PROCESSES USING SPLIT HYDROCARBON PROCESSING (SHCP) FOR HYDROGEN PRODUCTION AND CARBON DIOXIDE CAPTURE

Abstract

The present invention discloses various applications of split hydrocarbon processing (SHCP) across an array of technologies for hydrogen (H.sub.2), power and industrial production purposes. These applications generate nearly pure carbon dioxide CO.sub.2 with no need for separation, making it ready for compression and storage or utilization.

Claims

1. An application of split hydrocarbon processing (SHCP) to high pressure oxy-fired once through steam generation process (HiPrOx-OTSG-SHCP) for steam-assisted gravity drainage (SAGD) process, wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, the carbon black is fed to a high pressure oxy-fired combustion once through steam generation process unit as fuel to supply energy for the split hydrocarbon processing (SHCP) unit while indirectly produces steam for steam assisted gravity drainage (SAGD) process from cleaned SAGD recycled process water (PW) and fresh make up water, the high pressure flue gas containing steam and CO.sub.2 further indirectly produces steam through heat recovery steam generation for a power cycle to produce electricity, and the condensed H.sub.2O and gaseous CO.sub.2 are separated with the water being recycled for slurring the carbon black while a fraction of the CO.sub.2 is recirculated for flame moderation with the balance being ready for CO.sub.2 compression and storage or utilization.

2. An application of split hydrocarbon processing (SHCP) to high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG-SHCP) for steam-assisted gravity drainage (SAGD) process, wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, the carbon black is fed to a high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) process as fuel to supply energy for the split hydrocarbon processing (SHCP) while directly produce a high pressure mixture of steam and CO.sub.2 for steam assisted gravity drainage (SADG) process from the untreated SADG recycled process water (PW) and fresh makeup water, the high pressure mixture of steam and CO.sub.2 are directly injected in steam assisted gravity drainage (SADG) wells, or the steam H.sub.2O can be separated by condensing the steam to water and re-boiling the water to steam for steam assisted gravity drainage (SADG) wells, leaving the CO.sub.2 for compression and storage or utilization after remaining moisture is condensed, and the condensed H.sub.2O is recycled for conveying carbon black.

3. An application of split hydrocarbon processing (SHCP) to gas turbine combined cycle (GTCC-SHCP) process, wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, a portion of the carbon black is fed to a high pressure oxy-fired gasification processing unit to supply energy for the split hydrocarbon processing (SHCP) while produce a CO stream and indirectly generate steam for steam power cycle to produce power, the rest of the carbon black C is fed to a high pressure oxy-fired combustion processing unit to supply energy for the split hydrocarbon processing (SHCP) while produce a CO.sub.2 stream driving a gas turbine for power generation, the CO.sub.2 stream after expansion is cooled by the feedwater of steam cycle and compressed to the pressure of the CO stream from the gasification process, part of the CO.sub.2 stream is recycled to high pressure oxy-fired combustion for temperature moderation, and the rest of the CO.sub.2 stream is mixed with the CO stream for deoxygenation, then is liquefied by the condensed water of steam cycle for compression and storage or utilization, and a portion of the liquefied CO.sub.2 stream is recycled for conveying carbon black.

4. An application of split hydrocarbon processing (SHCP) to Allam Cycle (Allam-SHCP), wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, the carbon black is fed to a high pressure oxy-fired combustion processing unit to supply energy for the split hydrocarbon processing (SHCP) while produce a high pressure and high temperature CO.sub.2 stream to drive a gas turbine for power generation, after expansion the exhaust CO.sub.2 is cooled and a portion of it is recycled back through compression to the high pressure oxy-fired combustion processing unit for moderating the combustion flame temperature and conveying carbon black, and the rest of the exhaust CO.sub.2 cooled and ready for compression and storage or utilization, and slurry processing to convey the carbon black C with liquefied CO.sub.2 to the high pressure oxy-fired combustion processing unit employs a flash tank to depressurize the liquefied CO.sub.2 at room temperature, to achieve chilly gaseous CO.sub.2 and chilly liquid CO.sub.2, the chilly gaseous CO.sub.2 then transports the carbon black C to a slurry tank, where it mixes with the chilly liquid CO.sub.2 to produce a chilly CO.sub.2 and carbon C slurry.

