO, H.sub.2 O, CO.sub.2 and at least one material from the group consisting of CH.sub.4, N.sub.2, A.sub.r, particulate carbon, and ash;
(2) cooling the effluent gas stream by indirect heat exchange in a separate heat-exchange zone, removing any entrained particulate carbon and ash, and dehumidifying the cooled gas stream;
(3) splitting the soot-free dehumidified gas stream from (2) into first and second gas streams with said first split gas stream comprising about 10 to 90 volume percent of the effluent gas stream from (2), and said second split stream comprising the remainder;
(4) purifying said first split gas stream from (3) in a first gas-purification zone and separating therefrom at least a portion of the CO.sub.2 ;
(5) splitting the gas stream from (4) into third and fourth gas streams with said third gas stream comprising about 10 to 100 volume percent of said synthesis-gas stream from (4) and said fourth gas stream containing the remainder if any and introducing all of said third gas stream into a second gas-purification zone;
(6) removing a stream of CO-rich gas and a stream of H.sub.2 -rich gas from said second gas-purification zone;
(7) mixing together at least a portion of said second gas stream from (3), at least a portion of said H.sub.2 -rich gas stream from (6), and at least a portion of said fourth gas stream if any from (5), to produce a stream of methanol-synthesis gas;
and
(8) reacting at least a portion of said methanol synthesis gas in the presence of a methanol catalyst in a methanol-synthesis zone at a temperature in the range of about 400.degree. to 750.degree. F and at a pressure in the range of about 40 to 350 atm. to produce crude methanol, and purifying said crude methanol to produce substantially pure methanol and by-product oxygen-containing organic materials.

6 more elements

Process for the simultaneous production of a product stream of purified synthesis gas and a product stream of CO-rich gas, comprising:

(1) reacting a hydrocarbonaceous feedstock with a free-oxygen-containing gas, optionally in the presence of a temperature moderator, in the reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300.degree. to 3000.degree. F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H.sub.2, CO, H.sub.2 O, CO.sub.2, H.sub.2 S, COS and optionally at least one material from the group consisting of CH.sub.4, N.sub.2, A.sub.r, and solid particles;
(2) removing a portion of said solid particles if present, cooling the effluent gas stream by indirect heat exchange in a separate heat-exchange zone, removing any remaining entrained solid particles and dehumidifying the cooled gas stream;
(3) desulfurizing the gas stream from (2) in the first stage of a two-stage first gas purification zone, introducing at least a portion of the desulphurized gas stream from the first stage into the second stage of said first gas purification zone and removing at least a portion of the CO.sub.2 ;
and by-passing said second stage with the remainder of said desulfurized gas from the first stage of said first gas purification zone if any;
(4) introducing at least a portion of the gas stream leaving the second stage of said first gas purification zone into a second gas purification zone when there is a stream of desulfurized gas from the first stage that by-passes said second stage, or introducing into said second gas purification zone a portion of the gas stream leaving the second stage of said first gas purification zone when there is no desulfurized gas stream that by-passes said second stage;
and by-passing said second gas purification zone with the remainder of said gas stream leaving the second stage of said first gas purification zone if any;
(5) removing from said second gas purification zone, a product stream of CO-rich gas and a stream of H.sub.2 -rich gas;
and
(6) mixing together at least a portion of the H.sub.2 -rich gas stream from (5) with at least a portion of at least one of the following:
(a) desulfurized gas stream that by-passes the second stage of the first gas purification zone in (3);
(b) desulfurized gas stream with at least a portion of the CO.sub.2 removed that leaves the second stage of the first gas purification zone and which by-passes said second gas purification zone in (4);
producing said product stream of purified synthesis gas having a controlled H.sub.2 /CO mole ratio.

9 more elements

Process for simultaneous production of a product stream of purified synthesis gas and a product stream of CO-rich gas, comprising:

(1) reacting a substantially sulfur-free hydrocarbonaceous feedstock with a free-oxygen-containing gas, optionally in the presence of a temperature moderator, in the reaction zone of a free-flow noncatalytic partial-oxidation gas generator at a temperature in the range of about 1300.degree. to 3000.degree. F and at a pressure in the range of about 1 to 250 atmospheres to produce an effluent gas stream comprising H.sub.2, CO, H.sub.2 O, CO.sub.2 and optionally at least one material from the group CH.sub.4, N.sub.2, A.sub.r and solid particles;
(2) cooling the effluent gast stream by indirect heat exchange in a separate heat-exchange zone, removing any entrained solid particles and dehumidifying the cooled gas stream;
(3) introducing at least a portion of the dehumidified gas stream from (2) into a first gas-purification zone, and by-passing said first gas-purification zone with the remainder of said dehumidified gas stream from (2) if any;
and removing from the process gas stream in said first gas purification zone at least a portion of the CO.sub.2 ;
(4) introducing at least a portion of the gas stream leaving the first gas purification zone into a second gas purification zone when there is a stream of soot-free dehumidified gas by-passing said first gas purification zone, or introducing a portion of the gas stream leaving the first gas purification zone into the second gas purification zone when there is no stream of soot-free dehumidified gas by-passing said first gas purification zone;
and by-passing said second gas purification zone with the remainder of the gas stream leaving the first gas purification zone if any;
(5) removing from said second gas purification zone, a product stream of CO-rich gas and a stream of H.sub.2 -rich gas;
and
(6) mixing together at least a portion of the H.sub.2 -rich gas stream from (5) with at least a portion of at least one of the following:
(a) dehumidified gas stream from (2) that by-passes the first gas-purification zone in (3);
(b) partially purified synthesis gas leaving the first gas purification zone with at least a portion of the CO.sub.2 removed and which by-passes the second gas-purification zone in (3) if any;
producing said product stream of purified synthesis gas having a controlled H.sub.2 /CO mole ratio.

9 more elements

Dependencies are inferred from the claim text.

Production of purified synthesis gas and carbon monoxide

Life of this patent

Production of purified synthesis gas and carbon monoxide

Life of this patent

Abstract

Claims37