Note: Descriptions are shown in the official language in which they were submitted.
CA 02757824 2013-07-15
= 78396-168
A HOT SOLIDS PROCESS HAVING AN OUTPUT SUITABLE FOR THE INPUT TO
A PETROCHEMICAL PROCESS
TECHNICAL FIELD
[00021 This invention relates generally to a hot solids process
that is capable of
generating a predetermined output that is designed to be suitable for use as
an input to a
petrochemical process. Moreover, the present invention relates to such a hot
solids
process that is designed to employ a portion of the otherwise normally
unusable product
output, which is produced from such a petrochemical process, for purposes of
generating,
in accordance with the present invention, the output from the hot solids
process that is
designed to be suitable for use as an input to said petrochemical process.
BACKGROUND
[0003] The World today faces a critical challenge as all nations
strive to satisfy
basic human requirements - - food, shelter, clothing and work - - that are so
dependent on
adequate supplies of energy. The great increase in the use of energy has been
met mostly
by fossil fuels - - primarily, coal, oil and gas. The belief is that
environmental concerns,
security of supply, and economic impacts must all be balanced as the demand
for energy
continues to increase. Real economic growth and energy use nevertheless still
remain
inextricably linked.
- 1 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
[0004] While the quest for ultimate solutions to provide adequate energy
supplies
continues, near term, interim solutions must be considered for meeting the
immediate
growth in demand for energy. Technological improvements in the mining,
drilling,
moving, processing, and using of fossil fuels can, of course, stretch energy
resource
reserves, as can a determined effort at conservation of energy. Similarly, the
utilization
of advanced clean fossil fuel technologies involving the employment of various
forms of
hot solids processes such as, by way of exemplification and not limitation,
fossil fuel
gasification, fluidized-bed combustion, or hybrid combustion-gasification
fossil fuel
technologies, are capable of having the effect of that of widening the use of
the World's
vast fossil fuel resources.
[0005] In accordance with the mode of operation of electrical power
generation
systems, as is well known to most, the steam that is produced by steam
generators, which
are employed in such electrical power generation systems, from the combustion
of fossil
fuel therein is designed to be employed in steam turbines. Such steam, which
commonly
is both at a high temperature and at a high pressure, is expanded in the
aforementioned
steam turbine in order to thereby effect a rotation of the steam turbine. Such
rotation of
the steam turbine in turn is operative in a known manner to cause a generator
that is
suitably operatively connected to the steam turbine to rotate as well. Then,
when the
generator undergoes such rotation, a conductor is made to move through a
magnetic field
thereby causing an electric current to be generated. The aforedescribed mode
of
operation is fundamentally the basis upon which electrical power generation
systems
continue to be predicated even to this day.
[0006] In an effort to realize higher efficiencies for electrical power
generation
systems, attempts have been known to have been made to increase the
temperatures and
the pressures at which the steam generators that are employed in such
electrical power
generation systems are capable of being operated. Such efforts to date have
resulted in
steam generators being supplied commercially for employment in electrical
power
generation systems that are capable of being operated at subcritical pressure
conditions or
that are capable of being operated at supercritical pressure conditions.
Improvements in
the strength of the materials from which such steam generators, which are
intended for
employment in electrical power generation systems, are designed to be
constructed have
permitted such materials, and thus such steam generators, to be operated both
at such
higher temperatures and at such higher pressures.
- 2 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
[0007] Discussing further the advanced clean fossil fuel technologies to
which
reference has been had above previously wherein various forms of hot solids
processes
are employed, and in particular to that of fossil fuel gasification
technologies, attention is
first directed in this connection, by way of exemplification and not
limitation, to U.S.
Patent No. 2,602,809, which issued on July 8, 1952 to The M. W. Kellogg
Company.
The teachings of U.S. Patent No. 2,602,809 are considered to be representative
of an
exemplification of an early development in the continuing development of
fossil fuel
gasification technologies of the type wherein hot solids processes are
employed. To this
end, in accordance with the teachings thereof, the teachings of U.S. Patent
No. 2,602,809
are directed to a proves, which is said to be particularly suited for the
gasification of low-
grade solid carbon-containing materials. More specifically, insofar as the
mode of
operation of the process to which the teachings of U.S. Patent No. 2,602,809
are directed
is concerned, the solid carbon-containing materials are designed to be
oxidized in order to
convert such solid carbon-containing materials to carbon oxides by virtue of
the indirect
oxidation thereof with air in such a manner that the nitrogen of the air does
not
contaminate the product gas. Such gasification of the solid carbon-containing
materials is
accomplished by virtue of the alternate oxidation and reduction of a fluidized
metal oxide.
