Process for converting heavy crude oils and petroleum coke to syngas using external source of radiation

0001The invention relates to a process for converting heavy hydrocarbons to high-quality syngas, i.e. a mixture mainly of hydrogen and carbon monoxide.

0002Anthropogenic emissions of greenhouse gases and other pollutants can be significantly reduced or even completely eliminated by replacing fossil fuels with cleaner fuels, e.g. solar fuels. Further, the conversion of solar energy into a chemical energy carrier that can be long-term stored and long-range transported would overcome major drawbacks of solar energy, namely, that solar energy is conventionally a diluted, intermittent, and unequally distributed energy source.

0003The replacement of fossil fuels with solar fuels is a long-term goal requiring the development of novel technologies. Intermediate progress along this transition would also be desirable. Clearly, the need remains for a more viable process for using solar energy to overcome the limitations mentioned above.

0004An apparatus for generating power using synthetic gas according to the teaching of <patcit id="pcit0001" dnum="US6510695B1"><text>US 6,510,695 B1</text></patcit> includes equipment constructed and arranged to reform a hydrocarbon gas, material or biogas produced from a source into synthetic gas. Supply means are provided for supplying hydrocarbon gas, material or biogas feedstock to a reformer contained in the equipment and the hydrocarbon material or biogas feedstock is produced by fuel producing apparatus by use of solar radiation. A gas turbine unit includes a compressor for producing compressed air, a combustor for combusting the synthetic gas and heating the compressed air to produce heated, compressed air, and a turbine coupled to a generator and to the compressor for expanding the heated, compressed air and producing power and hot exhaust gases. Further supply means are provided for supplying the synthetic gas produced by the equipment to the combustor, while a vaporizer preferably containing water is responsive to the hot exhaust gases produced by the gas turbine for producing steam. This steam can be used as process steam in, for example, an industrial process or in other cogeneration processes. Preferably, however, a steam turbine is provided for expanding steam produced by the vaporizer and producing power and expanded steam.

0005In <patcit id="pcit0002" dnum="US5934231A"><text>US 5,934,231 a</text></patcit> solar collection antenna has a large aperture reflective dish which is mounted on a dish support fame. When the dish is pointed at the sun, it reflects received solar radiation into a zone of concentration, at which either a solar energy receiver or a secondary reflector (supported by an ancillary support) is located. To track the sun, the dish is rotated about a first axis which is transverse the dish aperture and a second, orthogonal axis, which intersects the first axis. The center of mass of the combination of the dish, its support frame, the solar energy receiver or secondary reflector and the ancillary support is relatively close to the lower edge of the dish, and lies substantially on the transverse axis of rotation, at the point where the first and second axes almost intersect. The dish aperture is chosen so that the dish experiences balanced wind loading about its transverse axis of rotation.

0006A method for employing an external moderately high temperature heat source in the pyrolysis and gasification of solid wastes, coal, or other organic materials is described in <patcit id="pcit0003" dnum="US3993458A"><text>US 3,993,458 A</text></patcit> as follows: steam, CO₂, or some mixture of these two gases is heated to a temperature of 600 °C or more in a chemical reactor located at the focus of a tower top solar furnace which is situated in the lower section of said reactor. This working fluid (steam, CO₂, or a mixture thereof) is used to fluidize the reactant bed of char and organic material, i. e. solid wastes as coal, manure, food waste.

0007It is therefore the primary object of the present invention to provide a process whereby solar energy is converted to chemically stored energy

0008It is a further object of the invention to provide a process wherein the stored energy is a relatively clean fossil fuel.

0009Other objects and advantages will appear hereinbelow.

0010The problems are solved by the teaching according to the independent claims. Particular developments are given in the dependent claims. Within the frame of the invention are all combinations of at least two of the descriptive elements and technical features disclosed in the claims and/or in the description. For all the ranges given, also limits lying within these limits shall be considered maximum or minimum values, and shall be deemed disclosed as such.

0011According to the present invention, the foregoing objects and advantages have been readily attained.

0012According to the invention, a process is provided for thermochemical conversion of heavy oil and petroleum coke to fluid fuels, comprising the steps of providing a fossil fuel selected from the group consisting of heavy oil, petroleum coke and mixtures thereof; and exposing the fossil fuel to an external source of concentrated radiation so as to increase temperature and pressure of the fossil fuel and convert the fossil fuel to a product selected from the group consisting of hydrogen, carbon monoxide and mixtures thereof. The temperature of the fossil fuel shall be increased to a temperature of at least about 1000°C.

0013A preferred source of external radiation is solar energy, preferred a concentrated solar energy.

