Methods and apparatus may permit the generation of consistent output synthesis gas from highly variable input feedstock solids carbonaceous materials. A stoichiometric objectivistic chemic environment may be established to stoichiometrically control carbon content in a solid carbonaceous materials gasifier system. Processing of carbonaceous materials may include dominative pyrolytic decomposition and multiple coil carbonaceous reformation. Dynamically adjustable process determinative parameters may be utilized to refine processing, including process utilization of negatively electrostatically enhanced water species, process utilization of flue gas, and adjustment of process flow rate characteristics. Recycling may be employed for internal reuse of process materials, including recycled negatively electrostatically enhanced water species, recycled flue gas, and recycled contaminants. Synthesis gas generation may involve predetermining a desired synthesis gas for output and creating high yields of such a predetermined desired synthesis gas.

A method of processing a first material including an oil source, and a second material including a medium. The method includes mixing the first material and the second material to provide a blended feedstock mixture including predetermined respective proportions of the first material and the second material, and also including water. The blended feedstock mixture is heated in a pre-distillation process and is further heated in a distiller to at least partially crack and vaporize the oil source, to provide atmospheric gas oil and vacuum gas oil from the oil source, coked medium material including carbon-heavy hydrocarbons and sand, and a first barren hot medium material. The coked medium material is heated in a gasifier to provide a second barren hot medium material and syngas. Heat energy from certain products resulting from such heating is transferred to the blended feedstock mixture.

The present invention relates to a process and system for complete conversion of crude oils by integrating delayed coking process, high severity catalytic cracking process and naphtha cracking processes along with olefin recovery section, aromatic recovery section and gasifier section to maximize the crude oil conversion to valuable products like light olefins, aromatics and chemicals.

A process for the gasification of a solid carbonaceous feed, the process comprising the steps of: introducing a batch of the solid carbonaceous feed into a sluice vessel, while an internal pressure in the sluice vessel is at a first pressure; introducing at least recycled CO2 into the sluice vessel via one or more gas inlets covered by the solid carbonaceous feed, to pressurize the sluice vessel from the first pressure to a second pressure exceeding the first pressure, during a predetermined time period; closing the one or more gas inlets; opening a feed outlet of the sluice vessel to supply the batch of the solid carbonaceous feed to a feed vessel for feeding the solid carbonaceous feed to a gasification reactor; closing the feed outlet; venting the sluice vessel to reduce the internal pressure to the first pressure; and repeating the process.

A continuous multi-stage vertically sequenced gasification process for conversion of solid carbonaceous fuel material into clean (low tar) syngas. The process involves forming a pyrolysis residue bed having a uniform depth and width to pass raw syngas there through for an endothermic reaction, while controlling the reduction zone pressure drop, resident time and syngas flow space velocity during the endothermic reaction to form substantially tar free syngas, to reduce carbon content in the pyrolysis residue, and to reduce the temperature of raw syngas as compared to the temperature of the partial oxidation zone.

Methods and apparatus may permit the generation of consistent output synthesis gas from highly variable input feedstock solids carbonaceous materials. A stoichiometric objectivistic chemic environment may be established to stoichiometrically control carbon content in a solid carbonaceous materials gasifier system. Processing of carbonaceous materials may include dominative pyrolytic decomposition and multiple coil carbonaceous reformation. Dynamically adjustable process determinative parameters may be utilized to refine processing, including process utilization of negatively electrostatically enhanced water species, process utilization of flue gas, and adjustment of process flow rate characteristics. Recycling may be employed for internal reuse of process materials, including recycled negatively electrostatically enhanced water species, recycled flue gas, and recycled contaminants. Synthesis gas generation may involve predetermining a desired synthesis gas for output and creating high yields of such a predetermined desired synthesis gas.

Pre-ground plastics of small particle size not more than 2 mm are co-fed into a solid fossil fuel fed entrained flow partial oxidation gasifier. High solids concentrations in the feedstock stream can be obtained without significant impact on the feedstock stream stability and pumpability. A consistent quality of syngas can be continuously produced, including generation of carbon dioxide and a carbon monoxide/hydrogen ratio while stably operating the gasifier and avoiding the high tar generation of fluidized bed or fixed bed waste gasifiers and without impacting the operations of the gasifier. The subsequent syngas produced from this material can be used to produce a wide range of chemicals.

Pre-ground plastics of small particle size not more than 2 mm are co-fed into a solid fossil fuel fed entrained flow partial oxidation gasifier. High solids concentrations in the feedstock stream can be obtained without significant impact on the feedstock stream stability and pumpability. A consistent quality of syngas can be continuously produced, including generation of carbon dioxide and a carbon monoxide/hydrogen ratio while stably operating the gasifier and avoiding the high tar generation of fluidized bed or fixed bed waste gasifiers and without impacting the operations of the gasifier. The subsequent syngas produced from this material can be used to produce a wide range of chemicals.

Systems and methods are provided for adding a heated stream of light hydrocarbons to a fluidized coking environment to improve liquid product yield and/or reduce coke production. The light hydrocarbons can correspond to C.sub.1-C.sub.10 hydrocarbons and/or hydrogen. The light hydrocarbons can be heated so that the light hydrocarbons are exposed to an activation temperature of 535 C. to 950 C. and/or an activation temperature higher than the temperature in the coking zone by 50 C. or more for an activation time prior to entering the fluidized coking reactor and/or the coking zone in the fluidized coking environment.

Systems and methods are provided for integrating a fluidized coking process with a catalyst-enhanced coke gasification process. The catalyst for the gasification process can correspond to calcium oxide, a thermally decomposable calcium salt, a potassium salt such as potassium carbonate, or a combination thereof. Examples of suitable calcium salts can include, but are not limited to, calcium hydroxide, calcium nitrate, and calcium carbonate. The calcium oxide, potassium salts, and/or thermally decomposable calcium salts can be introduced into the integrated system, for example, as part of the feed into the coker. It has been unexpectedly discovered that using catalytic gasification as part of an integrated fluidized coking and gasification process can result in an overhead gas stream from the gasifier with increased energy content and/or overhead gas pressure.