According to the teachings of U.S. Patent No. 2,602,809, solid fuels are
subjected to
being converted to gases as a consequence of the contacting by a metal oxide
with finely-
divided solid carbon-containing materials under conditions such as to cause
the metal
oxide to be reduced and the carbon of the solid fuel to be oxidized to carbon
oxides, with
the metal oxide being the principal source of oxygen that is required for the
oxidation of
the carbon. Then, after the metal oxide has been reduced, the reduced metal
oxide is
subjected to being re-oxidized whereupon the process cycle is capable of being
repeated
once again.
[0008] With further regard to the fossil fuel gasification technologies
of the
advanced clean fossil fuel technologies to which reference has been had above
previously
wherein various forms of hot solids processes are employed, attention is next
directed
herein, by way of exemplification and not limitation, to U.S. Patent No.
4,602,573, which
issued on July 29, 1986 to Combustion Engineering, Inc. The teachings of U.S.
Patent
No. 4,602,573 are considered to be representative of an exemplification of a
further
development in the continuing evolution of fossil fuel gasification
technologies of the
type wherein hot solids processes are employed. To this end, in accordance
with the
- 3 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
teachings thereof, the teachings of U.S. Patent No. 4,602,573 are stated to be
directed to a
method of gasifying and combusting a carbonaceous fuel and, more particularly
to an
integrated process wherein a sulfur and nitrogen-bearing carbonaceous fuel is
gasified to
produce a carbon monoxide-rich low BTU fuel gas that is deigned to be
subsequently
combusted with additional carbonaceous fuel in a steam generator. More
specifically,
insofar as the mode of operation of the process to which the teachings of U.
S. Patent No.
4,602,573 are directed is concerned, a first portion of sulfur and nitrogen-
bearing
carbonaceous fuel is gasified in a gasification reactor in a reducing
atmosphere of air to
produce a hot, char-containing, carbon monoxide-rich fuel gas having a low BTU
content.
Thereafter, a sulfur capturing material is introduced into the gasification
reactor so that
the gasifying of the carbonaceous fuel is carried out in the presence of the
sulfur
capturing material whereby a substantial portion of the sulfur in the
carbonaceous fuel
being gasified is captured by the sulfur capturing material.
[0009] Attention will next be directed herein further to the advanced
clean fossil
fuel technologies to which reference has been had above previously wherein
various
forms of hot solids processes are employed and in particular to that of
fluidized-bed
combustion technologies. Thus, more specifically, attention is therefore
directed in this
connection, by way of exemplification and not limitation, to U.S. Patent No.
4,111,158,
which issued on September 5, 1978 to Metallgesellschaft Aktiengesellschaft.
The
teachings of U.S. Patent No. 4,111,158 are considered to be representative of
an
exemplification of an early development in the continuing development of the
fluidized-
bed combustion technologies of the type wherein hot solids processes are
employed. To
this end, in accordance with the teachings thereof, the teachings of U.S.
Patent No.
4,111,158 are stated to be directed to a method of and an apparatus for
carrying out an
exothermic process in which a solid feed contains a combustible such as, for
example,
carbonaceous or sulfurous compounds. Continuing, insofar as the mode of
operation of
the method of and the apparatus for to which the teachings of U.S. Patent No.
4,111,158
are directed is concerned, the combustible compounds of the solid feed are
designed to be
burned under approximately stoichiometric conditions in a fluidized bed.
Thereafter, the
solids, which are produced as a consequence of such burning of the combustible
compounds of the solid feed and which are withdrawn from the fluidized bed are
caused
to be recycled back to the fluidized bed, while the heat that is produced from
such
burning of the combustible compounds of the solid feed is available to be
recovered.
- 4 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
[00101 Regarding further the fluidized-bed combustion technologies of the
advanced clean fossil fuel technologies to which reference has been had above
previously
wherein various forms of hot solids processes are employed, attention is next
directed
herein, by way of exemplification and not limitation, to U. S. Patent No.
5,533,471, which
issued on July 9, 1996 to A. Ahlstrom Corporation. The teachings of U.S.
Patent No.
