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    • 专利摘要:
    The present invention provides a methanation system for the conversion of carbonaceous material to methane and a process for the conversion of carbonaceous material to methane using such a methanation system.
    公开号:BE1025408B1
    申请号:E2018/5108
    申请日:2018-02-22
    公开日:2019-02-18
    发明作者:Lathauwer Bart De
    申请人:B.A.T. Services Bvba；
    IPC主号:
    专利说明:

    GASER AND PROCESS FOR GASKING CARBON-MATERIAL
    FIELD OF THE INVENTION
    The present invention relates to a methanation system suitable for the conversion of carbonaceous material to methane and a process for the conversion of carbonaceous material to methane. Further disclosed herein are a gasifier for gasification of carbonaceous material for the production of syngas, an electricity generating system comprising the gasifier and a process for gasification of carbonaceous material.
    BACKGROUND OF THE INVENTION
    Gasification of organic material is one of the most effective ways to recover energy from biomass and / or waste material. For example, gasifying an amount of biomass to produce a syngas that can feed a gas turbine is more energy efficient than burning the same amount of biomass to generate steam that drives a turbine.
    Gasification is the thermochemical conversion of carbonaceous material into a gaseous product (i.e., synthesis gas or syngas). Reactions take place at elevated temperatures (500-1400 ° C) and a series of pressures (from atmospheric to 33 bar). The gasification medium used can be air, pure oxygen, steam or a mixture thereof. The most important syngas components are H 2 and CO, with lower concentrations of CO 2 , H 2 O, CH 4 j higher hydrocarbons and N 2 . Different types of gasifiers are currently available for gasification processes such as fixed bed gasifiers, fluidized bed reactors and plasma gasifiers.
    Fluidized bed gasifiers include a reactor bed that is fluidized through the inlet of gases such as steam and oxidizing agent. Raw material particles are suspended in the bed material. These gasifiers use back mixing and efficiently mix incoming feed particles with particles that are already undergoing gasification. Due to the thorough mixing in the gasifier, a constant temperature is maintained in the reactor bed. To maintain fluidization, a raw material with a small particle size (less than 6 mm) is normally used.
    Plasma torches are known in the art as a source of thermal energy in gasification processes. Especially electric arc torches are used, but these have one
    BE2018 / 5108 short service life. This leads to high maintenance costs and considerable time periods that the installation does not work.
    There are gasification units with plasma torches. For example, WO 2014/126895 describes a gasifier in which plasma torches are arranged around a catalytic bed that directly transfer thermal energy into the catalytic bed. One of the major drawbacks of this type of gasifiers is that the catalyst life is particularly short because the catalyst particles are heated to extreme temperatures by the plasma torches.
    SUMMARY OF THE INVENTION
    It is an object of the invention to overcome at least some of the above problems. It is an object of the invention to provide a gasifier, in particular a gasifier as a component of a methanation system, and a gasification process, in particular a gasification process as a step of a process for the conversion of a carbonaceous material to methane, which is very is efficient. Another object of the invention is to provide a cleaner syngas, substantially free of tar. It is also an object of the invention to provide a syngas in which the amount of H 2 and CO can be regulated, preferably close to a 3/1 ratio. Another object of the invention is to provide a sustainable gasifier and a sustainable process, preferably with low maintenance.
    In another aspect of the invention, it is an object to provide a methanation system that is highly efficient in converting carbonaceous material to methane or natural gas substitute. It is a further object of the invention to reuse heat released during this conversion. In one aspect, the invention relates to a methanation system (36) for the conversion of carbonaceous material to methane, comprising:
    a gasifier (1) for gasifying carbonaceous material to syngas, wherein the gasifier is at least partially supplied with steam and comprises the following:
    - an internal volume (4) comprising an upper part (5), a middle part (6) and a lower part (7), and optionally a first connecting part (10) connecting the upper part (5) and the middle part (6) and / or a second connecting portion (11) connecting the middle portion (6) and the lower portion (7), the upper portion (5), middle portion (6) and lower portion (7) along the longitudinal direction of the gasifier (1) ) are arranged, the upper part (5) on top of the
    BE2018 / 5108 middle portion (6) is placed on top of the lower portion (7);
    - one or more inlets (2) for carbonaceous material that are configured to receive a supply of carbonaceous material and that are in fluid communication with the internal volume (4);
    - a bed material (9) in the middle part (6) and / or the lower part (7) and connected to at least one gas inlet (12) to fluidize the bed material;
    - a gas outlet (16) which is in fluid communication with the upper part (5) of the internal volume (4); and
    - at least one plasma system (8) configured in the upper part (5) so that gas leaving the gasifier (1) through the gas outlet (16) passes through a zone that is heated by the at least one plasma system (8);
    a first cooling unit (18, 29) comprising a hot gas inlet (19) and a cold gas outlet (20), the hot gas inlet (19) being in fluid communication with the gas outlet (16) of the gasifier (1);
    a methanization unit (21) suitable for producing raw methane from syngas, comprising a syngas inlet (22) and a raw methane outlet (23), wherein the syngas inlet (22) is in fluid communication with the cold gas outlet (20) of the first cooling unit (18);
    a second cooling unit (24, 28) comprising a hot methane inlet (25) and a cold methane outlet (26), the hot methane inlet (25) being in fluid communication with the raw methane outlet (23) of the methanization unit (21);
    wherein the first cooling unit and the second cooling unit independently comprise an economizer, an evaporator and / or a superheater for steam production for the gasifier.
    The gasifier and the gasification process described herein produce high yields of a relatively clean syngas in a highly efficient manner, because raw syngas produced in the fluidized bed and / or via plasma gasification of the carbonaceous material by a by the at least one Heated plasma system must go before it leaves the gasifier, where tar components are subjected to thermal cracking and residual carbonaceous material is further gasified. This results in higher conversion yields of the carbonaceous material into syngas and cleaner syngas through destruction of tar components and removal of dust particles.
    The design of the methanation system according to the invention is such that the heat that is released upon cooling of the syngas before the methanization reaction and / or upon cooling of
    BE2018 / 5108 the raw methane to condense and separate water, is efficiently reused to generate the steam required for the gasifier.
