Production of synthesis gas

Abstract

A process for the production of synthesis gas by partial combustion of a hydrocarbon feed using a burner with a plurality of coaxial channels, the method comprising the following steps: supplying a non-gaseous hydrocarbon feed using at least one of the plurality of coaxial channels; supplying a gaseous hydrocarbon feed using at least one of the plurality of coaxial channels; supplying an oxidizer gas using at least one of the plurality of coaxial channels; separately supplying a moderator gas using at least one of the plurality of coaxial channels; arranging the at least one channel supplying the non-gaseous hydrocarbon feed between two adjacent channels among the plurality of coaxial channels, wherein the two adjacent channels both supplying a flow containing the gaseous hydrocarbon feed or respectively supplying a flow containing the gaseous hydrocarbon feed and a flow of the moderator gas.

Claims

1. A process for the production of synthesis gas by partial combustion of a hydrocarbon feed using a burner with a plurality of coaxial channels, the method comprising the following steps: supplying a non-gaseous hydrocarbon feed using at least one of the plurality of coaxial channels; supplying a gaseous hydrocarbon feed using at least one of the plurality of coaxial channels; supplying an oxidizer gas using at least one of the plurality of coaxial channels; separately supplying a moderator gas using at least one of the plurality of coaxial channels; arranging the at least one channel supplying the non-gaseous hydrocarbon feed between two adjacent channels among the plurality of coaxial channels, wherein the two adjacent channels both supplying a flow containing the gaseous hydrocarbon feed or respectively supplying a flow containing the gaseous hydrocarbon feed and a flow of the moderator gas.

2. A process according to claim 1, wherein the gaseous hydrocarbon feed is at least partly supplied via a central channel among the plurality of coaxial channels.

3. A process according to claim 1, wherein the gaseous hydrocarbon feed is at least partly supplied via an outer channel among the plurality of coaxial channels.

4. A process according to claim 1, wherein the gaseous hydrocarbon feed is supplied via only one of the plurality of coaxial channels.

5. A process according to claim 1, wherein the gaseous hydrocarbon feed is a mixture of steam and a hydrocarbon gas.

6. A process according to claim 5, wherein the gaseous hydrocarbon feed has a hydrocarbon gas content in the range of 30-70 wt. %.

7. A process according to claim 1, wherein the gaseous hydrocarbon feed is natural gas.

8. A process according to claim 1, wherein the moderator gas is steam.

9. A process according to claim 1 using a burner with coaxial channels including: a first inner central channel supplying a gaseous hydrocarbon feed, an adjacent annular second channel supplying an oxidizer gas, a third channel supplying a flow of steam, a fourth channel supplying a flow containing oil, a fifth channel supplying a flow of steam, a sixth channel supplying an oxidizer gas and an outer seventh channel supplying a gaseous hydrocarbon feed.

10. A process according to claim 1 using a burner with coaxial channels including: a first inner central channel supplying a first flow of an oxidizer gas, an adjacent annular second channel supplying a second flow of an oxidizer gas with a flow rate which is higher than the flow rate of the first flow; a third channel supplying a flow of steam, a fourth channel supplying a flow containing oil, an outer fifth channel supplying a gaseous hydrocarbon feed.

11. A process according to claim 1 wherein, the at least one channel supplying the gaseous hydrocarbon feed includes a first inner central channel and an outer seventh channel; the at least one channel supplying the oxidizer gas includes an adjacent annular second channel and a sixth channel; the at least one channel separately supplying the moderator gas includes a third channel and a fifth channel each providing a flow of steam; the at least one channel supply the non-gaseous hydrocarbon feed includes a fourth channel supplying a flow containing oil.

12. A process according to claim 1 wherein, the at least one channel supplying the moderator gas includes a first inner central channel supplying a first flow of the oxidizer gas, and an adjacent annular second channel supplying a second flow of the oxidizer gas with a flow rate which is higher than the flow rate of the first flow; the at least one channel separately supplying the moderator gas includes a third channel supplying a flow of steam; the at least one channel supplying the non-gaseous hydrocarbon feed includes a fourth channel supplying a flow containing oil; the at least one channel supplying the gaseous hydrocarbon feed includes an outer fifth channel.

Description

(1) Those skilled in the art will be able to generate other combinations within the scope of the present invention.

(2) The flow(s) containing a gaseous hydrocarbon feed, such a mixture of steam with natural gas, through the central channel can for instance have a medium flow velocity of 5-85 m/sec, more particular of about 25-about 65 m/sec.

(3) The flow(s) containing an oxidizer gas can for instance have a medium flow velocity of about 50-about 150 m/sec, more particular of about 80-about 120 m/sec.

(4) The flow(s) containing a moderator gas, such as steam, can for instance have a medium flow velocity of 5-85 m/sec, more particular of about 25-about 65 m/sec.

(5) The non-gaseous hydrocarbon feed, such as oil, can for instance have a medium flow velocity of about 15 m/sec or less, more particular of about 7-about 12 m/sec.

(6) The various flow velocities can be varied by appropriate dimensioning of the flow through capacities of the coaxial channels.

(7) In a particular embodiment the process can be carried out at a pressure between about 0.1-12 MPa, e.g., of about 0.5-6 MPa. The temperature in the reactor will typically be in the range of about 1000 C. to about 1800 C.

(8) It has been found that the process of the present disclosure makes it possible to achieve any H2/CO ratio between about 0.75 (e.g., when the mass flow ratio of hydrocarbon gas to liquid is very low or 0) and about 1.25 (e.g., when the mass flow ratio of hydrocarbon gas to liquid is very high, e.g., 1).

(9) The process can be practiced with a reactor comprising a burner with a plurality of coaxial burner channels, wherein at least one channel is operatively connected to a supply of a non-gaseous hydrocarbon feed, at least one other channel is operatively connected to a supply of a gaseous hydrocarbon feed and at least one channel is operatively connected to a supply of a moderator gas.

(10) In a particular embodiment, the process can be practiced with a reactor comprising a burner comprising seven coaxial channels:

(11) a first inner central channel supplying a flow of a gaseous hydrocarbon feed,

(12) an adjacent annular second channel supplying an oxidizer gas,

(13) a third channel supplying a flow of steam,

(14) a fourth channel supplying a flow containing oil,

(15) a fifth channel supplying a flow of steam,

(16) a sixth channel supplying an oxidizer gas and

(17) an outer seventh channel supplying a flow of a gaseous hydrocarbon feed.

(18) Optionally, the gaseous hydrocarbon feed in the first channel can be replaced by a flow of an oxidizer gas, or the gaseous hydrocarbon feed in the seventh channel can be replaced by a steam flow.

(19) The burner can comprise a number of slits at the burner outlet and hollow wall members with internal passages for a cooling fluid, such as water. Optionally, these passages may be converging at the burner outlet. The burner may further be provided with a ceramic or refractory lining applied onto or suspended by a means closely adjacent to the outer surface of the burner wall for resisting the heat load during operation or heat-up/shut down situations of the burner. The channels may be provided with retracted or protruding exit(s), if so desired.

(20) The reactor may further comprise a vessel, such as a vertically oriented cylindrical vessel having an outlet for the mixture of carbon monoxide and hydrogen at its lower end. The burner can for instance be arranged at the top end of the reactor vessel.

(21) Optionally, the reactor can have more than one burner, if so desired.