5,533,471 are considered to be representative of an exemplification of a
further
development in the continuing evolution of fluidized-bed combustion
technologies of the
type wherein hot solids processes are employed. To this end, in accordance
with the
teachings thereof, the teachings of U.S. Patent No. 5,533,471 are stated to be
directed to a
system and to a method that allow the temperature of the fluidized bed reactor
to be
controlled efficiently, allowing adequate heat transfer surface area for
cooling of solid
materials. More specifically, insofar as the mode of operation of the system
and of the
method to which the teachings of U.S. Patent No. 5,533,471 are directed is
concerned, a
circulating (fast) fluidized bed and a bubbling (slow) fluidized bed are
utilized.
Continuing, these two (2) fluidized beds are mounted adjacent each other with
first and
second interconnections between them, typically with the fluidizing gas
introducing grid
of the bubbling fluidized bed being below that of the circulating fluidized
bed. Because
the bubbling fluidized bed has a substantially constant density throughout,
with a clear
demarcation line at the top thereof, the first interconnection is provided
above the top of
the bubbling fluidized bed so that the pressure and density conditions between
the two (2)
fluidized beds result in a flow of particles from the circulating fluidized
bed to the
bubbling fluidized bed through the first interconnection. However, since the
average
density in the bubbling fluidized bed is higher than the density in the
circulating fluidized
bed, the pressure and density conditions cause the particles after treatment
in the bubbling
fluidized bed (e.g., after the cooling of the particles therein) to return to
the circulating
fluidized bed through the second interconnection.
[0011] Discussing further the advanced clean fossil fuel technologies to
which
reference has been had above previously wherein various forms of hot solids
processes
are employed, and in particular that of hybrid combustion-gasification
technologies,
attention is first directed in this connection, by way of exemplification and
not limitation,
to U.S. Patent No. 4,272,399, which issued on June 8, 1981 to the Monsanto
Company.
The teachings of U.S. Patent No. 4,272,399 are considered to be representative
of an
exemplification of an early development in the continuing evolution of the
hybrid
- 5 -
=
CA 02757824 2013-07-15
78396-168
combustion-gasification technologies of the type wherein hot solids processes
are
employed. To this end, in accordance with the teachings thereof, the teachings
of U.S.
Patent No. 4,272,399 are stated to be directed to a unified process for
producing high
purity synthesis gas from carbon-containing materials. More specifically,
insofar as the
mode of operation of the unified process to which the teachings of U.S. Patent
No.
4,272,399 are directed is concerned, a metal-oxygen containing material, which
can be
characterized as a heat and oxygen carrier and which can be referred to
generally as an
oxidant, is used as the transfer agent of oxygen and heat for oxidatively
gasifying carbon-
containing material. Continuing, steam, carbon dioxide, synthesis gas or
mixtures thereof
are employed to fluidize and transport the oxidant through an up-flow, co-
current system.
Thus, in accordance with the mode of operation of the subject unified process,
synthesis
gas is first oxidized and heated by the oxidant to form water and carbon
dioxide in an
oxidant reducing zone prior to contact of the oxidant and gases with the
carbon-
containing material in a gasifying zone. In addition, the carbon-containing
materials are
oxidized to predominately carbon monoxide and hydrogen in a manner such that
the
nitrogen contained in the air does not contaminate the product synthesis gas.
Furthermore, the gasification of the carbon-containing material is
accomplished by the
alternate oxidation and reduction of a fluidized oxidant. Then, after such
gasification, the
reduced oxidant, which may be in the form of the elemental metal or lower
oxidized state
is re-oxidized in an oxidizing zone and the cycle is then repeated.
[0012] Regarding further the hybrid combustion-gasification technologies
of the
advanced clean fossil fuel technologies to which reference has been had above
previously
wherein various forms of hot solids processes are employed, attention is next
directed
herein, by way of exemplification and not limitation, to U.S. Patent No.
7,083,658, which
issued on August 1, 2006 to ALSTOM Technology Ltd. The teachings of U.S.
Patent No. 7,083,658 are
considered to be representative of an exemplification of a further development
in the continuing evolution
of hybrid combustion-gasification technologies of the type wherein hot solids
processes are employed. To
this end, in accordance with the teachings thereof, the teachings of U.S.