    The present invention will now be further described. In the following passages, various aspects of the invention are defined in more detail. Every aspect that is defined in this way can be combined with any other aspect or other aspects, unless the contrary is clearly indicated. In particular, any feature that is indicated to be preferred or advantageous may be combined with any other feature or features that are indicated to be preferred or advantageous.
    DESCRIPTION OF THE FIGURES
    Figure 1 shows a schematic view of a gasifier as described herein.
    Figure 2 shows a schematic view of an alternative gasifier as described herein.
    Figure 3 shows a schematic view of a methanation system according to an embodiment of the invention.
    DETAILED DESCRIPTION OF THE INVENTION
    Before describing the present method used in the invention, it is to be understood that this invention is not limited to specifically described gasifiers, methanization systems, electricity generating systems and processes, since such gasifiers, methanation systems, electricity generating systems and processes may of course vary. It is also to be understood that the terminology used herein is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
    In describing the gasifiers, methanation systems, electricity generating systems, and processes of the invention, the terms used must be constructed in accordance with the following definitions, unless a context requires otherwise.
    As used herein, the singular forms include one and both the single and the multiple references, unless the context clearly dictates otherwise. For example, a gasifier means one gasifier or more than one gasifier.
    The terms comprising and including as used herein are synonymous with inclusive, containing or containing, and are inclusive or non-exclusive and do not include additional, not 5
    BE2018 / 5108 included members, elements or process steps. The terms comprising and including also include the term consisting of.
    Naming numeric ranges by end points includes all integers and, where applicable, fractions that fall within this range (for example, 1 to 5 may include 1, 2, 3, 4 when referring to, for example, a number of elements, and may also be 1 , 5, 2, 2.75 and 3.80 when referring to measurements, for example). The naming of endpoints also includes the endpoint values themselves (for example from 1, .0 to 5.0 includes both 1.0 and 5.0). Each numeric range mentioned herein is intended to include all sub-ranges included therein.
    Reference throughout this specification to one embodiment or an embodiment means that a specific feature, specific structure or feature described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases in one embodiment or in an embodiment at different locations throughout this specification do not necessarily all refer to the same embodiment, but can do so. Furthermore, the specific features, structures or properties can be combined in any suitable manner, as will be apparent to one skilled in the art, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are considered to be within the scope of the invention, and constitute different embodiments, as would be appreciated by those skilled in the art. understood. For example, in the following claims and explanations, any of the embodiments may be used in any combination.
    Unless otherwise defined, all terms used to disclose the invention, including technical and scientific terms, have the meaning as generally understood by one skilled in the art to which this invention belongs. By way of further guidance, definitions for the terms used in the specification have been included to better appreciate the teachings of the present invention.
    The term gasifier refers to a system that can turn a carbonaceous material into a gas, in particular a syngas. The system can be housed in one unit or can be a series of subunits that are connected to each other with tubes and pipes.
    BE2018 / 5108 The term carbonaceous material refers to a material that is rich in carbon. The carbonaceous material can be in any form, such as liquid and / or solid form. Preferably the carbonaceous material used in the invention is selected from the list comprising waste, biomass such as animal waste and vegetable materials, oil, refined oil, crude oil, coal or coke. More preferably, the carbonaceous material is waste or biomass, most preferably biomass.
    The term bed material refers to a mixture of particles that forms a reaction bed.
    The term cross-section can refer to the intersection between the internal volume and a plane perpendicular to the longitudinal direction of the gasifier.
    In the context of the present invention, the term crude syngas refers to the syngas produced by gasification of a carbonaceous material in a fluidized bed and / or by plasma gasification of a carbonaceous material. Typically, the carbonaceous material is not fully gasified in these reactions, with residual carbonaceous material remaining in the crude syngas. The crude syngas may further comprise impurities, such as tar components, but also inorganic material, bed material and / or catalyst.
    Purifying or cleaning crude syngas is herein understood to mean the further conversion of residual carbonaceous material into syngas, the destruction of tar components and / or the removal of particulate material or dust.
    The term tar refers to any component other than syngas that is released from the carbonaceous material during gasification. Tar can include light organic compounds such as methylene and ethylene but also aromatic compounds such as benzene, xylene and anthracene.
    The term carbon residue refers to the part of the supply of carbonaceous material that cannot be gasified. When the carbonaceous material is derived from a biological source, the term bio-carbon residue is suitable.
    A first aspect relates to a gasifier comprising:
    an internal volume comprising an upper part, a middle part and a lower part, and optionally a first connecting part connecting the upper part and the middle part and / or a second connecting part connecting the middle part and the lower part; an inlet for carbonaceous material that is configured to receive a supply of carbonaceous material and that is in fluid communication with the internal volume;
    BE2018 / 5108 a bed material that is configured in the middle section and / or bottom section and is connected to at least one gas inlet to fluidize the bed;
    a gas outlet in fluid communication with the upper portion, at least one plasma system in the upper portion, wherein the at least one plasma system is configured such that the gas, in particular the syngas, leaves the gasifier through the gas outlet through a zone that is heated by the at least one plasma system, preferably by the plasma flame.
    The upper portion can function as a gasification / thermal cracking zone to purify the crude syngas, the middle portion can function as a fluid bed holder, and the lower portion can function as a coal residue collector. If there is not enough carbon residue to fill the lower part, this lower part can also contain part of the fluidised bed.
    Thus, a gasifier as described herein may comprise the following:
    an internal volume;
    an inlet for carbonaceous material for receiving a supply of carbonaceous material, the inlet being in fluid communication with the internal volume;
    a bed material in the internal volume and connected to at least one gas inlet to fluidize the bed material, the bed material being positioned in the internal volume to receive the carbonaceous material supplied to the internal volume via the carbonaceous material inlet;
    a (syn) gas outlet to enable the (syn) gas produced in the internal volume to leave the gasifier, the (syn) gas outlet being in fluid communication with the internal volume;
    at least one plasma system in the internal volume, the at least one plasma system being configured such that the gas, in particular the syngas, leaving the gasifier through the gas outlet, passes through a zone that is heated by the at least one plasma system, preferably by the plasma flame (s).
    In embodiments, the bed material is located in the inner volume of the gasifier between the at least one gas inlet to fluidize the bed material and the at least one plasma system.
