US 4,668,429 AGranted

Partial oxidation process

AssigneeTexaco Inc.

InventorMitri S. Najjar

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Abstract

Synthesis gas is produced by the partial oxidation of a feedstock comprising petroleum coke and/or heavy liquid hydrocarbonaceous fuel containing sulfur and having an ash that contains nickel, vanadium and a comparatively high level of silicon. An iron and calcium-containing additive is introduced into the reaction zone along wth the feed. Separate portions of the additive (i) combine with a portion of the nickel, calcium and sulfur to generate a liquid phase washing agent that collects and transports out of the gas generator a portion of the vanadium-containing oxide laths and spinels and other ash components; and (ii) combine with a portion of the nickel, calcium and silicon to generate a liquid oxide-silicate phase that fluxes e.g. dissolves substantially all of the remaining portion of said vanadium-containing oxide laths and spinels and other ash components. In another embodiment, a minor amount of an additonal material selected from the group of elements consisting of magnesium, chromium, manganese, and mixtures thereof is included in the iron and calcium-containing additive. In still another embodiment, the iron and calcium-containing additive is uniformly dispersed in petroleum coke having a nickel and vanadium-containing ash. By this method two types of molten slag having reduced viscosities and containing the nickel and vanadium-containing impurities from the feedstock are readily removed from the gas generator at a lower temperature. Further, the life of the refractory lining is extended.

Claims30

Dependent claims

A process for the production of gaseous mixtures comprising H.sub.2 +CO by the partial oxidation of a feedstock comprising a heavy liquid hydrocarbonaceous fuel having a nickel and vanadium-containing ash or petroleum coke having a nickel and vanadium-containing ash, or mixtures thereof;

and said feedstock includes a minimum of 0.5 wt. % of sulfur;
and said ash includes a minimum of 5.0 wt. % vanadium, a minimum of 2.0 wt. % of nickel and about 400 parts per million of silicon or more;
said process comprising:
(1) mixing together an iron and calcium-containing additive with said feedstocks;
wherein said additive comprises a mixture of at least one iron compound and at least one calcium compound, and wherein the weight ratio of iron and calcium-containing additive to ash in the reaction zone in (2) is in the range of about 1.0-10.0 to 1.0, and there is at least 10 parts by weight of iron for each part by weight of vanadium;
(2) reacting said mixture from (1) at a temperature in the range of 2200.degree. F. to 2900.degree. F. and a pressure in the range of about 5 to 250 atmospheres in a free-flow refractory lined partial oxidation reaction zone with a free-oxygen containing gas in the presence of a temperature moderator and in a reducing atmosphere to produce a hot raw effluent gas stream comprising H.sub.2 +CO and entrained molten slag;
and where in said reaction zone separate portions of said iron and calcium-containing additive (i) combine with a portion of said nickel, calcium and sulfur to generate a liquid phase washing agent that collects and transports a portion of the vanadium-containing oxide laths and spinels and other ash components and refractory;
and (ii) combine with a portion of said nickel, calcium and silicon to generate a liquid oxide-silicate phase that fluxes substantially all of the remaining portion of said vanadium-containing oxide laths and spinels and other ash components;
and
(3) separating nongaseous materials from said hot raw effluent gas stream.

7 more elements

In a process for coking a heavy liquid hydrocarbonaceous fuel having a nickel and vanadium-containing ash to produce petroleum coke and gasifying said petroleum coke to produce gaseous mixtures comprising H.sub.2 and CO, the improvement comprising:

(1) mixing together said heavy liquid hydrocarbonaceous fuel with an iron and calcium-containing additive comprising a mixture of at least one iron compound and at least one calcium compound;
wherein said heavy liquid hydrocarbonaceous fuel includes a minimum of 0.5 wt. % sulfur and has an ash which contains a minimum of 5.0 wt. % vanadium, a minimum of 2.0 wt. % nickel, and about 400 parts per million of silicon or more;
and wherein the weight ratio of iron and calcium-containing additive to ash in the reaction zone in (4) is in the range of about 1.0-10.0 to 1.0, and there is at least 10 parts by weight of iron for each part by weight of vanadium;
(2) coking said mixture from (1) to produce petroleum coke having a nickel and vanadium-containing ash and having dispersed therein said iron and calcium-containing additive;
(3) introducing the petroleum coke from (2) into partial oxidation reaction zone in (4) as a pumpable slurry of petroleum coke in water, liquid hydrocarbonaceous fluid or mixtures thereof, or as substantially dry petroleum coke entrained in a gaseous transport medium;
(4) reacting said petroleum coke from (3) at a temperature in the range of 2200.degree. F. to 2900.degree. F. and a pressure in the range of about 5 to 250 atmospheres in said free-flow refractory lined partial oxidation reaction zone with a free-oxygen containing gas in the presence of a temperature moderator and in a reducing atmosphere to produce a hot raw effluent gas stream comprising H.sub.2 +CO and entrained molten slag;
and where in said reaction zone separate portions of said iron and calcium-containing additive (i) combine with a portion of said nickel, calcium, and sulfur to generate a liquid phase washing carrier that collects and transports a portion of the vanadium-containing oxide laths and spinels and other ash components and refractory;
and (ii) combine with a portion of said nickel, calcium and silicon to generate a liquid oxide-silicate phase that fluxes substantially all of the remaining portions of said vanadium-containing oxide laths and spinels and other ash components;
and
(5) separating nongaseous materials from said hot raw effluent gas stream.

7 more elements

Dependencies are inferred from the claim text.