5. An application of split hydrocarbon processing (SHCP) to hydrogen production for clean fuel process (H.sub.2-SHCP), wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, the carbon black is fed to a high pressure oxy-fired gasification followed by a high temperature shift reaction slightly exothermic and provides sufficient heat to maintain within the optimal range of 700-800 C., the shifted gas is cooled through heat recovery network to remove H.sub.2O for reuse of making carbon C slurry, hydrogen is separated using a pressure swing adsorption (PSA) unit for export, and a portion of the off-gas from pressure swing adsorption is sent through an amine stripper to remove CO.sub.2 and the remaining CO rich gas is then recycled back to the shift processing through compression, and the remaining off-gas from the pressure swing adsorption and the amine stripper undergoes CO oxy-fired combustion processing to supply energy for the split hydrocarbon processing (SHCP) and the amine stripper.

6. An application of split hydrocarbon processing (SHCP) to lime or cement production process (CaO-SHCP), wherein: hydrocarbon fuel is fed into a split hydrocarbon processing (SHCP) unit where decomposition of the carbon and hydrogen components takes place and the resulting products are separated into hydrogen and carbon black C, the hydrogen is further processed through an air-fired combustion processing unit to supply energy, resulting in the release of nitrogen and water, or exported as a product, the carbon black is fed to an oxy-fired combustion process unit to supply energy for the split hydrocarbon processing (SHCP) while produce a high temperature CO.sub.2 stream meeting the heat requirement of calcination reaction of limestone, the CO.sub.2 stream is combined with a second CO.sub.2 stream produced from a calcination reaction in a calcination processing unit, after exiting the calcination, the combined CO.sub.2 stream is used to drive a power cycle to generate electricity while undergoes cooling, a portion of the cooled CO.sub.2 is recycled to cool the lime or cement product and back to the calcination reaction for moderating the required calcination temperature, and another portion of the cooled CO.sub.2 is recycled to convey carbon black, and the rest of the cooled CO.sub.2 is ready for compression and storage or utilization.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0100] By way of example only, embodiments of the present invention are described hereinafter with reference to the accompanying drawings, wherein:

[0101] FIG. 1a is a schematic representation of an embodiment of general industrial production processes incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, intended products and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage or utilization;

[0102] FIG. 1b is a schematic representation of an embodiment of general power production processes incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, power and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage or utilization;

[0103] FIG. 2 is a schematic representation of an embodiment of general industrial production processes incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, intended products and generating CO.sub.2 wherein air-fired combustion processing. Post-combustion CO.sub.2 separation is used for CO.sub.2 capture, after which it is ready for compression and storage or utilization;

[0104] FIG. 3 is a schematic representation of an embodiment of a high pressure oxy-fired once through steam generation (HiPrOx-OTSG) process incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, steam for SAGD, power, and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage or utilization;

[0105] FIG. 4 is a schematic representation of an embodiment of a high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) process incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, steam for SAGD, and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage or utilization;

[0106] FIG. 5 is a schematic representation of an embodiment of a gas turbine combined cycle (GTCC) process incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, power and generating CO.sub.2 wherein oxy-fired combustion and gasification processing. The CO.sub.2 output is ready for compression and storage or utilization;

[0107] FIG. 6 is a schematic representation of an embodiment of an Allam power cycle incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, power and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage and or utilization;

[0108] FIG. 7 is a schematic representation of an embodiment of a carbon gasification process incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, power and generating CO.sub.2 wherein oxy-fired gasification processing. The CO.sub.2 output is ready for compression and storage or utilization; and

[0109] FIG. 8 is a schematic representation of an embodiment of a lime/cement production process incorporating split hydrocarbon processing (SHCP) for producing H.sub.2, power, lime/cement and generating CO.sub.2 wherein oxy-fired combustion processing. The CO.sub.2 output is ready for compression and storage or utilization.

DETAILED DESCRIPTION OF THE INVENTION

[0110] It is to be understood that the disclosure is not limited in its application to the details of the embodiments as set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. By way of example only, preferred embodiments of the present invention are described hereinafter with reference to the accompanying drawings.

[0111] Furthermore, it is to be understood that the terminology used herein is for the purpose of description and should not be regarded as limiting. Contrary to the use of the term consisting, the use of the terms including, containing, comprising, or having and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of the term a or an is meant to encompass one or more.