    BE2018 / 5108 The inlet of carbonaceous material can be positioned such that the carbonaceous material enters the internal volume between the at least one plasma system and the fluid bed material.
    Preferably the gasifier is in the form of a cyclone or funnel-shaped with the wider opening at the upper portion. In embodiments, the lower portion has a smaller cross-section than the middle portion and the middle portion has a smaller cross-section than the upper portion.
    In one embodiment, the cross-section of the central portion along the longitudinal direction of the gasifier varies within a range of 20%, preferably within a range of 10%, more preferably within a range of 5%, even more preferably within a range of 2 %, and is most preferably a constant value. This has the advantage that a stable fluidized bed can be generated in this middle section. Indeed, if the shape containing a fluidized bed is too conical, the fluidized bed is disturbed and hotspots are created.
    In embodiments, a first connecting portion is provided, which connects the upper portion and the middle portion, and / or a second connecting portion, which connects the middle portion and the lower portion. Preferably, the first connecting portion and / or the second connecting portion can be a frustoconic connecting portion. This has the advantage that the upper part, middle part and / or lower part can be tubular or tube-shaped, while the frustoconic connecting parts ensure that solid particles can easily roll off the inner surface of the gasifier. This simplifies the gasifier construction.
    The upper part, middle part and lower part are preferably arranged along the longitudinal direction of the gasifier, the upper part being placed on top of the middle part placed on top of the lower part, and this preferably when the gasifier is configured in working conditions.
    Such a gasifier as described herein has the advantage that the at least one plasma flame is generated above the fluidized bed. In this way a zone is created with a correspondingly high temperature above the fluidized bed. Tar that is present in the raw syngas produced in the fluidized bed will undergo thermal cracking due to the high temperature in the zone. Residual carbonaceous material present in the raw syngas is also gasified further into the zone, resulting in a more efficient gasification of the carbonaceous material and much fewer solid particles in the zone of the upper portion above the plasma flame. That is why a lot
    BE2018 / 5108 fewer solid particles and tar reach the gas outlet, resulting in cleaner syngas. In addition, a syngas is produced in the plasma system that is rich in H 2 and CO.
    In embodiments, at least 2, preferably at least 3 and more preferably at least 4 plasma systems are provided in the upper portion and / or in the first connecting portion. These 2 or more plasma systems can be arranged in a circle according to the contours of the internal volume. These 2 or more plasma systems can also be applied at different levels.
    In one embodiment, the at least one plasma system, such as the two or more plasma systems, is oriented at an acute angle with the longitudinal direction of the gasifier, and this with the plasma flame outlet pointing towards the middle portion or the lower portion.
    In some embodiments, the internal volume, in particular the upper portion of the internal volume, comprises a restriction at or near the at least one plasma system. Preferably, the restriction reduces the inner diameter of the inner volume, in particular of the upper portion of the inner volume, at or near the at least one plasma system by at least 10% to at most 80%, more preferably at least 20% up to at most 70%, even more preferably at least 30% to at most 60% and most preferably at least 40% to at most 50%. This narrowing forces the syngas produced to pass through or in close proximity to the plasma flames, thereby inducing further thermal cracking and a reduction of tar.
    In a preferred embodiment, the plasma system is a microwave-induced plasma system, wherein a microwave generator produces an electromagnetic field through which a gas mixture is passed through which the gas is ionized and plasma is generated. This has the advantage that a stable plasma is produced that can transfer a large amount of energy to the internal volume and the carbonaceous material. The durability of a microwave-induced plasma system is considerably higher than with other plasma systems, such as electro-arc plasma systems. This makes the entire gasifier robust and low in maintenance.
    Preferably, the at least one plasma system comprises a gas inlet to receive the plasma gases. These plasma gases are preferably selected from the list comprising steam, air, oxygen gas, air enriched with oxygen gas, carbon dioxide or mixtures thereof, more preferably selected from the list comprising steam, air, oxygen gas, air enriched with oxygen gas or mixtures thereof and with the most preferably the plasma gas is steam.
    BE2018 / 5108 In a preferred embodiment the inlet for carbonaceous material is in fluid communication with the upper part, middle part and / or the first connecting part of the gasifier, preferably in fluid connection with the upper part and / or first connecting part, more preferably in fluid connection with the upper part. Also preferably the carbonaceous material is introduced in the vicinity of the at least one plasma system, such that the elevated temperature caused by the plasma flame can at least partially gasify the freshly added carbonaceous material before it enters the fluidized bed. The inlet of carbonaceous material can thus be positioned such that the carbonaceous material enters the internal volume in the vicinity of, and preferably above, the at least one plasma system. In this way larger particles of carbonaceous material can be added to the gasifier than with conventional gasifiers. In certain embodiments, the carbonaceous material comprises particles with a diameter of up to 10 cm, such as up to 9, 8, 7 or 6 cm, preferably up to 5 cm, such as up to 4.5, 4.0, 3.5 or 3.0 cm .
    In one embodiment, the carbonaceous material inlet comprises a pressurized gas inlet, which is preferably configured to be able to propel the carbonaceous material into the internal volume. By propelling the carbonaceous material, the material can be directed to a certain area in the gasifier, such as the hot area in the vicinity of, such as just above or just below the plasma flame, or even in the plasma flame. This results in an efficient first gasification, so that the carbonaceous material almost immediately loses at least a part of its mass. When the gasification is carried out under the plasma flame, an additional advantage is that the tar formed must pass through the zone that is heated by the at least one plasma flame before it leaves the gasifier, so that the tar itself undergoes thermal cracking, which leads to cleaner syngas above the plasma flame.
    In a preferred embodiment, the gasifier described herein further comprises at least one filter that at least partially covers the gas outlet. More preferably, the gas outlet is completely covered by one or more filters in such a way that gases, in particular syngas, can pass through the filter before they leave the gasifier and larger particles present in the syngas, including tar components, by the filter being held. The at least one filter thus has a further cleaning effect by further removing solid particles and tar particles from the syngas. In this way the syngas is ready for further use without the need for downstream purifiers and / or gas washers, and less or substantially no tar deposition takes place downstream of the gasifier.
