Reactor and process for making synthesis gas

• Main Authors: MCMAHON JAMES A, RAPIER C. ROBERT
• Format: Patent
• Language: English
• Published: 03.06.2008
• Subjects: BASIC ELECTRIC ELEMENTS; CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOIDCHEMISTRY; CHEMISTRY; CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION ORPROCESSING OF GOODS; COMPOUNDS THEREOF; CRACKING HYDROCARBON OILS; ELECTRICITY; FUELS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; INORGANIC CHEMISTRY; LUBRICANTS; METALLURGY; MINERAL WAXES; NON-METALLIC ELEMENTS; PEAT; PERFORMING OPERATIONS; PETROLEUM, GAS OR COKE INDUSTRIES; PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL; PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSIONOF CHEMICAL INTO ELECTRICAL ENERGY; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVEHYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, ORGASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; TECHNICAL GASES CONTAINING CARBON MONOXIDE; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS; TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINSTCLIMATE CHANGE; THEIR RELEVANT APPARATUS; TRANSPORTING

The invention relates to reactor systems and processes for producing synthesis gas. In one embodiment, a reactor comprises a first reaction zone comprising a combustion catalyst, wherein the first reaction zone is operated at conditions sufficient to produce a combustion zone product comprising heat generated by the combustion of a fuel. The reactor further comprises a second reaction zone comprising a partial oxidation catalyst, wherein the second reaction zone is adapted to receive the combustion zone product and a reaction feed comprising a hydrocarbon gas. The second reaction zone is operated at conditions sufficient for partially oxidizing the hydrocarbon gas to a product stream comprising synthesis gas. The heat of combustion is transferred directly to the reaction feed by mixing it in a feed mix region located in the reactor between the first and second reaction zones, in such a manner that the reaction feed does not need preheating prior to entering the partial oxidation zone.