0014This external radiation can advantageously be concentrated using parabolic dish concentrators, solar tower technology, arc lamps and the like.

0015The final product may comprise hydrogen and carbon monoxide. The inventor is of the opinion that the final product consists essentially of hydrogen and carbon monoxide.

0016The frame of the invention may comprise the step of converting the final product to a further refined product selected from the group consisting of hydrogen, synthetic fuels and chemicals, and mixtures thereof.

0017The conversion uses an oxidant, and wherein the oxidant is selected from the group consisting of steam, oxygen, metal oxides, other oxygen-containing compounds, and mixtures thereof. And it is possible that the oxidant is steam.

0018It is shown by the inventor that the exposing step converts the fossil fuel without the need for pure oxygen as reactant.

0019The exposing step shall be carried out using only steam as oxidant, resulting in a product mixture of hydrogen and carbon monoxide. And the source of external radiation shall provide sensible and latent heat required to bring reactants to the reaction temperature; the source of external radiation may be created by hybrid operation with fossil fuels.

0020The invention shows that the fossil fuel comprises petroleum coke particles and heavy crude oil directly exposed to the external source of radiation, whereby the fossil fuel simultaneously serves as radiant absorber and chemical reactant.

0021The process further comprises the step of entraining the particles of petroleum coke and heavy crude oil in a flow of steam, oxygen, or other gaseous oxidant. The flow serves simultaneously as reactant and as an aerodynamic curtain to keep a window clean for access of radiation to the fossil fuel.

0022Further advantages, characteristics and details of the invention are apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings, wherein: <ul id="ul0001" list-style="none"><li><figref idref="f0001">Figure 1</figref> shows the relationship between temperature and equilibrium mole fraction of reactants and products in a process of the present invention;</li><li><figref idref="f0002">Figures 2a-b</figref> show an example of product gas composition as a function of temperature for two types of petcoke processed according to the present invention.</li></ul>

0023The invention relates to a process for converting fossil fuel such as heavy crude oil and petroleum coke (petcoke) to syngas using a source of external radiation, preferably solar energy.

0024The current limitations with using solar energy have been outlined above.

0025Strategically, it is desirable to consider mid-term goals aiming at the development of hybrid solar/fossil endothermic processes in which fossil fuels are used substantially exclusively as chemical reactants and external radiation such as solar energy as the source of process heat. The process of the present invention is directed toward this goal.

0026According to the invention, one preferred embodiment of this process is the solar gasification of petroleum coke (petcoke). This produces cleaner fuels whose energy content has been upgraded by solar energy. The calorific value of the fuel is increased above the value of the feedstock by the solar input in an amount equal to the enthalpy change of the reaction.

0027According to the invention, a suitable fossil fuel is provided, which is petcoke, heavy crude oil and mixtures thereof. The fuel is exposed to an external source of radiation, preferably concentrated radiation, whereby the radiation increases the temperature of the fuel and provides the necessary high temperature process heat to drive the endothermic reactions to the desired syngas. The process can be used with other hydrocarbons as well, but a particularly preferred process is in connection with petcoke and heavy crude oils.

0028The external radiation can advantageously be external concentrated radiation such as that provided by parabolic dish concentrators, solar tower technology, arc lamps and the like. In addition, although solar energy is a preferred source of the external radiation, other sources can also be used, as well as hybrids with conventional fossil fuel powered sources of radiation. The equipment for providing these sources of concentrated radiation are known to a person of skill in the art. As set forth below, the resulting final product can be used to power conventional combustion engines or power plants, or can be further processed to further refined products such as more pure hydrogen, synthetic fuels and chemicals and the like, for example to products more suitable as fuel for fuel cells, and the like.

0029Suitable oxidant can advantageously include steam, oxygen, metal oxides, other oxygen containing compounds and mixtures thereof. A preferred oxidant is steam, and using essentially steam, and advantageously without the need for pure oxygen, a product mixture of essentially hydrogen and carbon monoxide can be produced.

0030In the embodiment wherein the feed to be treated includes petcoke particles, these particles advantageously serve to both absorb radiation and act as chemical reactants to the desired end product.

0031According to the invention, the fossil fuel can advantageously contain both petcoke particles and heavy liquid crude oil. This fossil fuel can be entrained in a stream of suitable carrier, which is preferably also a reactant, such as steam, oxygen, or other gaseous oxidant, and the like. This stream of entrained fossil fuel can be used to enhance exposure of the fossil fuel to the radiation, both through atomizing and increasing of surface area to the radiation. Further, radiation is preferably applied to the feed through an optical access, i.e. a window, or some other kind of suitable aperture. The flow or stream of carrier can be adapted to serve as an aerodynamic curtain to keep the optical access clean, thereby reducing the maintenance needed to keep the process of the present invention efficient. Keeping the window or other optical access through which radiation is passed clean allows maximum effect of the radiation upon the fossil fuel as desired.