    BE2018 / 5108 The at least one filter is preferably configured in the internal volume of the gasifier, preferably in the upper portion of the internal volume, more preferably downstream (wherein downstream is defined by the gas flow through the gasifier) of the at least one plasma system. This allows particles retained by the filter to fall back into the internal volume, passing through the zone heated by the at least one plasma flame before entering the bed material, so that they are further gasified, which contributes to a higher yield.
    The at least one filter can be a ceramic filter, more preferably a ceramic candle filter. The at least one filter can be a catalytic filter, that is, a filter comprising a catalyst. The catalytic material can be an iron catalyst or nickel catalyst, preferably a nickel-calcium catalyst, an iron / olivine catalyst or a nickel catalyst supported on MgO-Al 2 O 3 . The catalyst is capable of at least partially gasifying at least a portion of the material retained by the filter. Gasification of this retained material results in a higher yield and reduces blockage of the filters, further limiting the maintenance and down time of the gasifier. Advantageously, the catalytic reactions occurring on the filter are endothermic, so that gases passing through the filter are cooled by the catalytic reactions. This has the advantage that fewer hot gases need to be handled downstream of the gasifier.
    The gasifier described herein further comprises a bed material in the internal volume, in particular in the middle portion and / or the lower portion. The main purpose of the presence of the bed material is heat storage and heat transfer between the particles that undergo gasification. In this way large temperature peaks are avoided and an almost uniform temperature distribution can be observed
    In a preferred embodiment the bed material is connected to at least one gas inlet, preferably at least one steam inlet and at least one inlet for air, oxygen gas, air enriched with oxygen gas or carbon dioxide or mixtures thereof. The at least one steam inlet preferably functions as a primary gas inlet to create the fluidized bed, and the at least one inlet for air, oxygen gas, air enriched with oxygen gas or carbon dioxide or mixtures thereof as a secondary gas inlet to maintain the desired temperature in the fluidized bed. By varying the ratio of steam to other gases added to the fluidized bed, the composition of the syngas produced can be influenced. Preferably the ratio of steam to other gases is regulated to ensure that the molar ratio of H 2 / CO in the syngas is from 2/1 to 4/1, more preferably from 2.2 / 1 to 3.8 / 1, more preferably 2.4 / 1 to 3.6 / 1, with still more
    BE2018 / 5108 more preferably 2.6 / 1 to 3.4 / 1, even more preferably from 2.8 / 1 to 3.2 / 1 and most preferably from 2.9 / 1 to 3.1 / 1 , such as 3.0 / 1.
    Preferably, the at least one gas inlet is in fluid communication with the center section, the second connection section or the bottom section, more preferably with the center section or the second connection section. The steam inlet is also preferably placed lower in the gasifier than the inlet for air, oxygen gas, air enriched with oxygen gas or carbon dioxide or mixtures thereof. The at least one gas inlet is preferably configured such that the bed material is suspended or fluidized after addition of gases through the at least one gas inlet. Heat transfer is optimal in a fluidized bed and there is intense contact between the carbon-containing material and the gas or steam that is added to the gasifier through the at least one gas inlet.
    In certain embodiments, the bed material is inert, that is, it does not affect the gasification process. A non-limiting example of an inert bed material is quartz sand. In other embodiments, the bed material may comprise catalytic particles. The bed material may comprise, for example, particles comprising a metal-based catalyst, preferably an iron-based catalyst or a nickel-based catalyst, more preferably the catalyst nickel is dispersed on alumina (Al 2 O 3 ) or an iron-olivine catalyst, at preferably an iron-olivine catalyst with an iron content of 5 to 45% by weight, more preferably of 7 to 35% by weight, even more preferably of 10 to 25% by weight, most preferably 20% by weight. These catalytic particles considerably speed up the gasification process. The presence of the catalyst particles also affects the composition of the syngas produced, for example, less carbon dioxide is generated and reduced amounts of methane and tar are generated when using catalytic particles. The iron-based catalysts have the additional advantage that they are considered environmentally safe and therefore they can be left in the coal residue or biocarbon residue. In still other embodiments, the bed material comprises a mixture of inert particles and catalytic particles.
    In certain embodiments, sorbents for the removal of heavy metals, alkali and / or acid gas are added to the internal volume or to the fluidized bed. The sorbents are preferably placed in a bed, preferably a fixed bed in the internal volume. Preferably, the sorbents are selected from the list of bauxite, kaolinite, zeolite, lime, slag lime, Ba-based sorbents, aluminosilicate, or mixtures thereof.
    BE2018 / 5108 In embodiments, the average temperature of the fluidised bed is between 400 ° C and 1000 ° C, preferably between 500 ° C and 900 ° C, more preferably between 600 ° C and 875 ° C, even more preferably between 700 ° C and 850 ° C. ° C and most preferably between 750 ° C and 825 ° C.
    In a preferred embodiment, the bed material is connected to a carbon residue outlet in the lower portion. Via this carbon residue outlet, coal residue, but also unreacted and / or heavy carbonaceous material and bed material can be removed from the gasifier, preferably without having to switch off the gasifier. When carbonaceous material from a biological source is used, biocarbon residue leaves the gasifier. This bio-coal residue can be used in agricultural applications.
    The specification also relates to a methanation system for the conversion of carbonaceous material to methane, comprising:
    a gasifier, suitable for gasifying carbonaceous material to syngas, wherein the gasifier is at least partially supplied with steam, and wherein the gasifier comprises a syngas outlet;
    a first cooling unit comprising a hot gas inlet and a cold gas outlet, the hot gas inlet being in fluid communication with the gasifier syngas outlet;
    a methanization unit suitable for producing raw methane from syngas, comprising a syngas inlet and a raw methane outlet, the syngas inlet being in fluid communication with the cold gas outlet of the first cooling unit;
    a second cooling unit comprising a hot methane inlet and a cold methane outlet, the hot methane inlet being in fluid communication with the raw methane outlet of the methanation unit;
    wherein the first cooling unit and the second cooling unit comprise an economizer, evaporator and / or superheater for steam production for the gasifier.