[0112] Fuel is a solid, liquid, or gaseous hydrocarbon, or carbon, or hydrogen, or a mixture thereof.

[0113] Carbon can be the waste carbon black generated from a natural gas pyrolysis system that produces hydrogen, or another source of carbon, such as petroleum coke.

[0114] Processes mean industrial processes and include power generation and oil and gas processes.

[0115] Split hydrocarbon processing (SHCP) refers to the decomposition of the carbon and hydrogen components of hydrocarbon fuels into two streams: hydrogen and solid carbon, and these resultant energy productshydrogen (H.sub.2) and solid carbon (carbon black C)are subsequently exported as products or utilized in diverse production processes.

[0116] For example, after the decomposition of CH.sub.4 into hydrogen and solid carbon, 45% of the energy value of CH.sub.4 goes to solid carbon (C) and 55% to hydrogen (H.sub.2), as shown in Table 1.

TABLE-US-00001 TABLE 1 SHCP Low Heat Value (LHV) Energy Balance Split Energy/ Reaction CH.sub.4 mol CH.sub.4 2 H.sub.2 C LHV, kJ/mole 802 + 75 .fwdarw. 2 242 + 393.5 Percentage .sub.91% .sub.9% 55% 45%

[0117] As addressed earlier, the approach of burying the solid carbon stream, known as solid carbon sequestration, has detrimental effects on both aquatic and terrestrial ecosystems if there is not viable market to consume it. Moreover, this approach results in a 45% loss of the energy value of CH.sub.4. The solution as disclosed by the present invention addresses the carbon C stream differently by fully harnessing its energy value through oxidation in oxygen, resulting in nearly pure CO.sub.2 that is ready for compression and storage or utilization. This approach offers unique advantages over conventional CO.sub.2 capture methods from CH.sub.4 combustion.

[0118] Table 2 compares, based on supplying the same amount of energy output, the conventional combustion of 1 mole of CH.sub.4 in both air-fired and oxy-fired combustion modes against two scenarios of the CH.sub.4 split hydrocarbon processing and combustion.

[0119] In Table 2, the conventional combustion of 1 mole of CH.sub.4 supplies 802 KJ/mole (LHV), while produces 10.52 moles of flue gas with 9.5% of CO.sub.2 in air-fired combustion mode and produces 3 moles of flue gas with 33.3% of CO.sub.2 in oxy-fired combustion mode. Before the CO.sub.2 can be captured, an additional CO.sub.2 separation process is required for both modes.

[0120] In the first scenario of the CH.sub.4 split hydrocarbon processing, splitting 1 mole of CH.sub.4 produces 2 moles of H.sub.2 and 1 mole of C. All the H.sub.2 can be burnt in air-fired combustion mode, producing no green house gas emissions. A portion of the H.sub.2 (0.31 mol) can supply energy (75 KJ/mol) required for splitting 1 mole of CH.sub.4. The entire carbon (C) can be burnt in oxy-fired combustion mode, producing only 1 mole of flue gas with 100% of CO.sub.2 requiring no separation, while supplying the same energy output of 802 KJ/mole (LHV). Moreover, this scenario consumes only 1 mole of O.sub.2 that is just half of the O.sub.2 consumption of the conventional combustion of 1 mole of CH.sub.4 in oxy-fired combustion mode. Therefore, the first scenario reduces costs and energy penalty for CO.sub.2 capture by using a smaller air separation unit, handling much less flue gas (1 mole vs. 10.52 moles or 3 moles) and capturing CO.sub.2 without CO.sub.2 separation.