Patent No. 7,083,658 are stated to
be directed to apparatus utilizing fossil fuels, biomass, petroleum coke, or
any other carbon bearing fuel to
produce hydrogen for power generation, which minimizes or eliminates the
release of carbon dioxide
(CO2). More specifically, insofar as the mode of operation of the apparatus to
which the teachings of
- 6 -
CA 02757824 2011-11-21
78396-168
7
U.S. Patent No. 7,083,658 are directed is concerned, a gasifier is provided
for
producing a gas product from a carbonaceous fuel, which comprises a first
chemical
process loop including an exothermic oxidizer reactor and an endothermic
reducer
reactor. Continuing, the exothermic oxidizer reactor has a CaS inlet, a hot
air inlet
and a CaSO4/waste gas outlet. Whereas, the endothermic reducer reactor has a
CaSO4 inlet in fluid 5 communication with the exothermic oxidizer reactor
CaSO4/waste gas outlet, a CaS/gas product outlet in fluid communication with
the
exothermic oxidizer reactor CaS inlet, and a materials inlet for receiving the
carbonaceous fuel. Moreover, CaS is oxidized in air in the exothermic oxidizer
reactor
to form hot CaSO4, which is discharged to the endothermic reducer reactor.
Furthermore, hot Ca504 and carbonaceous fuel that is 10 received in the
endothermic reducer reactor undergo an endothermic reaction utilizing the heat
content of the CaSO4 with the carbonaceous fuel stripping the oxygen from the
CaSO4 to form CaS and the gas product. Thereafter, the CaS is discharged to
the
exothermic oxidizer reactor, and with the gas product being discharged from
the first
chemical process loop. 15
[0013] U.S. Patent No. 4,309,198 entitled "Method of converting
liquid and/or
solid fuel to a substantially inerts-free gas," issued January 5, 1984 to
Moss. U.S.
Patent No. 4,309,198 discloses a method of converting liquid and/or solid fuel
to a
substantially inerts-free gas. U.S. Patent No. 4,309,198 also discloses the
conversion
of solid and/or liquid hydrocarbon or carbonaceous (i.e. carbon-containing)
fuels to
reducing gas, useful 20 for the production of heat, power, chemicals and for
the
reduction of metal oxides. U.S. Patent No. 4,704,136 entitled "Sulfate
reduction
process useful in coal gasification" issued November 3, 1987 to Weston. U.S.
Patent
No. 4,704,136 discloses reduction of alkaline earth metal sulfates. U.S.
Patent No.
4,704,136 also discloses gasification of coal and the like and sulfur recovery
from
calcium sulfate such as phosphogypsum. U.S. 25 Patent No. 4,704,136 also
discloses coal gasification by reducing an alkali metal sulfate and an
alkaline earth
metal sulfate to corresponding metal sulfides during gasification and
thereafter
regenerating the alkali metal sulfate while recovering sulfur.
CA 02757824 2011-11-21
78396-168
8
[0014] It is, therefore, an object of some embodiments of the present
invention
to provide a hot solids process.
[0015] It is also an object of some embodiments of the present
invention to
provide such a hot solids process 30 that is capable of generating an output.
[0016] It is another object of some embodiments of the present invention to
provide such a hot solids process that is capable of generating such an output
that is
designed to be suitable for use as an input to a petrochemical process.
[0017] It is still another object of some embodiments of the present
invention to
provide such a hot solids process that is designed to employ a portion of the
otherwise normally unusable product 5 output, which is produced from such a
petrochemical process, for purposes of generating in accordance with the
present
invention the output from the hot solids process of the present invention that
is
designed to be suitable for use as an input to such a petrochemical process.
[0018] Yet another object of some embodiments of the present
invention is to
provide such a hot solids process 10 that is relatively inexpensive to
provide, is
relatively uncomplicated to employ, and is characterized by its great
versatility insofar
as the applicability thereof to petrochemical processes is concerned.
SUMMARY OF THE INVENTION
[0018] In accordance with an embodiment of the present invention a
hot solids
process is provided, which is capable of generating a predetermined output
that is
designed to be suitable for use as an input to a petrochemical process. To
this end,
the mode of operation, in accordance with the present invention of such a hot
solids
process, is such that preferably a portion of the otherwise normally unusable
product
output, which is produced from such a petrochemical process, is designed to be
employed as an input to the hot solids process of the present invention for
purposes
of generating in accordance with the present invention the predetermined
output from
CA 02757824 2011-11-21
=
78396-168
9
the hot solids process of the present invention, which is designed to be
suitable for
use as an input to said petrochemical process.