0032According to the invention, external concentrated radiation is advantageously applied to the fossil fuel so as to provide a temperature of at least about 1000°C and to supply the enthalpy, sensible and latent heat required for the reaction.

0033When a conventional process is practiced at an industrial scale, the energy required for heating the reactants and for the heat of the reaction is conventionally supplied by burning a significant portion of the feedstock, either directly by internal combustion, or indirectly by external combustion. Internal combustion, as applied in autothermal reactors, results in the contamination of the gaseous products, while external combustion, as applied in allothermal reactors, results in lower thermal efficiency because of the irreversibilities associated with indirect heat transfer.

0034Alternatively, the advantages of supplying solar energy for process heat in accordance with the present invention are three-fold: 1) the calorific value of the feedstock is upgraded; 2) the gaseous products are not contaminated by the byproducts of combustion; and 3) the discharge of pollutants to the environment is avoided. Further, the direct irradiation of reactants provides a very efficient means of heat transfer directly to the reaction site, where the energy is needed, bypassing the limitations imposed by heat exchangers.

0035The steam-gasification of carbonaceous materials and related reactions has been performed using solar energy in exploratory early studies with coal, and with oil shales. More recently, the CO₂-gasification of coal was investigated using a fluidized bed reactor under direct irradiation. Several solar reactor concepts have been proposed and tested with small-scale prototypes.