[0121] In the second scenario of the CH.sub.4 split hydrocarbon processing, splitting 2.04 moles of CH.sub.4 produces 4.08 moles of H.sub.2 and 2.04 moles of C. 15% H.sub.2 (0.63 mol) can be burnt in air-fired combustion mode, producing no green house gas emissions, to supply energy (153 KJ/mol) for splitting 2.04 moles of CH.sub.4. The entire carbon (C) can be burnt in oxy-fired combustion mode, producing 2.04 mole of flue gas with 100% of CO.sub.2 requiring no separation, while supplying the same energy output of 802 KJ/mole (LHV). Moreover, the second scenario consumes 2.04 mole of O.sub.2 that is slightly more than the 2 moles of O.sub.2 consumed by the conventional combustion of 1 mole of CH.sub.4 in oxy-fired combustion mode but is able to use 2.04 moles of CH.sub.4 for producing 3.44 moles of H.sub.2 as a product or clean fuel for other applications or market. Therefore, the advantage of this second scenario is that it is able to reduce cost and energy penalty for CO.sub.2 capture by using the same size air separation unit, handling much less flue gas (2.04 moles vs. 10.52 moles or 3 moles), capturing CO.sub.2 without CO.sub.2 separation and producing 3.44 moles of H.sub.2 as a product or clean fuel.

TABLE-US-00002 TABLE 2 Comparison of CH.sub.4 combustion and CH.sub.4 split hydrocarbon processing combustion for the same amount of energy output CH.sub.4 combustion: material balance and energy output (LHV) Flue H2 CH.sub.4, O.sub.2, N.sub.2, C(s), H2, H.sub.2O, CO.sub.2, N2, C(s), H.sub.2, LHV, gas, mol Product Mode mol mol mol mol mol mol mol mol mol mol kJ/mol (CO2%) mol air-fired 1.00 2.00 7.52 2.00 1.00 7.52 802.sup.(2) 10.52 combustion 9.5% oxy-fired.sup.(3) 1.00 2.00 2.00 1.00 802.sup.(2) 3.00 combustion 33.3% CH.sub.4 SHCP material balance and energy balance (LHV) Scenario 1 combustion of 100% H.sub.2 and 100% C for energy supply, without H2 production Flue H.sub.2 CH.sub.4, O.sub.2, N.sub.2, C(s), H2, H2O, CO.sub.2, N2, C(s), H.sub.2, LHV, gas, mol Product Mode mol mol mol mol mol mol mol mol mol mol kJ/mol (CO2%) mol CH4 SHCP 1.00 1.00 2.00 75 H.sub.2 air-fired 0.16 0.58 0.31 0.31 0.58 75.sup.(1) combustion H2 air-fired 0.84 3.18 1.69 0.84 3.18 409.sup.(2) combustion C oxy-fired.sup.(3) 1.00 1.00 1.00 394.sup.(2) 1.00 combustion 100% CH.sub.4 SHCP material balance and energy balance (LHV) Scenario 2 combustion of 15% H.sub.2 and 100% C for energy supply, with H.sub.2 production Flue H.sub.2 CH.sub.4, O.sub.2, N.sub.2, C(s), H2, H.sub.2O, CO.sub.2, N2, C(s), H.sub.2, LHV, gas, mol Product Mode mol mol mol mol mol mol mol mol mol mol kJ/mol (CO2%) mol CH4 SHCP 2.04 2.04 4.08 153 3.44 H2 air-fired 0.32 1.19 0.63 0.63 1.19 153.sup.(1) combustion C oxy-fired.sup.(3) 2.04 2.04 2.04 802.sup.(2) 2.04 combustion 100% Notes: .sup.(1)Energy needed to split CH.sub.4, .sup.(2)Energy output from the combustion, .sup.(3)Energy needed to separate O.sub.2 from air by ASU is not included in this table. In general, comparing oxy-fired combustion CO.sub.2 capture with post-combustion CO.sub.2 capture, energy needed for separating O.sub.2 from air is less than energy needed for separating CO.sub.2 from flue gas.

[0122] Therefore, CH.sub.4 split hydrocarbon processing combustion can result in a better energy and economic performance than conventional combustion of CH.sub.4 in both air-fired and oxy-fired combustion modes.

[0123] The present invention has the following characteristics and advantages: [0124] It employs split hydrocarbon processing (SHCP) to make separate solid carbon C stream and hydrogen H.sub.2 stream from a hydrocarbon fuel, and handles the separated solid carbon C stream and hydrogen H.sub.2 stream differently; [0125] It integrates the split hydrocarbon processing (SHCP) into a variety of industrial and power processes to allow a localized production of clean H.sub.2 stream; [0126] It utilizes the clean H.sub.2 stream as an exported product or a clean fuel for other applications, and/or utilizes part of the clean H.sub.2 stream as fuel in air-combustion to energize split hydrocarbon processing (SHCP) for the intended industrial or power processes; [0127] It utilizes the solid carbon C stream as fuel in oxy-fired combustion to energize the intended industrial or power processes, and/or utilizes part of the solid carbon C stream to energize the split hydrocarbon processing (SHCP); and [0128] It produces nearly pure CO.sub.2 effluent streams universal to different industrial or power processes with the aim that the CO.sub.2 output is ready for compression and storage or utilization.