[0019] Continuing, in accordance with an embodiment of the present
invention
the mode of operation of the hot solids process of the present invention is
such that
preferably a limestone based sorbent, such as, by way of exemplification and
not
limitation, CaS, is designed to be combusted in an oxidizing reactor, such
oxidizing
reactor preferably, by way of exemplification and not limitation, being a
circulating
bed reactor, which is designed to be selected from a group of reactors that
includes a
fixed bed reactor, a bubbling bed reactor, a circulating bed reactor, a
transport
reactor, and an entrained bed reactor, in order to thereby produce hot CaS 04
from
the combustion of such limestone based sorbent. This hot CaSO4 is then in turn
designed to be employed in a reducing reactor, such reducing reactor
preferably, by
way of exemplification and not limitation, being a circulating bed reactor,
which is
designed to be selected from a group of reactors that includes a fixed bed
reactor, a
bubbling bed reactor, a circulating bed reactor, a transport reactor, and an
entrained
bed reactor, for purposes of generating the predetermined output, which is
designed
to be suitable for use as an input to a petrochemical process.
[0020] With further regard to the mode of operation of the hot solids
process, in
some embodiments, the inputs to the oxidizing reactor, which is employed in
accordance with the mode of operation of the hot solids process of the present
invention, when the fuel that is designed to be combusted in accordance
therewith
comprises a carbonaceous fuel, such as, preferably a portion of the otherwise
normally unusable product output, which is produced from a petrochemical
process,
and wherein a portion of such otherwise normally unusable product output,
which is
produced from a petrochemical process, and which more particularly comprises
petcoke and/or oil residuals that are known to be otherwise produced as
normally
unusable product outputs from a petrochemical process, and when the
predetermined output that is being generated in accordance with the preferred
mode
of operation of the hot solids process of the present invention is designed to
be
suitable for use as an input to a petrochemical process, include CaS and air,
and the
CA 02757824 2013-07-15
= 78396-168
outputs from such an oxidizing reactor in such a case include ash, CaSO4, and
N2. Whereas,
the inputs to the reducing reactor, which is employed in accordance with the
mode of
operation of the hot solids process of the present invention, when the fuel
that is designed to
be combusted in accordance therewith comprises a carbonaceous fuel, such as,
preferably a
portion of the otherwise normally unusable product output, which is produced
from a
petrochemical process, and wherein a portion of such otherwise normally
unusable product
output, which is produced from a petrochemical process, and which more
particularly
comprises petcoke and/or oil residuals that are known to be otherwise produced
as normally
unusable product outputs from a petrochemical process, and when the
predetermined output
that is being generated in accordance with the preferred mode of operation of
the hot solids
process of the present invention is designed to be suitable for use as an
input to a
petrochemical process, include the carbonaceous fuel, CaCCP, steam, and CaSO4,
and the
output from such a reducing reactor in such a case is designed to be the
predetermined output,
which is being generated in accordance with the preferred mode of operation of
the hot solids
process of the present invention such that the predetermined output generated
from the hot
solids process of the present invention is suitable for use as an input to a
petrochemical
process.
[0020a] According to one aspect of the present invention, there is
provided a hot solids
process for generating a predetermined output suitable for use as an input to
a petrochemical
process comprising: providing a first reactor that operates as a reducing
reactor; providing a
second reactor that operates as an oxidizing reactor; supplying both a sulfur
containing
carbonaceous fuel and a source of calcium as inputs to the first reactor;
supplying air as an
input to the second reactor; effecting with the source of calcium the capture
in the first reactor
of the sulfur in the sulfur containing carbonaceous fuel so as to thereby
produce CaS in the
first reactor; effecting the discharge as an output from the first reactor of
the CaS produced in
the first reactor; supplying as an input to the second reactor the CaS
discharged as an output
from the first reactor; effecting the production of CaSO4 in the second
reactor from the CaS
supplied as an input to the second reactor; effecting the discharge as an
output from the
second reactor of the CaSO4 produced in the second reactor; supplying the
CaSO4 discharged
as an output from the second reactor as an input to the first reactor;
effecting in the first
- 9a -
CA 02757824 2013-07-15
= 78396-168
reactor the generation of a predetermined output suitable for use as an input
to a
petrochemical process by virtue of the utilization of the CaSO4 supplied to
the first reactor
from the second reactor both as an oxygen source and as a heat source;
connecting in
operative relation to the hot solids process a petrochemical process operable
for purposes of
producing a usable product output as well as an otherwise normally unusable
product output;
effecting the discharge as an output from the first reactor of the
predetermined output suitable
for use as an input to a petrochemical process produced in the first reactor;
supplying as an
input to the petrochemical process the predetermined output suitable for use
as an input to a
petrochemical process that is discharged as an output from the first reactor;
effecting the
discharge as an output from the petrochemical process the otherwise normally
unusable
product output; and supplying as an input to the first reactor the otherwise
normally unusable
product output.