0036The steam-gasification of petcoke is a complex process, but the overall chemical conversion can be represented by the simplified net reaction:<maths id="math0001" num="(1)"><math display="block"><msub><mi mathvariant="italic">C</mi><mn mathvariant="italic">1</mn></msub><mo>⁢</mo><msub><mi mathvariant="italic">H</mi><mi mathvariant="italic">x</mi></msub><mo>⁢</mo><msub><mi mathvariant="italic">O</mi><mi mathvariant="italic">y</mi></msub><mo>+</mo><mfenced><mn mathvariant="italic">1</mn><mo>-</mo><mi>y</mi></mfenced><mo>⁢</mo><msub><mi mathvariant="italic">H</mi><mn mathvariant="italic">2</mn></msub><mo>⁢</mo><mi mathvariant="italic">O</mi><mo>=</mo><mfenced><mfrac><mi mathvariant="italic">x</mi><mn mathvariant="italic">2</mn></mfrac><mo mathvariant="italic">+</mo><mn mathvariant="italic">1</mn><mo mathvariant="italic">-</mo><mi>y</mi></mfenced><mo>⁢</mo><msub><mi mathvariant="italic">H</mi><mn mathvariant="italic">2</mn></msub><mo>+</mo><mi mathvariant="italic">CO</mi></math><img file="EP1520901B1_D0001.tif" /></maths> where x and y are the elemental molar ratios of H/C and O/C in petcoke, respectively. The chemical product is synthesis gas (syngas), whose quality depends on x and y. Table 1 shows the approximate chemical composition, the heating value, and the elemental molar ratios for three different types of petcoke: Flexicoke, and Delayed Coke from Petrozuata and Amuay. In the analysis that follows, sulfur compounds and other impurities contained in the raw materials are assumed to be cleaned out. The moisture content is also not accounted for in Eq.(1), but the stoichiometric addition of water can be adjusted accordingly. <tables id="tabl0001" num="0001"><table frame="topbot"><title><b><i>Table 1:</i></b> Approximate main elemental chemical composition in wt% (ultimate analysis), low heating value in kJ/kg, and elemental molar ratios of H/C and O/C, for three types of petcoke.</title><tgroup cols="4" rowsep="0"><colspec colnum="1" colname="col1" colwidth="41mm" /><colspec colnum="2" colname="col2" colwidth="42mm" /><colspec colnum="3" colname="col3" colwidth="40mm" /><colspec colnum="4" colname="col4" colwidth="44mm" /><thead valign="top"><row rowsep="1"><entry morerows="1" colsep="0" valign="middle">petcoke type</entry><entry morerows="1" colsep="0" valign="middle">Flexicoke</entry><entry namest="col3" nameend="col4" colsep="0" rowsep="0" align="left" valign="middle">Delayed Coke</entry></row><row rowsep="1"><entry colsep="0" valign="middle">Petrozuata</entry><entry colsep="0" valign="middle">Amuay</entry></row></thead><tbody><row><entry colsep="0">C</entry><entry colsep="0">92.70</entry><entry colsep="0">88.21</entry><entry colsep="0">88.47</entry></row><row><entry colsep="0">H</entry><entry colsep="0">0.67</entry><entry colsep="0">4.14</entry><entry colsep="0">4.17</entry></row><row><entry colsep="0">O</entry><entry colsep="0">0.92</entry><entry colsep="0">1.46</entry><entry colsep="0">1.42</entry></row><row><entry colsep="0">N</entry><entry colsep="0">0.90</entry><entry colsep="0">2.28</entry><entry colsep="0">1.84</entry></row><row rowsep="1"><entry colsep="0">S</entry><entry colsep="0">1.98</entry><entry colsep="0">4.16</entry><entry colsep="0">4.18</entry></row><row><entry colsep="0"><i>LHV</i> [kJ/kg]</entry><entry colsep="0">32983</entry><entry colsep="0">35876</entry><entry colsep="0">35926</entry></row><row><entry colsep="0">H/C [mol/mol]</entry><entry colsep="0">0.0859</entry><entry colsep="0">0.5581</entry><entry colsep="0">0.5598</entry></row><row rowsep="1"><entry colsep="0">O/C [mol/mol]</entry><entry colsep="0">0.0074</entry><entry colsep="0">0.0124</entry><entry colsep="0">0.0120</entry></row></tbody></tgroup></table></tables> Equation (1) summarizes the overall reaction, but a group of competing intermediate reactions that are essential for the successful gasification need to be considered, namely: <ul id="ul0002" list-style="none" compact="compact"><li>steam-gasification:         <i>C_(gr)+H₂O=CO+H₂</i>     (2) </li><li>Boudouard equilibrium:         <i>2CO = C_(gr) + CO₂</i>     (3) </li><li>hydro-gasification (methanization) :         <i>C_(gr) +2H₂</i> = <i>CH₄</i>     (4) </li><li>reforming:         <i>CH₄ + H₂O = CO + 3H₂</i>     (5) </li><li>water-gas shift:         <i>CO+H₂O=CO₂+H₂</i>     (6) </li></ul> all of which depend strongly on the temperature as well as on the pressure and the carbon/oxygen ratio, and determine the relative amounts of H₂, H₂O, CO, CO₂, CH₄, in the gas phase, and C(gr) in the solid phase. The HSC Outokumpu code was used to compute the equilibrium composition of the system <i>C₁H_xO_y+(1-y)H₂O</i> at 1 bar and over the range of temperatures of interest. <figref idref="f0001">Figure 1</figref> shows the results for the Delayed cokes. Species whose mole fraction is less than 10^-5 have been omitted. Below about 700 K, C (gr), CH₄, CO₂, H₂O are the thermodynamically stable components. In the temperature range 800-1100 K, they are used up by a combination of reactions (1) to (6). When the gasification goes to completion, at above about 1200 K, the system consists of a single gas phase containing H₂ and CO in a molar ratio equal to (<i>x</i>/<i>2+1</i>-<i>y</i>)<i>.</i> At higher pressures, as preferred in industrial applications, the thermodynamic equilibrium of Eq. (1) is shifted to the left in such a way so as to relieve the pressure in accordance with Le Chatelier's principle. For example, at 10 bar, the equilibrium composition is shifted such that the gasification goes to completion at above 1500 K. The results for the other two types of petcoke are comparable to the ones shown in <figref idref="f0001">Fig. 1</figref>, and the same conclusions can be drawn regarding temperature

0037The quality of the syngas produced is described by the H₂/CO and CO₂/CO molar ratios. The H₂/CO molar ratio can be adjusted by the water-gas shift reaction to meet the requirements for the post-processing of syngas to hydrogen, ammonia, methanol, or Fischer-Tropsch's chemicals. The CO₂/CO molar ratio is a measure of the contamination and should preferably be kept as low as possible. Thermodynamics predict a CO₂-free syngas at above 1300 K. The syngas quality is notably higher than the one typically obtained when heat is supplied by internal combustion of petcoke, besides the additional benefit of avoiding contamination by undesirable species. The CO content in the syngas can be further processed via the exothermic water-gas shift reaction to obtain more H₂ and process heat, and the resulting H₂/CO₂ mixture can be separated.