[0129] According to the present invention, split hydrocarbon processing (SHCP) for producing hydrogen and generating pure CO.sub.2 is a universal approach that can be applied to different industrial and/or power processes. This approach allows different industrial and/or power processes to locally produce clean hydrogen H.sub.2 as an exported product or as a clean fuel. This approach also allows different industrial and power processes to fully utilize the energy of carbon C and produce pure CO.sub.2 ready for compression and storage or utilization.

[0130] FIGS. 1a and 1b are, respectively, schematic representations of: [0131] a. an embodiment of industrial production processes, and [0132] b. an embodiment of power production processes.

[0133] Both using split hydrocarbon processing (SHCP) for H.sub.2 production and intended product production, while generating CO.sub.2 for compression and storage or utilization.

[0134] Referring to FIGS. 1a and 1b, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0135] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0136] The solid carbon (carbon black C) is further processed by an oxy-fired combustion processing unit 30, where oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the oxy-fired combustion processing unit 30. An air separation unit (ASU) 40 is a device that separates air into its components, primarily oxygen, nitrogen, and argon.

[0137] The oxy-fired combustion of solid carbon (carbon black C) supplies energy for the split hydrocarbon processing unit 10 and the production process while produces CO.sub.2. The CO.sub.2 capture from the oxy-fired combustion unit 30 will depend on the conveying mediums that transport bulk solid carbon C into the combustion process. With liquefied CO.sub.2, a nearly pure CO.sub.2 stream can be achieved.

[0138] The oxy-fired combustion processing unit 30 can burn the solid carbon (carbon black C) under ambient pressure or at above ambient pressure.

[0139] As an illustrative example, high pressure oxy-fired (HiPrOx) combustion requires the entire system at pressure resulting in the release of a pressurized CO.sub.2 stream. The pressure needs to be as high as above 75 bars allowing for the liquefaction of CO.sub.2 stream at near-ambient temperatures for pipeline transportation. In such a way, the high energy penalties of compressing gaseous CO.sub.2 are avoided. Furthermore, a high pressure oxy-fired (HiPrOx) combustion system is more compact.

[0140] The difference between FIGS. 1a and 1b is that in FIG. 1a the split hydrocarbon processing unit 10 is applied to industrial production processing 50 on raw materials to provide products, whereas in FIG. 1b the split hydrocarbon processing unit 10 is applied to power production processing 60 to provide electricity.

[0141] FIG. 2 is a schematic representation of an embodiment of industrial production process 50 using split hydrocarbon processing (SHCP) unit 10 for H.sub.2 production and intended product production, while generating CO.sub.2 in air-fired combustion processing unit 20. Post-combustion CO.sub.2 capture is used for CO.sub.2 separation, followed by compression and storage or utilization.

[0142] Referring to FIG. 2, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0143] Hydrogen (H.sub.2) can be exported and/or further processed through a first air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0144] The solid carbon (carbon black C) is further processed by a second air-fired combustion processing unit 20 (as opposed to an oxy-fired combustion processing unit 30 in FIG. 1a). This is particularly applicable where the air-fired combustion processing is available and less costly than oxy-fired combustion CO.sub.2 capture.

[0145] Similar process (using an air-fired combustion processing unit 20 as opposed to an oxy-fired combustion processing unit 30 as depicted in FIG. 1b) for power production processing can also be employed.

Application of SHCP to the Oil and Gas Industry

[0146] The approach of using split hydrocarbon processing (SHCP) can be applied to the oil and gas industry for bitumen extraction using steam assisted gravity drainage (SAGD) process. As disclosed herein, two novel steam-assisted gravity drainage (SAGD) processes incorporating split hydrocarbon processing (SHCP) are described below: [0147] 1. a high pressure oxy-fired once through steam generation (HiPrOx-OTSG-SHCP) process; and [0148] 2. a high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG-SHCP) process.