[0020b1 According to another aspect of the present invention, there is
provided a hot
solids process for generating a predetermined output suitable for use as an
input to a
petrochemical process comprising: providing a first reactor that operates as a
reducing
reactor; providing a second reactor that operates as an oxidizing reactor;
supplying both a
sulfur containing carbonaceous fuel and an oxide as inputs to the first
reactor; supplying air as
an input to the second reactor; effecting with the oxide the capture in the
first reactor of the
sulfur in the sulfur containing carbonaceous fuel; effecting the production of
an oxide in the
second reactor; effecting the discharge as an output from the second reactor
of the oxide
produced in the second reactor; supplying the oxide discharged as an output
from the second
reactor as an input to the first reactor; effecting in the first reactor the
generation of a
predetermined output suitable for use as an input to a petrochemical process
by virtue of the
utilization of the oxide supplied to the first reactor from the second reactor
both as an oxygen
source and as a heat source; connecting in operative relation to the hot
solids process a
petrochemical process operable for purposes of producing a usable product
output as well as
an otherwise normally unusable product output; effecting the discharge as an
output from the
first reactor of the predetermined output suitable for use as an input to a
petrochemical process
produced in the first reactor; supplying as an input to the petrochemical
process the
predetermined output suitable for use as an input to a petrochemical process
that is discharged
- 9b -
CA 02757824 2013-07-15
= 78396-168
as an output from the first reactor; effecting the discharge as an output from
the petrochemical
process the otherwise normally unusable product output; and supplying as an
input to the first
reactor the otherwise normally unusable product output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 of the drawing is a schematic diagram of a preferred
embodiment of
the mode of operation of a hot solids process that functions in accordance
with the present
invention to generate a predetermined output, which is suitable for use as an
input to a
petrochemical process, the latter petrochemical process also being
schematically depicted as
well in Figure 1.
1 0 DETAILED DESCRIPTION
- 9c -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
[0022] Referring now to Figure 1 of the drawing, there is depicted
therein a
schematic diagram of a hot solids process, generally denoted by the reference
numeral 10
in Figure 1 of the drawing, that is designed to be operable in accordance with
the present
invention for purposes of generating a predetermined output, such as, by way
of
exemplification and not limitation, H2 or syngas and steam, and with the
latter
predetermined output being denoted by the arrow 12 in Figure 1 of the drawing.
The
predetermined output 12 from the hot solids process 10 is designed in
accordance with the
present invention to be suitable for use as an input to a petrochemical
process, the latter
petrochemical process being denoted generally by the reference numeral 14 in
Figure 1 of
the drawing. To this end, the mode of operation, in accordance with the
present invention
of the hot solids process 10, is such that preferably a portion of the
otherwise normally
unusable product output, denoted by the reference numeral 16 in Figure 1 of
the drawing,
which is produced from the petrochemical process 14, is designed to be
utilized as an
input to the hot solids process 10 of the present invention for purposes of
generating in
accordance with the present invention the predetermined output 12 from the hot
solids
process 10 of the present invention that is designed to be suitable for use as
an input to the
petrochemical process, which is schematically depicted at 14 in Figure 1 of
the drawing.
The remainder, which is denoted by the reference numeral 17 in Figure 1 of the
drawing,
of the otherwise normally unusable product output 16 that is produced from the
petrochemical process 14, which is schematically depicted in Figure 1 of the
drawing, is
designed so as to be capable of being discharged from the petrochemical
process 14 in
any conventional manner, which is deemed to be suitable for use for such a
purpose.
[0023] Continuing, the hot solids process of the present invention in
accordance
with the preferred mode of operation thereof is designed to utilize air; a
carbonaceous
fuel, such as, by way of exemplification and not limitation, the portion of
the otherwise
normally unusable product output, which is 16 from a petrochemical process,
such as, the
petrochemical process that is schematically depicted at 14 in Figure 1 of the
drawing, and
wherein such a portion of the otherwise normally unusable product output 16,
which is
produced from the petrochemical process 14, and which preferably comprises
petcoke
and/or oil residuals that are known to be producible as an otherwise normally
unusable
product output from a petrochemical process, such as, the petrochemical
process 14 that
is schematically depicted in Figure 1 of the drawing; a source of calcium
(e.g., calcium
oxide); and steam to effect therewith the generation of the predetermined
output 12,
- 10 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
which is designed to be suitable for use as an input to a petrochemical
process, such as,
the petrochemical process that is schematically depicted at 14 in Figure 1 of
the drawing.
