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(12) Patent Application Publication (10) Pub. No.: US 2011/0062721 A1 Sirdeshpande Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2011/0062721 A1 Sirdeshpande Et Al US 20110062721A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2011/0062721 A1 Sirdeshpande et al. (43) Pub. Date: Mar. 17, 2011 (54) INTEGRATED HYDROMETHANATION Publication Classification COMBINED CYCLE PROCESS (51) Int. Cl. (75) Inventors: Avinash Sirdeshpande, Houston, HO2K 7/18 (2006.01) TX (US); William E. Preston, Sugar Land, TX (US) (52) U.S. Cl. ........................................................ 29Of1 R (73) Assignee: GREATPOINT ENERGY, INC., Cambridge, MA (US) (57) ABSTRACT (21) Appl. No.: 12/882,408 The present invention relates to an integrated process for preparing combustible gaseous products via the hydrometha (22) Filed: Sep.15, 2010 nation of carbonaceous feedstocks in the presence of steam, carbon monoxide, hydrogen, a hydromethanation catalyst Related U.S. Application Data and optionally oxygen, and generating electrical power from (60) Provisional application No. 61/242,891, filed on Sep. those combustible gaseous products as well as a hydrogen 16, 2009. and/or methane by-product stream. 31-32 52 Patent Application Publication Mar. 17, 2011 Sheet 1 of 4 US 2011/0062721 A1 [GIRI[I]OIH SI Patent Application Publication Mar. 17, 2011 Sheet 2 of 4 US 2011/0062721 A1 0I B69 12 9I------------ ZEIRI[C]OIH |-----?#çSI~.|| 00Z 06||0ççI~------89 SZ1. 00£ ZS Zº99 Patent Application Publication Mar. 17, 2011 Sheet 4 of 4 US 2011/0062721 A1 As ON \Ot CO c 3. 5. S. US 2011/0062721 A1 Mar. 17, 2011 INTEGRATED HYDROMETHANATION remove side-products Such as carbon monoxide, and undesir COMBINED CYCLE PROCESS able contaminants including carbon dioxide and hydrogen Sulfide, to produce a methane product stream. CROSS REFERENCE TO RELATED 0006. The hydromethanation of a carbon source to meth APPLICATION ane typically involves four concurrent reactions: 0001. This application claims priority under 35 U.S.C. Steam carbon: C+H2O->CO+H2 (I) S119 from U.S. Provisional Application Ser. No. 61/242,891 (filed 16 Sep. 2009), the disclosure of which is incorporated Water-gas shift: CO+HO->H2+CO (II) by reference herein for all purposes as if fully set forth. 0002 This application is related to commonly-owned U.S. CO Methanation: CO+3H->CH+H2O (III) patent application Ser. Nos. 12/562.925 (attorney docket no. Hydro-gasification: 2H2+C->CH (IV) FN-0042 US NP1, entitled PROCESSES FOR HYDROMETHANA TION OF A CARBONACEOUS FEEDSTOCK, filed 18 Sep. 2009), 0007. In the hydromethanation reaction, the first three and 12/778,552 (attorney docket no. FN-0049 US NP1, reactions (I-III) predominate to result in the following overall entitled PROCESSES FOR HYDROMETHANATION OF A CARBON reaction: ACEOUS FEEDSTOCK, filed 12 May 2010), and (attor ney docket no. FN-0052 US NP1, entitled INTEGRATED HYDROMETHANATION COMBINED CYCLE PROCESS, filed con 0008. The overall reaction is essentially thermally bal currently herewith). anced; however, due to process heat losses and other energy requirements (such as required for evaporation of moisture FIELD OF THE INVENTION entering the reactor with the feedstock), some heat must be added to maintain the thermal balance. 0003. The present invention relates to an integrated pro 0009. The reactions are also essentially syngas (hydrogen cess for preparing combustible gaseous products via the and carbon monoxide) balanced (syngas is produced and hydromethanation of carbonaceous feedstocks in the pres consumed); therefore, as carbon monoxide and hydrogen are ence of steam, carbon monoxide, hydrogen, a hydrometha withdrawn with the product gases, carbon monoxide and nation catalyst and optionally oxygen, and generating elec hydrogen need to be added to the reaction as required to avoid trical power from those combustible gaseous products. a deficiency. 0010. In order to maintain the net heat of reaction as close BACKGROUND OF THE INVENTION to neutral as possible (only slightly exothermic or endother 0004. In view of numerous factors such as higher energy mic), and maintain the syngas balance, a Superheated gas prices and environmental concerns, the production of value stream of steam, carbon monoxide and hydrogen is often fed added gaseous products from lower-fuel-value carbonaceous to the hydromethanation reactor. Frequently, the carbon mon feedstocks, such as petroleum coke, coal and biomass, is oxide and hydrogen streams are recycle streams separated receiving renewed attention. The catalytic gasification of from the product gas, and/or are provided by reforming a Such materials to produce methane and other value-added portion of the product methane. See, for example, U.S. Pat. gases is disclosed, for example, in U.S. Pat. No. 3,828,474, No. 4,094,650, U.S. Pat. No. 6,955,595 and US2007/ U.S. Pat. No. 3,998,607, U.S. Pat. No. 4,057,512, U.S. Pat. O83O72A1. No. 4,092,125, U.S. Pat. No. 4,094,650, U.S. Pat. No. 4,204, 0011. The separation of the recycle gases from the meth 843, U.S. Pat. No. 4,468,231, U.S. Pat. No. 4,500,323, U.S. ane