    The term methanation system refers to a system capable of converting a carbonaceous material into methane gas or a gas rich in methane, preferably a gas comprising more than 50 volume% methane, more preferably a gas comprising more than 75 volume% methane , and most preferably a gas comprising more than 90 volume% methane. In the case that biomass is used as a carbonaceous material, the term bio-methanization is suitable. The methane produced is then called bio-methane. Other commonly used terms to refer to methane gas that is produced instead of being mined is substitute natural gas or synthetic natural gas or SNG.
    BE2018 / 5108 The term methanation unit refers to a unit that can convert syngas, in particular hydrogen and carbon oxides, preferably carbon monoxide, into methane and water.
    In preferred embodiments, the methanization unit is a fluid bed methanizer. Fluidized bed methanizers include a reactor bed that is fluidized through the inlet of gases such as steam and oxidizing agent. Accordingly, fluidized bed methodizers typically include an internal volume comprising a bed material, and at least one gas inlet that is in fluid communication with the inner volume and in fluid communication with the bed material. In a preferred embodiment, the methanation unit comprises a catalyst bed, preferably a vortex catalyst bed. The catalyst bed can comprise iron-based or nickel-based catalytic particles. Because the conversion of syngas to methane is exothermic, the fluidized bed ensures good heat transfer and heat transfer, avoiding hot spots that could damage the unit or the catalyst. Proper heat dissipation will also thermodynamically favor the conversion reaction. Preferably, the fluidized bed is held in a portion of the methanation unit that is cooled, more preferably water-cooled.
    The methane generated in the methanation system can be injected into the natural gas network, or it can be used to produce electricity, or stored for later use (e.g., compressed bio-methane for vehicles, for example).
    The first cooling unit in the methanation system described herein cools the syngas leaving the gasifier before it enters the methanation unit. The optimum temperature for the methanation reaction is lower than the temperature of the syngas leaving the gasifier and methanization is an exothermic reaction. Hence, without cooling the gas entering the methanization unit, the temperature in the methanization unit would be too extreme for the catalyst and building materials of the methanization unit itself. In preferred embodiments, the heat released from the gas stream in this first cooling unit is used for steam production. Accordingly, in embodiments, the first cooling unit is an economizer, an evaporator, and / or a super heater.
    The second cooling unit in the methanization system described herein can serve as a water separator, which removes the water from the effluent of the methanization unit to produce a relatively dry methane gas that can be used further. Accordingly, in embodiments, the second cooling unit comprises a condenser, preferably a condensing economizer or a condensing evaporator. In preferred embodiments, the heat is removed from this gas stream from this second cooling unit
    BE2018 / 5108 extracts used in the production of steam. Accordingly, in embodiments, the second cooling unit is an economizer, an evaporator, and / or a super heater.
    The term economizer as used herein refers to a heat exchange device that heats fluids, such as water, to but not normally beyond the boiling point of that fluid.
    The term evaporator as used herein refers to a heat exchange device where the heat is used to convert a fluid such as water to a gaseous state such as water vapor.
    The term superheater as used herein refers to a heat exchange device that heats steam to temperatures above 100 ° C.
    In embodiments, the second cooling unit comprises an economizer and evaporator for steam production. In embodiments, the first cooling unit comprises an evaporator and a super heater for steam production. In embodiments, the first cooling unit comprises an evaporator and a superheater for steam production and the second cooling unit comprises an evaporator and a superheater for steam production. In embodiments, the first cooling unit comprises an evaporator and a superheater for steam production and the second cooling unit comprises an evaporator and an economizer for steam production.
    In embodiments where the heat released in the first and / or second cooling units is used to produce steam, the energy efficiency of the entire methanation system is optimized, since the necessary cooling is used to produce steam that can be used for other purposes turn into. In preferred embodiments, the steam, in particular the superheated steam, is used at least in part to feed the gasifier of the methanation system, in particular a fluidized bed and / or a plasma system of the gasifier.
    In a preferred embodiment, the second cooling unit comprises a condenser adapted to at least partially separate water from the crude methane exiting the methanization unit. In embodiments, the second cooling unit comprises a condensing economizer or a condensing evaporator. In embodiments, the separated water is returned to the methanation system as a coolant or heat transfer medium and converted to steam by passing it through the economizer, the evaporator and / or the super heater. In embodiments, the water outlet of the condenser is in fluid communication with the inlet of heat transfer medium from the second cooling unit and / or from the first cooling unit. The water outlet of the condenser collects the water separated from the crude methane. In specific embodiments, the separated water is introduced into the condenser as coolant or heat transfer medium and transformed into steam by the
    BE2018 / 5108 by leading the economizer, the evaporator and / or the super heater. In specific embodiments, the water outlet of the condenser is in fluid communication with the inlet of the heat transfer medium of the condenser.
    Preferably, the second cooling unit of the methanation system described herein comprises one or more of the economizer, evaporator and superheater, more preferably an economizer and an evaporator. Preferably, the first cooling unit of the methanation system described herein comprises one or more of the economizer, evaporator and superheater, more preferably an evaporator and a superheater. An additional water cooler can be placed to cool the separated water leaving the second cooling unit before it enters the second cooling unit as a coolant. Therefore, the methanation system as described herein may further comprise a cooler positioned between the water outlet of the condenser and the inlet of the heat transfer medium of the second cooling unit and / or the first cooling unit, or between the water outlet of the condenser and the inlet of the heat transfer medium of the condenser.
    In a preferred embodiment, a steam drum is placed between the superheater and the one or more evaporators.
    In a preferred embodiment of the methanation system, the gasifier is a gasifier according to an embodiment of the first aspect of the invention.
    In some embodiments, the following features of the methanation unit may be provided from downstream to upstream, with downstream and upstream defined by the gas flow through the methanization system: a vortex reactor bed of the gasifier (9); at least one plasma system (8); optionally a filter from the gasifier (17); a first evaporator (29); a super heater (18); a fluid bed methanizer (21); optionally a filter of the methanation unit (31); a second evaporator (28); a condenser (24).
    The advantage of the methanation system described herein is its high energy efficiency, as described elsewhere herein. A further advantage is that steam is consumed in the gasifier during the gasification of carbonaceous material, but water vapor / steam is generated in the methanization unit during the methanation step, resulting in a system where only a small amount of water needs to be added to the methanization system added to maintain the amount of water in the system.