10024] With further reference to Figure 1 of the drawing, a reducing
reactor,
denoted generally by the reference numeral 18 in Figure 1 of the drawing,
selected from a
group of reactors that includes a fixed bed reactor, a bubbling bed reactor, a
circulating
bed reactor, a transport reactor and an entrained bed reactor and preferably
comprising a
circulating bed reactor, and an oxidizing reactor, denoted generally by the
reference
numeral 20 in Figure 1 of the drawing, selected from a group of reactors that
includes a
fixed bed reactor, a bubbling bed reactor, a circulating bed reactor, a
transport reactor and
an entrained bed reactor and preferably comprising a circulating bed reactor,
are each
designed to be employed in the hot solids process 10 of the present invention,
in
accordance with the preferred mode of operation thereof. Continuing, in
accordance with
the preferred embodiment of the hot solids process 10 of the present
invention, the
carbonaceous fuel, such as, by way of exemplification and not limitation, the
portion of
the otherwise normally unusable product output 16 that is produced from the
petrochemical process, which is schematically depicted at 14 in Figure 1 of
the drawing,
that is designed to be supplied from the petrochemical process 14 as an input
to the
reducing reactor 18, is designed to be burned in the reducing reactor 18
preferably using
air indirectly. To this end, a source of calcium (i.e., calcium oxide), and
with the latter
source of calcium being denoted by the arrow 22 in Figure 1 of the drawing,
which is
designed to be added, in accordance with the preferred mode of operation of
the hot solids
process 10 of the present invention, is also supplied, by way of
exemplification and not
limitation, as an input to the reducing reactor 18. However, such source of
calcium 22
could equally well be supplied elsewhere in the hot solids process 10 of the
present
invention other than as an input to the reducing reactor 18, without departing
from the
essence of the present invention. Such source of calcium 22, which may be
selected from
the group including of limestone (CaCO3) or lime (CaO) or gypsum or the spent
bed
material from a circulating bed boiler, by way of exemplification and not
limitation,
preferably comprises limestone (CaCO3). With further reference thereto, such
limestone
(CaCO3) 22, which is added in accordance with the preferred mode of operation
of the
hot solids process 10 of the present invention, is designed to be operative to
capture in the
reducing reactor 18 the sulfur (S), which is contained in the carbonaceous
fuel 16, such as
to thereby produce calcium sulfide (CaS) therefrom in the reducing reactor 18.
- 11 -
CA 02757824 2011 10 05
WO 2010/117772
PCT/US2010/029179
[0025] Continuing, such calcium sulfide (CaS), as denoted by the arrow 24
in
Figure 1 of the drawing, is then made to exit from the reducing reactor 18 as
an output
therefrom, whereupon such calcium sulfide (CaS) 24 is designed to be supplied
as an
input to the oxidizing reactor 20. In the oxidizing reactor 20, this calcium
sulfide (CaS)
24 is designed to be burned in a heat liberation reaction with air, and with
the latter air
being denoted by the arrow 26 in Figure 1 of the drawing, which is designed to
be
supplied as an input to the oxidizing reactor 20, such as to thereby effect
the production
therefrom of calcium sulfate (CaSO4) in the oxidizing reactor 20. This calcium
sulfate
(CaSO4), as is denoted by the arrow 28 in Figure 1 of the drawing, is then
designed to be
made to exit as an output from the oxidizing reactor 20, whereupon this
calcium sulfate
(CaSO4) 28 is designed to be cycled to the reducing reactor 18 as an input
thereto for
purposes of thereby producing therefrom the supply of oxygen and of heat that
is required
both in order to burn the carbonaceous fuel 16 and in order to reduce the
calcium sulfate
(CaSO4) 28 to calcium sulfide (CaS) 24 in the reducing reactor 18, such as to
thereby
permit a continuous recycling thereof to be had. With further regard thereto,
in
accordance with the preferred mode of operation of the hot solids process 10
of the
present invention that is depicted in Figure 1 of the drawing, steam, and with
the latter
steam being denoted by the arrow 30 in Figure 1 of the drawing, is preferably
also
supplied as an input to the reducing reactor 18.