product, for example by cryogenic distillation, and the Pat. No. 4,541,841, U.S. Pat. No. 4,551,155, U.S. Pat. No. reforming of the methane product, greatly increase the engi 4,558,027, U.S. Pat. No. 4,606,105, U.S. Pat. No. 4,617,027, neering complexity and overall cost of producing methane, U.S. Pat. No. 4,609,456, U.S. Pat. No. 5,017,282, U.S. Pat. and decrease the overall system efficiency. No. 5,055,181, U.S. Pat. No. 6,187,465, U.S. Pat. No. 6,790, 0012 Steam generation is another area that can increase 430, U.S. Pat. No. 6,894,183, U.S. Pat. No. 6,955,695, the engineering complexity of the overall system. The use of US2003/0167961A1, US2006/0265953A1, US2007/ externally fired boilers, for example, can greatly decrease 000177A1, US2007/083072A1, US2007/0277437A1, overall system efficiency. US2009/0048476A1, US2009/0090056A1, US2009/ 0013 An improved hydromethanation process where gas 0090055A1, US2009/0165383A1, US2009/0166588A1, recycle loops are eliminated or improved, and steam is gen US2009/0165379A1, US2009/0170968A1, US2009/ erated efficiently, to decrease the complexity and cost of 0.165380A1, US2009/0165381A1, US2009/0165361A1, producing methane, is described in US2009/0165376A1, US2009/0165382A1, US2009/01694.49A1, US2009/ US2010/0120926A1, US2010/0071262A1, US2010/ 0169448A1, US2009/0165376A1, US2009/0165384A1, 0076235A1 and US2010/0179232A1, as well as commonly US2009/0217584A1, US2009/0217585A1, US2009/ owned and co-pending U.S. patent application Ser. Nos. 0217590A1, US2009/0217586A1, US2009/0217588A1, 12/778,538 (attorney docket no. FN-0047 US NP1, entitled US2009/0217589A1, US2009/0217575A1, US2009/ PROCESSES FOR HYDROMETHANATION OF A CARBONACEOUS O217587A1 and GB1599932. FEEDSTOCK), 12/778,548 (attorney docket no. FN-0048 US 0005. In general, carbonaceous materials, such as coal, NP1, entitled PROCESSES FORHYDROMETHANATION OF ACAR biomass, asphaltenes, liquid petroleum residues and/or petro BONACEOUS FEEDSTOCK) and 12/778,552 (attorney docket no. leum coke, can be converted to a plurality of gases, including FN-0049 US NP1, entitled PROCESSES FOR HYDROMETHANA value-added gases such as methane and hydrogen, by the TION OF A CARBONACEOUS FEEDSTOCK), each of which was reaction of the material in the presence of a catalyst Source filed 12 May 2010. and steam at elevated temperatures and pressures. The raw 0014. In the hydromethanation reaction, as indicated gases are cooled and Scrubbed in multiple processes to above, the result is a “direct methane-enriched raw product US 2011/0062721 A1 Mar. 17, 2011 gas stream, which can be Subsequently purified and further methane, carbon monoxide, hydrogen, carbon dioxide, methane-enriched to provide a final methane product. This is hydrogen Sulfide and heat energy; distinct from conventional gasification processes, such as 0025 (d) withdrawing the methane-enriched raw product those based on partial combustion/oxidation of a carbon stream from the hydromethanation reactor; Source, where a syngas (carbon monoxide--hydrogen) is the 0026 (e) introducing the methane-enriched raw product primary product (little or no methane is directly produced), stream into a first heat exchanger unit to remove heat energy which can then be further processed to produce methane (via from the methane-enriched raw product stream; catalytic methanation, see reaction (III)) or any number of 0027 (f) sour shifting at least a predominant portion of the other higher hydrocarbon products. carbon monoxide in the methane-enriched raw product 0015. When methane is the desired end-product, the stream to produce a hydrogen-enriched raw product stream hydromethanation reaction provides the possibility for comprising hydrogen, methane, carbon dioxide, hydrogen increased efficiency and lower methane cost than traditional Sulfide and optionally carbon monoxide; gasification processes. 0028 (g) removing a substantial portion of the carbon 0016 Since hydrogen is a syngas component of conven dioxide and a substantial portion of the hydrogen sulfide from tional gasification processes, conventional gasification pro the hydrogen-enriched raw product stream to produce a cesses can also be adapted for hydrogen production. The Sweetened gas stream comprising a Substantial portion of the hydromethanation process can also be adapted for hydrogen hydrogen, methane and carbon monoxide (if present) from production such as, for example disclosed in US2009/ the hydrogen-enriched raw product stream; 0259080A1, and previously incorporated U.S. patent appli 0029 (h) optionally separating at least a portion of the cation Ser. Nos. 12/778,548 (attorney docket no. FN-0048 US hydrogen from the Sweetened gas stream to produce (1) a NP1, entitled PROCESSES FORHYDROMETHANATION OF ACAR hydrogen product stream and (2) a hydrogen-depleted Sweet BONACEOUS FEEDSTOCK, filed 12 May 2010) and 12/851,864 ened gas stream comprising methane, carbon monoxide (if (attorney docket no. FN-0050 US NP1, entitled PROCESSES present in the Sweetened gas stream) and optionally hydro FOR HYDROMETHANATION OF A CARBONACEOUS FEEDSTOCK, gen, filed 6 Aug.
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