The present disclosure provides an integrated method and apparatus for catalytic cracking of heavy oil and production of syngas. A cracking-gasification coupled reactor having a cracking section and a gasification section is used as a reactor in the method. A heavy oil feedstock is fed into a cracking section to contact with a bed material in a fluidized state that contains a cracking catalyst, a catalytic cracking reaction is conducted under atmospheric pressure to obtain light oil-gas and coke. The coke is carried downward by the bed material into a gasification section to conduct a gasification reaction to generate syngas; the syngas goes upward into the cracking section to merge with the light oil-gas, and is guided out from the coupled reactor and enter a gas-solid separation system. Oil-gas fractionation is performed to a purified oil-gas product output from the gas-solid separation system to collect light oil and syngas products.

The description describes the integration of a gas fermentation process with a gasification process whereby effluent from the gas fermentation process is recycled to the gasification process. The one or more effluents which can be recycled include a stream comprising microbial biomass, a product stream comprising at least a portion of the at least one fermentation product, a by-product stream comprising fusel oil, and a waste water stream comprising microbial biomass. The stream comprising biomass can be dried before it is passed to the gasification zone. At least a portion of the waste water stream can be passed to the gasification process where one use is to replace at least a portion of the process water. The waste water stream can be further processed to produce a clarified water stream and a biogas stream comprising methane either or both of which can be passed to the gasification process.

A two-stage syngas production method to produce a final product gas from a carbonaceous material includes producing a first product gas in a first reactor, separating char from the first product gas to produce separated char and char-depleted product gas, and separately reacting the separated char and the char-depleted product gas with an oxygen-containing gas in a second reactor to produce a final product gas. The separated char is introduced into the second reactor above the char-depleted product gas. The solids separation device may include serially connected cyclones, and the separated char may be entrained in a motive fluid in an eductor to produce a char and motive fluid mixture prior to being transferred to the second reactor. A biorefinery method produces a purified product from the final product gas.

Methods and apparatuses for producing fuel and power from the reformation of organic waste include the use of steam to produce syngas in a Fischer-Tropsch reaction, followed by conversion of that syngas product to hydrogen. Some embodiments include the use of a heated auger both to heat the organic waste and further to cool the syngas.

This invention relates to a power recovery process in waste steam/CO.sub.2 reformers in which a waste stream can be made to release energy without having to burn the waste or the syngas. This invention in some embodiments does not make use of fuel cells as a component but makes use of exothermic chemical reactors using syngas to produce heat, such as Fischer-Tropsch synthesis. It also relates to control or elimination of the emissions of greenhouse gases in the power recovery process of this invention with the goal of producing energy in the future carbonless world economy.

A two-stage syngas production method to produce a final product gas from a carbonaceous material includes producing a first product gas in a first reactor, separating char from the first product gas to produce separated char and char-depleted product gas, and separately reacting the separated char and the char-depleted product gas with an oxygen-containing gas in a second reactor to produce a final product gas. The separated char is introduced into the second reactor above the char-depleted product gas. The solids separation device may include serially connected cyclones, and the separated char may be entrained in a motive fluid in an eductor to produce a char and motive fluid mixture prior to being transferred to the second reactor. A biorefinery method produces a purified product from the final product gas.

A disulfide oil hydrocarbon stream or a mixture of a disulfide oil hydrocarbon stream and a residual oil is partially oxidized in a gasifier to produce a hot raw synthesis gas containing hydrogen and carbon monoxide which can be passed to a steam generating heat exchanger to cool the hot raw synthesis gas and to produce steam which can be used to generate electricity via a turbine and, optionally, subjecting the cooled synthesis gas to the water/gas shift reaction to produce additional hydrogen and carbon dioxide.

A two-stage gasification reactor may include a reactor lower section and a reactor upper section. The reactor lower section may include (a) a lower reactor body, (b) two primary feed nozzles, configured to introduce at least one of a dry feedstock or a first slurried feedstock and located on opposing terminal ends of the lower reactor body, and (c) at least two secondary feed nozzles, configured to introduce a liquid hydrocarbon feedstock, located on the lower reactor body. The reactor upper section may include (a) an upper reactor body, (b) at least one upper feed nozzle, configured to introduce at least one of a dry feedstock or a first slurried feedstock, located on the upper reactor body, and (c) an outlet.

The invention provides for the integration of a gas fermentation process with a gasification process whereby effluent downstream from the gas fermentation process is recycled to the gasification process. The invention is capable of recycling one or more effluents including biogas generated from a wastewater treatment process, tail-gas generated from the fermentation process, unused syngas generated by the gasification process, microbial biomass generated from the fermentation process, microbial biomass generated from a wastewater treatment process, crude ethanol from the product recovery process, fusel oil from the product recovery process, microbial biomass depleted water, wastewater generated from the fermentation process, and clarified water from a wastewater treatment process to a gasification process.

An integrated refinery process for the disposal of metal-containing spent coked catalyst from hydrotreating and/or hydrocracking unit operations includes introducing the spent coked catalyst into a membrane wall gasification reactor in the form of flowable particles along with predetermined amounts of oxygen and steam based upon an analysis of the hydrocarbon content of the coke, and optionally, a liquid hydrocarbon; gasifying the feed to produce synthesis gas and a slag material; recovering and subjecting the slag material to further processes in preparation for a leaching step to solubilize and form one or more active phase metal compounds that are recovered from the leaching solution, either separately by sequential processing, or together. The recovered active metal compounds can be used, e.g., in preparing fresh catalyst for use in the refinery's hydroprocessing units.