[0026] Referring once again to Figure 1 of the drawing, the burning of
the
carbonaceous fuel 16 in the reducing reactor 18 is designed to be such that
the
predetermined output 12 is thus capable of being generated in the reducing
reactor 18,
and with the carbon and the hydrogen contained in the carbonaceous fuel 16
being
converted, in the course of such burning of the carbonaceous fuel 16 to a
product gas,
such as, H2 or syngas, in a suitable form such that such product gas, with the
possible
addition thereto of steam is capable of being made to function as the
predetermined
output 12 from the hot solids process 10 of the present invention, in
accordance with the
preferred mode of operation thereof, which is designed to be suitable for use
as an input
to a petrochemical process, such as, by way of exemplification and not
limitation, the
predetermined process, which is schematically depicted at 14 in Figure 1 of
the drawing.
In addition, as is indicated in Figure 1 of the drawing by the arrow that is
denoted therein
by the reference numeral 32, the nitrogen (N2), which remains from the
oxidation of the
calcium sulfide (CaS) 24 that takes place in the oxidizing reactor 20, is
designed to be
- 12 -
CA 02757824 2011 10 05
WO 2010/117772 PCT/US2010/029179
made to exit through an outlet (not shown in the interest of maintaining
clarity of
illustration in the drawing) with which the oxidizing reactor 20 is designed
to be suitably
provided for this purpose.
[0027] For purposes of completing the description of the nature of the
construction and of the mode of operation in accordance with the present
invention of
both the hot solids process 10 and the petrochemical process 14, which are
schematically
depicted in Figure 1 of the drawing, reference will once again be had herein
to Figure 1 of
the drawing. To this end, in accordance with the mode of operation of the
present
invention the hot solids process 10 is suitably constructed so as to be
capable of
generating a predetermined output 12, such as, by way of exemplification and
not
limitation, steam and H2 or syngas, that is designed to be suitable for use as
an input to a
petrochemical process, such as, for example, the petrochemical process, which
is
schematically depicted in Figure 1 of the drawing.
[0028] With further reference to the petrochemical process, which is
schematically depicted at 14 in Figure 1 of the drawing, in accordance with
the
conventional mode of operation of such petrochemical processes, crude, which
is denoted
by the arrow 34 in Figure 1 of the drawing, is designed to be supplied as an
input to the
petrochemical process 14. Continuing with the discussion of the mode of
operation
thereof, the crude 34 and the input 12, the latter being produced as an output
from the hot
solids process 10 of the present invention, are designed to be supplied as
inputs to the
petrochemical process 14 such that in accordance with conventional practice
the crude 34
and the input 12, which are supplied as inputs to the petrochemical process
14, are
designed to be converted in known fashion through operation of the
petrochemical
process 14 so as to thereby produce both a usable product output, the latter
usable product
output being denoted by the arrow 36 in Figure 1 of the drawingõ that commonly
consists
of one or more of the following: diesel fuel, gasoline, etc., and an otherwise
normally
unusable product output 16 to which reference has been had herein previously.
With
further regard thereto, in accordance with the present invention a portion of
the otherwise
normally unusable product output 16, which preferably comprises, by way of
exemplification and not limitation, petcoke and/or oil residuals, from the
petrochemical
process that is depicted at 14 in Figure 1 of the drawing, is designed to be
employed in
accordance with the present invention as an input to the hot solids process 10
for purposes
of effecting, in accordance with the present invention, the production within
the hot solids
- 13 -
CA 02757824 2011-11-21
. ,
78396-168
14
process 10 of the predetermined output 12 that is designed to be suitable for
purposes of being employed as the input 12 to the petrochemical process, which
is
schematically depicted at 14 in Figure 1 of the drawing. The remainder of the
otherwise normally unusable product output, such remainder being depicted in
Figure
1 of the drawing by the arrow that is denoted therein by the reference numeral
17,
which is produced from the petrochemical process 14 that is schematically
depicted
in Figure 1 of the drawing, is suitably designed such as to be capable of
being
discharged from the petrochemical process 14 in any conventional manner, which
is
deemed to be suitable for use for such a purpose.
[0030] While the embodiments of the present invention described
hereinbefore
included a calcium oxide, the invention contemplates that the oxide may
include a
metal oxide, for example, formed of iron such as FeO.
[0031] While the present disclosure has been described with
reference to
various exemplary embodiments, it will be understood by those skilled in the
art that
various changes may be made and equivalents may be substituted for elements
thereof without departing from the scope of the invention. In addition, many
modifications may be made to adapt a particular situation or material to the
teachings
of the invention without departing from the essential scope thereof.
Therefore, it is
intended that the invention not be limited to the particular embodiment
disclosed as
the best mode contemplated for carrying out this invention, but that the
invention will
include all embodiments falling within the scope of the appended claims.