    In a third aspect an electricity generating system is provided, comprising a gasifier according to an embodiment of the first aspect of the invention, wherein the gas outlet is in fluid communication with a gas turbine or a gas engine that is electrically
    BE2018 / 5108. When biomaterials are used as carbonaceous material, green electricity is produced.
    In certain embodiments, the electricity generating system further comprises a heat recovery steam generator. The heat in the exhaust gases from the gas engine or gas turbine can be recovered in the waste heat recovery steam generator (HRSG) and additional electrical power can be produced from the Rankine cycle that uses this steam. According to this embodiment, i.e. gas engine / gas turbine + HRSG + steam turbine, the total electrical efficiency can be doubled compared to the electrical efficiency obtained from the conventional single Rankine cycle. Preferably, a cooling unit is placed downstream of the gasifier but in front of the gas turbine or gas engine.
    In a fourth aspect, the invention relates to a process for gasifying carbonaceous material, comprising the steps of:
    a) supplying carbonaceous material to a gasifier via an inlet for carbonaceous material from the gasifier;
    b) optionally passing the carbonaceous material through a zone heated by a plasma system, whereby the carbonaceous material is partially gasified into a crude syngas before it enters the fluidized bed;
    c) gasifying the carbonaceous material in a fluidized bed in the gasifier, thereby producing a crude syngas;
    d) passing the crude syngas produced in steps b) and c) through a zone heated by at least one plasma system to at least partially purify the crude syngas;
    e) discharging the purified syngas produced in step d) from the gasifier through a gas outlet.
    In the processes described herein, crude syngas, which is generated during the gasification of carbonaceous material in the fluidized bed and / or by plasma gasification of carbonaceous material, passes through an area that is heated by at least one plasma torch. Passing through this elevated temperature region will cause thermal cracking of tar components in the raw syngas and further gasification of residual carbonaceous material. This results in a higher efficiency in syngas production and in a cleaner syngas that is about to leave the gasifier.
    The plasma system used in the process may be a microwave-induced plasma system as described elsewhere herein.
    BE2018 / 5108 In further embodiments, the (partially) purified syngas produced in step d) is passed through a filter before it is discharged from the gasifier to further purify the syngas. Preferably, the filter is a catalytic filter as described elsewhere herein.
    Preferably the gasifier used in the gasification process of carbonaceous material as described herein is a gasifier according to one of the embodiments of the first aspect of the invention.
    Yet another aspect relates to a process for the conversion of a carbonaceous material into methane gas, comprising steps of:
    a) supplying carbonaceous material to a gasifier (1) via an inlet (2) for carbonaceous material from the gasifier (1);
    b) optionally passing the carbonaceous material through a zone heated by at least one plasma system (8), whereby the carbonaceous material is partially gasified into a crude syngas before it enters the fluidized bed (9);
    c) gasifying the carbonaceous material in a fluidized bed (9) in the gasifier (1), thereby producing a crude syngas;
    d) passing the crude syngas produced in steps b) and c) through a zone heated by at least one plasma system (8) to at least partially purify the crude syngas;
    e) optionally passing the at least partially purified syngas obtained in step d) through a filter to further purify the syngas;
    f) discharging the purified syngas produced in steps d) and e) from the gasifier (1) via a gas outlet (16);
    g) at least partially converting the purified syngas into crude methane in a methanization unit (21), preferably a fluid bed methanizer, wherein the purified syngas discharged from the gasifier (1) is passed through a first cooling unit and wherein the crude methane exiting the methanization unit (21) is passed through a second cooling unit, the first cooling unit and the second cooling unit independently comprising an economizer, an evaporator and / or a superheater for steam production for the gasifier (1).
    explanations
    Preferred explanations (features) and embodiments of the gasifiers, methanation systems, electricity generation systems and processes described herein are given below. Each statement and embodiment thus defined can be combined with any other statement and / or
    BE2018 / 5108 embodiment, unless the contrary is clearly indicated. In particular, any feature indicated as preferred or advantageous may be combined with any other features or statements that are indicated as preferred or advantageous.
    A gasifier (1) comprising:
    - an internal volume (4) comprising an upper part (5), a middle part (6) and a lower part (7), and optionally a first connecting part (10) connecting the upper part (5) and the middle part (6) and / or a second connecting portion (11) connecting the middle portion (6) and the lower portion (7);
    - one or more inlets (2) for carbonaceous material, configured to receive a supply of carbonaceous material and in fluid communication with the internal volume (4);
    - a bed material (9) configured in the middle section (6) and / or the lower section (7) and connected to at least one gas inlet (12) to fluidize the bed;
    - a gas outlet (16), in fluid communication with the upper part (5) of the internal volume (4); and
    - at least one plasma system (8) configured in the upper part (5) so that gas leaving the gasifier (1) through the gas outlet (16) passes through a zone heated by the at least one plasma system (8).
    A gasifier according to statement 1, wherein the plasma system (8) is a microwave-induced plasma system.
    A gasifier according to any of claims 1-2, wherein the one or more carbonaceous material inlets (2) are in fluid communication with the upper portion (5) of the internal volume (4) and are configured such that the carbonaceous material is the zone heated by the at least one plasma system (8) passes before the bed (9) is entered.
    Gasifier as claimed in any of the claims 1-3, wherein at least one filter (17), preferably a catalytic filter, more preferably a filter comprising a nickel-based or iron-based catalyst, at least partially the gas outlet covers. (16), is preferably configured in the internal volume (4).
    BE2018 / 5108
    Gasifier according to any of the claims 1-4, wherein the bed material (9) comprises catalytic particles, preferably particles comprising a nickel-based catalyst or an iron-based catalyst.
    Gasifier according to one of the claims 1-5, wherein the lower part (7) has a smaller cross-section than the middle part (6), and wherein the middle part (6) has a smaller cross-section than the upper part (5).
    A methanization system (36) for the conversion of carbonaceous material to methane, comprising:
    a gasifier (1), suitable for gasifying carbonaceous material to syngas, wherein the gasifier is at least partially fed with steam, and wherein the gasifier comprises a syngas outlet (16);
    a first cooling unit (18, 29) comprising a hot gas inlet (19) and a cold gas outlet (20), the hot gas inlet (19) being in fluid communication with the syngas outlet (16) of the gasifier (1);
    a methanization unit (21) suitable for producing raw methane from syngas, comprising a syngas inlet (22) and a raw methane outlet (23), wherein the syngas inlet (22) is in fluid communication with the cold gas outlet (20) of the first cooling unit (18);
    a second cooling unit (24, 28) comprising a hot methane inlet (25) and a cold methane outlet (26), wherein the hot methane inlet (25) is in fluid communication with the raw methane outlet (23) of the methanization unit (21);
    characterized in that the first cooling unit and the second cooling unit independently comprise an economizer, an evaporator and / or a superheater for steam production for the gasifier.
    The methanization system (36) according to statement 7, wherein the methanization unit (21) comprises a vortex catalyst bed (33).
    Methanization system (36) according to one of the declarations 7-8, wherein the second cooling unit comprises an economizer (24) and an evaporator (28) for steam production and / or wherein the first cooling unit comprises an evaporator (29) and a super heater (18) ) for steam production.
    BE2018 / 5108
    Methanization system (36) according to one of the statements 7-9, wherein the gasifier is a gasifier (1) according to one of the statements 1-6.
    An electricity generating system, comprising a gasifier (1) according to any of claims 1-6, wherein the gas outlet (16) is in fluid communication with a gas turbine or a gas engine.
    12. Process for gasifying carbonaceous material, comprising steps of:
    a) supplying carbonaceous material to a gasifier (1) via an inlet (2) for carbonaceous material from the gasifier;
    b) optionally passing the carbonaceous material through a zone heated by at least one plasma system (8), whereby the carbonaceous material is partially gasified to a crude syngas before it enters the fluidised bed (9);
    c) gasifying the carbonaceous material in a fluidized bed (9) in the gasifier, thereby producing a crude syngas;
    d) passing the crude syngas produced in steps b) and c) through a zone heated by at least one plasma system (8) to at least partially purify the crude syngas;
    e) discharging the purified syngas produced in step d) from the gasifier via a gas outlet (16).
    A process according to statement 12, wherein the plasma system (8) is a microwave-induced plasma system.
    A process according to any of claims 12-13, wherein the purified syngas produced in step d) is passed through a filter (16), preferably through a catalytic filter, before being discharged from the gasifier.
    Process according to one of the statements 12-14, wherein the gasifier (1) is a gasifier according to one of the statements 1-6.
    BE2018 / 5108
    EXAMPLES
    Example 1
    Figure 1 shows a gasifier 1 according to an embodiment of the invention. Carbonaceous material enters gasifier 1 through inlets 2 for carbonaceous material. Pipes 3 connect the inlets 2 for carbonaceous material with the internal volume 4 of the gasifier. The internal volume 4 is subdivided into an upper part 5, a middle part 6 and a lower part 7. The upper part 5 is connected to the middle part 6 by a first connecting part 10. The middle part 6 is connected to the lower part 7 by a second connecting portion 11. The diameter of the upper portion 5 is larger than the diameter of the middle portion 6 and the diameter of the middle portion 6 is larger than the diameter of the lower portion 7. Plasma systems 8 are configured in the upper portion 5. In this example the carbonaceous material inlets 2 are placed above the plasma flames, but alternatively the carbonaceous material inlets 2 may be located at the same level of the plasma flames or below the plasma flames. The fluidized catalytic bed 9 is housed in the middle portion 6 and the second connecting portion 11. Steam is supplied to the bed 9 via the primary steam inlet 12. Oxygen-rich gas is supplied to the fluidized bed 9 via the secondary gas inlet 13. This oxygen-rich gas regulates the temperature from the fluidised bed, because this can cause part of the carbonaceous material to burn and heat to be released. Plasma gases, such as steam, are supplied via plasma gas inlets 14. Carbon residue can be collected in the lower part 7 and can be removed via carbon residue outlet 15. The syngas outlet 16 is covered by catalytic candle filters 17.
    Example 2
    In an alternative example, the carbonaceous material inlets 2 are placed in the vicinity of the plasma system 8 to ensure that the carbonaceous material entering the upper portion 5 is heated by the plasma flame, so that the carbonaceous material is at least partially gasified before it bed 9 enters. A schematic overview of this gasifier is shown in Figure 2.
    Example 3
    Figure 3 shows a schematic view of a methanation system 36 according to an embodiment of the invention. Syngas produced in the gasifier 1 of example 1 leaves the gasifier 1 via the syngas outlet 16, the temperature of the syngas is approximately 800 ° C at this point, the hot syngas passes through a first cooling unit which first
    BE2018 / 5108 evaporator 29, whereby the temperature of the syngas is lowered to approximately 500 ° C, and a super heater 18, in which the temperature of the syngas is further lowered to approximately 350 ° C when the syngas leaves the first cooling unit through the cold gas outlet 20. This syngas then enters the methanization unit 21 via the syngas inlet 22, where it enters a fluidized bed 33, which comprises a nickel catalyst. The syngas is converted to methane and water in an exothermic reaction. Cooling facilities are provided in the wall that holds the fluidized bed 33. The solid particles from the fluidized bed can be removed through the solids outlet 30 at the bottom of the methanation unit. A filter 31 covers the raw methane outlet 23 of the methanation unit 21. The methanization unit itself has an upper portion 32, a middle portion 33 and a lower portion 34, the diameter of the upper portion 32 being greater than the diameter of the middle portion 33 and the diameter of the middle portion 33 being greater than the diameter of the lower portion 34. The crude wet methane leaves the methanization unit 21 via crude methane outlet 23 at a temperature of about 400 ° C and is passed through a second cooling unit comprising a second evaporator 28 which cools the wet methane to about 100 ° C and a condenser 24 separating the water from the methane. The dry methane leaves the second cooling unit via the cold methane outlet 26.
    The water separated from the methane in the condenser 24 undergoes an additional cooling step and is returned to the condenser 24, but as a cooling liquid. The condenser 24 functions as an economizer for the water, heating the water to approximately 90 ° C. This water is then fed into the second evaporator 28, where it is converted into saturated vapor. This saturated vapor is led to a steam drum 35 where the liquid is separated from the vapor phase. The liquid enters the first evaporator 29 and is further converted into vapor, which is returned to the steam drum 35. The vapor phase in the steam drum 35 is fed into the super heater 18, where the temperature of the water vapor is raised to about 400 ° C and the water vapor is converted into steam. This steam is supplied to the gasifier 1 as primary gas to create the fluidized bed via gas inlet 12, and / or as plasma gas via plasma gas inlet 14.
    权利要求:
    Claims (10)
    [1]
    A methanization system (36) for the conversion of carbonaceous material to methane, comprising:
    a gasifier (1) for gasifying carbonaceous material to syngas, wherein the gasifier is at least partially supplied with steam and comprises the following:
    - an internal volume (4) comprising an upper part (5), a middle part (6) and a lower part (7), and optionally a first connecting part (10) connecting the upper part (5) and the middle part (6) and optionally a second connecting portion (11) connecting the middle portion (6) and the lower portion (7), the upper portion (5), middle portion (6) and lower portion (7) along the longitudinal direction of the gasifier (1) are arranged, the upper part (5) being placed on top of the middle part (6) which is placed on top of the lower part (7);
    - one or more inlets (2) for carbonaceous material that are configured to receive a supply of carbonaceous material and that are in fluid communication with the internal volume (4);
    - a bed material (9) comprising catalytic particles, in the middle part (6) and / or the lower part (7) and connected to at least one gas inlet (12) to fluidize the bed material;
    - a gas outlet (16) which is in fluid communication with the upper part (5) of the internal volume (4); and
    - at least one plasma system (8) configured within the upper portion (5) so that gas leaving the gasifier (1) through the gas outlet (16) passes through a zone that is heated by the at least one plasma system (8);
    a first cooling unit (18, 29) comprising a hot gas inlet (19) and a cold gas outlet (20), the hot gas inlet (19) being in fluid communication with the gas outlet (16) of the gasifier (1);
    a methanization unit (21) suitable for producing raw methane from syngas, comprising a syngas inlet (22) and a raw methane outlet (23), wherein the syngas inlet (22) is in fluid communication with the cold gas outlet (20) of the first cooling unit (18);
    BE2018 / 5108 a second cooling unit (24, 28) comprising a hot methane inlet (25) and a cold methane outlet (26), the hot methane inlet (25) being in fluid communication with the raw methane outlet (23) of the methanization unit (21);
    wherein the first cooling unit and the second cooling unit independently comprise an economizer, an evaporator and / or a superheater for steam production for the gasifier.
    [2]
    Methanization system (36) according to claim 1, wherein the at least one plasma system (8) of the gasifier (1) is a microwave-induced plasma system.
    [3]
    Methanization system (36) according to one of claims 1 or 2, wherein at least one filter (17), preferably a catalytic filter, more preferably a filter comprising a nickel-based or iron-based catalyst, the gas outlet ( 16) at least partially covers the gasifier (1), preferably wherein the at least one filter (17) is configured in the internal volume (4) of the gasifier (1).
    [4]
    Methanization system (36) according to one of claims 1 to 3, wherein the bed material (9) of the gasifier (1) comprises catalytic particles comprising a nickel-based catalyst or iron-based catalyst.
    [5]
    Methanization system (36) according to one of claims 1 to 4, wherein the lower part (7) of the internal volume (4) of the gasifier (1) has a smaller cross-section than the middle part (6), and wherein the middle part (6) has a smaller cross-section than the upper part (5).
    [6]
    The methanization system (36) according to any of claims 1 to 5, wherein the methanization unit (21) is a fluid bed methanizer.
    [7]
    Methanization system (36) according to one of claims 1 to 6, wherein the second cooling unit comprises an economizer (24) and an evaporator (28) for steam production and / or wherein the first cooling unit comprises an evaporator (29) and a super heater (18) ) for steam production.
    BE2018 / 5108
    [8]
    Methanization system (36) according to one of claims 1 to 7, wherein the second cooling unit comprises a condenser (24) for at least partially separating water from the crude methane.
    [9]
    The methanization system (36) of claim 8, wherein the water separated from the crude methane is recycled into the condenser (24) as cooling liquid and is at least partially converted to steam via passing through the first cooling unit and the second cooling unit.
    The methanization system (36) of claim 9, further comprising a cooler for cooling the water separated from the crude methane by the condenser (24) before the water in the condenser (24) is recycled as a cooling liquid.
    11. Process for converting carbonaceous material to methane, comprising the steps of:
    a) supplying carbonaceous material to a gasifier (1) via an inlet (2) for carbonaceous material from the gasifier (1);
    b) gasifying the carbonaceous material in a fluidized bed (9) comprising catalytic particles, in the gasifier (1), thereby producing a crude syngas;
    c) passing the crude syngas produced in step b) through a zone heated by at least one plasma system (8) to at least partially purify the crude syngas;
    d) optionally passing the at least partially purified syngas through a filter to further purify the syngas;
    e) discharging the purified syngas produced in step c) and optionally in step d) from the gasifier (1) via a gas outlet (16);
    f) at least partially converting the purified syngas to crude methane in a methanization unit (21), preferably a fluid bed methanizer, wherein the purified syngas discharged from the gasifier (1) is passed through a first cooling unit and wherein the crude methane leaving the methanization unit (21) is passed through a second cooling unit, the first cooling unit and the second cooling unit independently comprising an economizer, an evaporator and / or a super heater for steam production for the gasifier (1).
    The process of claim 10, wherein the process is performed in a methanation system (36) according to any of claims 1 to 10.
    BE2018 / 5108
    The process of any one of claims 11 or 12, further comprising the step of:
    g) at least partially removing water from the crude methane obtained in step f).
    The process of claim 13, wherein the water removed in step g) is recycled as cooling liquid into the methanation system (36) and converted to steam via passing through the first and second cooling units.
    [10]
    15. Process according to claim 14, wherein the water removed in step g) is further subjected to an additional cooling step before it is returned to the methanation system (36).
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    同族专利:
    公开号 | 公开日
    ES2768350T3|2020-06-22|
    PL3366753T3|2020-07-27|
    EP3366753B1|2019-10-23|
    BE1025408A1|2019-02-11|
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    法律状态:
    2019-03-18| FG| Patent granted|Effective date: 20190218 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP17157685.3|2017-02-23|
    EP17157685|2017-02-23|
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