0038The high quality of the syngas produced that is predicted by thermodynamics (see <figref idref="f0001">Fig. 1</figref>) has been verified experimentally using a fluidized bed of petcoke and steam directly exposed to an external source of concentrated thermal radiation. <figref idref="f0002">Figure 2</figref> shows the gas product composition as a function of temperature for the 2 types of petcoke listed in Table 1, that is, <figref idref="f0002">Fig. 2a</figref> shows results for Flexicoke and <figref idref="f0002">Fig. 2b</figref> shows results for Petrozuata coke. Temperatures were measured by pyrometry and by thermocouples submerged in the fluidized bed; gas composition was measured by gas chromotagraphy at the exit of the fluidized bed.

0039A 2^nd-Law (exergy) analysis was performed to examine two technically viable routes for extracting power from the chemical products of the gasification, and to establish a base for comparing them with electricity generation by conventional power plants. The two routes are: 1) syngas produced by solar steam-gasification of petcoke is used to fuel a 55%-efficient combined Brayton-Rankine cycle; and 2) syngas produced by solar steam-gasification of petcoke is further processed to H₂ by the water-shift gas reaction followed by H₂/CO₂ separation, and the H₂ is used to fuel a 65%-efficient fuel cell.

0040The exergy analysis indicates that both routes can double the specific electrical output and, consequently, reduce by half the specific CO₂ emissions, vis-à-vis a petcoke-fueled 35%-efficient Rankine cycle.

0041In summary, the proposed petcoke and heavy crude oil/solar hybrid thermochemical process conserves petroleum and reduces emissions. It further converts intermittent solar energy into a storable and transportable chemical fuel, to meet energy demands whenever and wherever needed. At the same time, petcoke is solar-upgraded to a cleaner fluid fuel that can be used for electricity generation in highly efficient combined cycles or fuel cells. In contrast to the gasification using process heat derived from the internal petcoke combustion, the solar-driven gasification produces high quality syngas that is not contaminated by the products of combustion. Syngas can be further processed to separate streams of H₂ and CO₂; if the latter is sequestered, the proposed process becomes a decarbonization process that converts petcoke to hydrogen without release of CO₂ to the atmosphere.

0042In <figref idref="f0001">Figure 1</figref> are shown the following graphs or curve diagrams:<maths id="math0002"><math display="block"><mi mathvariant="normal">a</mi><mo mathvariant="normal">=</mo><msub><mi mathvariant="normal">H</mi><mn mathvariant="normal">2</mn></msub><mo>⁢</mo><mi mathvariant="normal">O</mi><mo mathvariant="normal">;</mo><mspace width="4em" /><mi mathvariant="normal">b</mi><mo mathvariant="normal">=</mo><msub><mi mathvariant="normal">H</mi><mn mathvariant="normal">2</mn></msub><mo mathvariant="normal">;</mo></math><img file="EP1520901B1_D0002.tif" /></maths><maths id="math0003"><math display="block"><mi mathvariant="normal">c</mi><mo mathvariant="normal">=</mo><mi>CO</mi><mo mathvariant="normal">;</mo><mspace width="4em" /><mi mathvariant="normal">d</mi><mo mathvariant="normal">=</mo><mi mathvariant="normal">C</mi><mo>⁢</mo><msub><mi mathvariant="normal">H</mi><mn mathvariant="normal">4</mn></msub><mo mathvariant="normal">;</mo></math><img file="EP1520901B1_D0003.tif" /></maths><maths id="math0004"><math display="block"><mi mathvariant="normal">e</mi><mo mathvariant="normal">=</mo><mi mathvariant="normal">C</mi><mo>⁢</mo><msub><mi mathvariant="normal">O</mi><mn mathvariant="normal">2</mn></msub><mn mathvariant="normal">.</mn></math><img file="EP1520901B1_D0004.tif" /></maths>

0043In <figref idref="f0002">Figure 2</figref> there are three different graphical fields:<maths id="math0005"><math display="block"><mi mathvariant="normal">A</mi><mo mathvariant="normal">=</mo><mi mathvariant="normal">C</mi><mo>⁢</mo><msub><mi mathvariant="normal">O</mi><mn mathvariant="normal">2</mn></msub><mo>;</mo></math><img file="EP1520901B1_D0005.tif" /></maths><maths id="math0006"><math display="block"><mi mathvariant="normal">B</mi><mo mathvariant="normal">=</mo><mi>CO</mi><mo>;</mo></math><img file="EP1520901B1_D0006.tif" /></maths><maths id="math0007"><math display="block"><mi mathvariant="normal">C</mi><mo mathvariant="normal">=</mo><msub><mi mathvariant="normal">H</mi><mn mathvariant="normal">2</mn></msub><mn mathvariant="normal">.</mn></math><img file="EP1520901B1_D0007.tif" /></maths>

0044It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation.