Densified textile aggregates are co-fed with a fuel into a partial oxidation gasifier. High solids concentrations in the feedstock composition can be obtained without significant impact on the feedstock composition 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 syngas quality, composition, and throughput are suitable for produce a wide range of chemicals.

A gasification process may include (a) introducing a liquid hydrocarbon feedstock and at least one of a dry feedstock or a first slurried feedstock into a reactor lower section, wherein the at least one dry feedstock or first slurried feedstock is introduced through two primary feed nozzles while the liquid hydrocarbon feedstock is introduced through at least two secondary feed nozzles; (b) partially combusting the feedstocks in the reactor lower section with a gas stream comprising an oxygen-containing gas or steam to evolve heat and form products comprising hot synthesis gas; (c) passing said hot synthesis gas from step (b) upward into a reactor upper section; (d) and introducing a second slurried feedstock into said reactor upper section, whereby heat from said hot synthesis gas supports reaction of the second slurried feedstock by pyrolysis and gasification reactions.

The present invention provides a process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, the process comprising the steps of: continuously providing the carbonaceous feedstock of fluctuating compositional characteristics to a gasification zone; gasifying the carbonaceous feedstock in the gasification zone to obtain raw synthesis gas; recovering at least part of the raw synthesis gas from the gasification zone and supplying at least part of the recovered raw synthesis gas to a partial oxidation zone; equilibrating the H.sub.2:CO ratio of the raw synthesis gas in the partial oxidation zone to obtain equilibrated synthesis gas; recovering at least part of the equilibrated synthesis gas from the partial oxidation zone and treating the gas to remove impurities and generate a fine synthesis gas; optionally adjusting the H.sub.2:CO ratio of at least part of the fine synthesis gas to obtain adjusted fine synthesis gas; and converting the optionally adjusted fine synthesis gas into the useful product in a further chemical reaction requiring a usage ratio; wherein the fine synthesis gas H2:CO ratio is below the usage ratio and wherein any optional adjustment of at least part of the fine synthesis gas H.sub.2:CO ratio is effective to increase the H.sub.2:CO ratio in the fine synthesis gas to a level at, nearer to or above the usage ratio; wherein the H.sub.2:CO ratio of the raw synthesis gas fluctuates during operation of the process as a result of the fluctuating compositional characteristics of the carbonaceous feedstock by a percentage of ±x; and the H.sub.2:CO ratio of the equilibrated synthesis gas does not fluctuate during operation of the process or fluctuates during operation of the process as a result of the fluctuating compositional characteristics of the carbonaceous feedstock by a percentage±y, y being a lower percentage than x.

The integrated processes herein provide improved carbon efficiency for processes based on coal or biomass gasification or steam methane reforming. Provided are also ethylene oxide carbonylation products such as beta-propiolactone and succinic anhydride having a bio-based content between 0% and 100%, and methods for producing and analyzing the same.

A feedstock delivery system transfers a carbonaceous material, such as municipal solid waste, into a product gas generation system. The feedstock delivery system includes a splitter for splitting bulk carbonaceous material into a plurality of carbonaceous material streams. Each stream is processed using a weighing system for gauging the quantity of carbonaceous material, a densification system for forming plugs of carbonaceous material, a de-densification system for breaking up the plugs of carbonaceous material, and a gas and carbonaceous material mixing system for forming a carbonaceous material and gas mixture. A pressure of the mixing gas is reduced prior to mixing with the carbonaceous material, and the carbonaceous material to gas weight ratio is monitored. A transport assembly conveys the carbonaceous material and gas mixture to a first reactor where at least the carbonaceous material within the mixture is subject to thermochemical reactions to form the product gas.

The integrated processes herein provide improved carbon efficiency for processes based on coal or biomass gasification or steam methane reforming. Provided are also ethylene oxide carbonylation products such as beta-propiolactone and succinic anhydride having a bio-based content between 0% and 100%, and methods for producing and analyzing the same.

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.

A process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, comprising the steps of: continuously providing the carbonaceous feedstock of fluctuating compositional characteristics to a gasification zone; gasifying the carbonaceous feedstock in the gasification zone to obtain raw synthesis gas; recovering at least part of the raw synthesis gas from the gasification zone and supplying at least part of the recovered raw synthesis gas to a partial oxidation zone; equilibrating the H.sub.2:CO ratio of the raw synthesis gas in the partial oxidation zone to obtain equilibrated synthesis gas; recovering at least part of the equilibrated synthesis gas from the partial oxidation zone and treating the gas to remove impurities and generate a fine synthesis gas; and converting the optionally adjusted fine synthesis gas into the useful product in a further chemical reaction requiring a usage ratio.

A method of producing liquid fuel and/or chemicals from a carbonaceous material entails combusting a conditioned syngas in pulse combustion heat exchangers of a steam reformer to help convert carbonaceous material into first reactor product gas which includes carbon monoxide, hydrogen, carbon dioxide and other gases. A portion of the first reactor product gas is transferred to a hydrogen reformer into which additional conditioned syngas is added and a reaction carried out to produce an improved syngas. The improved syngas is then subject to one or more gas clean-up steps to form a new conditioned syngas. A portion of the new conditioned syngas is recycled to be used as the conditioned syngas in the pulse combustion heat exchangers and in the hydrocarbon reformer. A system for carrying out the method include, a steam reformer, a hydrocarbon reformer, first and second gas-cleanup systems, a synthesis system and an upgrading system.

An ASG system for polygeneration with CC includes a devolatilizer that pyrolyzes solid fuel to produce char and gases. A burner adds exothermic heat by high-pressure sub-stoichiometric combustion, a mixing pot causes turbulent flow of the gases to heat received solid fuel, and a riser micronizes resulting friable char. A devolatilizer cyclone separates the micronized char by weight providing micronized char, steam and gases to a gasifier feed and oversized char to the mixing pot. An indirect fluid bed gasifier combustion loop includes a gasifier coupled to the gasifier feed, a steam input to provide oxygen for gasification and to facilitate sand-char separation, and an output for providing syngas. A burner provides POC to a mixing pot which provides hot sand with POC to a POC cyclone via a riser, where the POC cyclone separates sand and POC by weight and provides POC and sand for steam-carbon reaction.