HiPrOx-OTSG-SHCP: High Pressure Oxy-Fired Once Through Steam Generation (HiPrOx-OTSG) Process Incorporating SHCP

[0149] FIG. 3 is a schematic representation of an embodiment of high pressure oxy-fired once through steam generation process using split hydrocarbon processing (HiPrOx-OTSG-SHCP) for steam assisted gravity drainage (SAGD) process to extract bitumen, while producing H.sub.2, power and generating CO.sub.2 for compression and storage or utilization.

[0150] Referring to FIG. 3, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0151] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0152] The carbon black C is fed to a high pressure oxy-fired once through steam generation (HiPrOx-OTSG) processing unit 70 as fuel. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the high pressure oxy-fired once through steam generation (HiPrOx-OTSG) processing unit 70. This high pressure oxy-fired once through steam generation (HiPrOx-OTSG) processing unit 70 produces the energy required for the split hydrocarbon processing unit 10 and indirectly produces steam for steam assisted gravity drainage (SAGD) wells 125 from cleaned SAGD recycled process water (PW) and fresh make up water.

[0153] The high-pressure flue gas from the high pressure oxy-fired once through steam generation (HiPrOx-OTSG) processing unit 70 containing steam and CO.sub.2 further indirectly produces steam through heat recovery steam generation (HRSG) unit 80 for a steam turbine 90 to produce electricity. Then the flue gas is cooled in a flue gas condenser 100. Finally, the condensed H.sub.2O and gaseous CO.sub.2 are separated with the water being recycled for slurring the carbon black while a fraction of the CO.sub.2 is recirculated for flame moderation in the high pressure oxy-fired once through steam generation (HiPrOx-OTSG) processing unit 70 with the balance being ready for CO.sub.2 compression and storage or utilization.

HiPrOx-DCSG-SHCP: High Pressure Oxy-Fired Direct Contact Steam Generation (HiPrOx-DCSG) Process Incorporating SHCP

[0154] FIG. 4 is a schematic representation of an embodiment of high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) process using split hydrocarbon processing (SHCP) for steam assisted gravity drainage (SAGD) process to extract bitumen, while producing H.sub.2 and generating CO.sub.2 for compression and storage or utilization.

[0155] Direct contact steam generation allows the fuel and the water to come in direct contact in oxy-fired combustion to produce a mixture of steam (90%) and CO.sub.2 (10%) for the steam assisted gravity drainage (SAGD) process. The water used for the steam assisted gravity drainage process is the untreated SAGD recycled process water (PW).

[0156] Referring to FIG. 4, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0157] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0158] The carbon black C is fed to a high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) processing unit 110 as fuel. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) processing unit 110. This high pressure oxy-fired direct contact steam generation (HiPrOx-DCSG) processing unit 110 produces the energy required for the split hydrocarbon processing unit 10 and directly produces steam from the untreated SAGD recycled process water (PW) and fresh make up water. The high pressure mixture of steam (90%) and CO.sub.2 (10%) can then be directly injected in steam assisted gravity drainage (SAGD) wells 125 for bitumen extraction, or can be processed through a CO.sub.2 and steam separation unit 120 where the H.sub.2O can be separated by condensing the steam to water and re-boiling the water to steam (100%) for steam assisted gravity drainage (SAGD) wells 125. The CO.sub.2 with remaining steam passes a flue gas condenser 100 for further cooling. The condensed H.sub.2O is recycled for conveying carbon black, leaving gaseous CO.sub.2 for compression and storage or utilization.

Application of the SHCP Technology to the Power Sector

[0159] The approach of using split hydrocarbon processing (SHCP) can also be applied to the power industry. As disclosed herein, two novel configurations for power cycles incorporating split hydrocarbon processing (SHCP) are described below: [0160] 1. Gas turbine combined cycle (GTCC) process incorporating split hydrocarbon processing (SHCP) for H.sub.2 and power production, while generating CO.sub.2 for compression and storage or utilization; and [0161] 2. Allam cycle incorporating split hydrocarbon processing (SHCP) for H.sub.2 and power production, while generating CO.sub.2 for compression and storage or utilization.

GTCC-SHCP: Gas Turbine Combined Cycle (GTCC) Process Incorporating SHCP

[0162] FIG. 5 is a schematic representation of an embodiment of gas turbine combined cycle process incorporating split hydrocarbon processing (GTCC-SHCP).

[0163] Gas turbine combined cycle (GTCC) generates power using a gas turbine and a steam turbine.

[0164] Referring to FIG. 5, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0165] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0166] Part of the carbon black C from the split hydrocarbon processing unit 10 is fed to a high pressure oxy-fired gasification (HiPrOx-G) processing unit 130 as fuel. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the high pressure oxy-fired gasification (HiPrOx-G) processing unit 130. This high pressure oxy-fired gasification (HiPrOx-G) processing unit 130 produces the energy required for split hydrocarbon processing unit 10, a CO stream, and indirectly generate steam for steam power cycle 150 to generate power.

[0167] The rest of the carbon black C is fed to a high pressure oxy-fired combustion (HiPrOx-C) processing unit 140 to produce a CO.sub.2 stream driving a gas turbine 145 for power generation. Then the CO.sub.2 stream is cooled by the feedwater of the steam power cycle unit 150 and compressed by a CO.sub.2 compressor 148 to the pressure of the CO stream from the high pressure oxy-fired gasification (HiPrOx-G) processing unit 130.

[0168] Part of the pressurized CO.sub.2 stream is recycled to high pressure oxy-fired combustion unit 140, the rest is mixed with the CO stream for deoxygenation in a deoxygenation unit 151, then is liquefied by the condensed water of steam power cycle 150. A portion of the liquefied CO.sub.2 is used to convey the carbon black C to both the high pressure oxy-fired gasification (HiPrOx-G) processing unit 130 and the high pressure oxy-fired combustion (HiPrOx-C) processing unit 140, the rest is ready for CO.sub.2 compression and storage or utilization.

Allam-SHCP: Allam Power Cycle Incorporating SHCP

[0169] FIG. 6 is a schematic representation of an embodiment of an Allam cycle incorporating split hydrocarbon processing (SHCP).

[0170] The Allam cycle is a gas turbine cycle using super critical CO.sub.2 for power generation and output the CO.sub.2 for sequestration.

[0171] Referring to FIG. 6, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0172] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0173] The carbon black C from the split hydrocarbon processing unit 10 is fed to a high pressure oxy-fired combustion (HiPrOx-C) processing unit 140. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the high pressure oxy-fired combustion (HiPrOx-C) processing unit 140. This high pressure oxy-fired combustion (HiPrOx-C) processing unit 140 produces the energy required for the split hydrocarbon processing unit 10 and a high pressure and high temperature CO.sub.2 stream to drive an Allem cycle unit 149 for power generation. Since there is no ash in the carbon black, it should have little concerns about fine solids damaging blades of the gas turbine within the Allem cycle unit 149. A part of the exhaust CO.sub.2 from the gas turbine within the Allem cycle unit 149 is compressed by a CO.sub.2 compressor 148 and cooled to liquid state. This liquefied CO.sub.2 after the CO.sub.2 compressor 148 is used to convey the carbon black C and recycled back to the high pressure oxy-fired combustion processing unit 140 for moderating the combustion flame temperature. The rest is ready for compression and storage or utilization.

[0174] To generate a nearly pure CO.sub.2 stream with no need of separation for CO.sub.2 compression and storage or utilization, it requires slurry processing to convey the carbon black C with liquefied CO.sub.2 to the high pressure oxy-fired combustion processing unit 140. The slurry process employs a flash tank 160 to depressurize the liquefied CO.sub.2 at room temperature (85 bar/21 C.) to achieve chilly gaseous CO.sub.2 and chilly liquid CO.sub.2, for example, both at about 30 bar/12.4 C. The chilly gaseous CO.sub.2 then transports the carbon black C to a slurry tank 170, where it mixes with the chilly liquid CO.sub.2 to produce a chilly CO.sub.2 and carbon C slurry by 74% weight of carbon C. This slurry is further pressurized to match the pressure of the high pressure oxy-fired combustion processing unit 140.

Application of the SHCP Technology to the Clean Fuel Industry

[0175] The approach of using split hydrocarbon processing (SHCP) can be applied to clean fuel industry. A novel H.sub.2 production process incorporating split hydrocarbon processing (SHCP) is described below.

H.sub.2-SHCP: H.sub.2 Production Process Incorporating SHCP

[0176] FIG. 7 is a schematic representation of an embodiment of carbon gasification process incorporating split hydrocarbon processing (SHCP).

[0177] Gasification of solid fuels for hydrogen H.sub.2 production through partial oxidation and water-gas shift reaction leaving a CO.sub.2-rich flue gas for capture has been described in section 2 Gasification in Oxygen.

[0178] Referring to FIG. 7, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0179] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0180] The carbon black C from the split hydrocarbon processing unit 10 is fed to a high pressure oxy-fired gasification unit 130 as fuel. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the high pressure oxy-fired gasification unit 130 to produce a mixture of CO and steam H.sub.2O.

[0181] This followed by a high temperature shift reaction which takes place in a high temperature shift processing unit 175 so that the highest overall yield of hydrogen H.sub.2 can be produced. This shift reaction is slightly exothermic and provides enough heat to maintain itself within the optimal range of 700-800 C.

[0182] In next step, the shifted gas is cooled through heat recovery network to remove H.sub.2O for reuse of making carbon C slurry, then hydrogen is separated using a pressure swing adsorption (PSA) unit 180 for export. A portion of the off-gas from pressure swing adsorption unit 180 is sent through an amine stripper 190 to remove CO.sub.2 and the remaining CO rich gas is then recycled back to the shift processing unit 175 through a CO compressor 200. The remaining off-gas from the pressure swing adsorption unit 180 and the amine stripper 190 undergoes CO oxy-fired combustion processing unit 140. This process not only supplies energy for split hydrocarbon processing unit 10 and amine stripper 190 but also generates a high-temperature and pure CO.sub.2 stream. Subsequently, this CO.sub.2 stream drives a power cycle unit 210 to produce power while simultaneously undergoing cooling for compression and storage or utilization.

Application of the SHCP Technology to the Lime/Cement Production Industry

[0183] The approach of using split hydrocarbon processing (SHCP) can be applied to lime/cement production industry. A novel configuration for lime/cement production incorporating split hydrocarbon processing (SHCP) is described below.

CaO-SHCP: Lime/Cement Production Incorporating SHCP

[0184] FIG. 8 is a schematic representation of an embodiment of lime/cement production process incorporating split hydrocarbon processing (CaO-SHCP).

[0185] Lime (CaO) and cement are produced from limestone (CaCO.sub.3) calcination in CO.sub.2 environment at 900 C. to 1050 C. emitting a nearly pure CO.sub.2 stream.

[0186] The chemical reaction is:

##STR00012##

[0187] Referring to FIG. 8, hydrocarbon fuels are fed into split hydrocarbon processing (SHCP) unit 10 where decomposition of the carbon and hydrogen components takes place. The resulting products are separated into two streams: hydrogen (H.sub.2) and solid carbon (carbon black C).

[0188] Hydrogen (H.sub.2) can be exported and/or further processed through an air-fired combustion processing unit 20 to supply energy, resulting in the release of nitrogen and water. The hydrogen H.sub.2 is an exported product, and part of it can be used to energize the split hydrocarbon processing unit 10 if needed.

[0189] The carbon black C from the split hydrocarbon processing unit 10 is fed to an oxy-fired combustion processing unit 30. Oxygen is pre-separated from nitrogen using an air separation unit (ASU) 40 and is also fed into the oxy-fired combustion processing unit 30. This oxy-fired combustion processing unit 30 produces the energy required for split hydrocarbon processing unit 10 and a high temperature CO.sub.2 stream meeting the heat requirement of limestone calcination and the CO.sub.2 stream is combined with that of the calcination which takes place in a calcination processing unit 220. After exiting the calcination processing unit 220, the CO.sub.2 stream is used to drive a power cycle unit 210 to generate electricity while undergoing cooling. A portion of the cooled CO.sub.2 is recycled to cool the lime/cement product while entering the calcination processing unit 220 for moderating the required calcination temperature. Another portion of the cooled CO.sub.2 is recycled to convey the carbon black to the oxy-fired combustion processing unit 30. The rest of the cooled CO.sub.2 is ready for compression and storage or utilization.

[0190] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other embodiments and modifications are possible. Therefore, the scope of the appended claims should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole.