Synthesis Gas. James G. Speight

sodium carbonate, potassium sulfide, sodium sulfide, and the like) will catalyze the steam gasification of feedstocks. The order of catalytic activity of alkali metals on the gasification reaction is:

      Catalyst amounts on the order of 10 to 20% w/w potassium carbonate will lower bituminous coal gasifier temperatures from 925°C (1695^oF) to 700°C (1090^oF) and that the catalyst can be introduced to the gasifier impregnated on coal or char. In addition, tests with potassium carbonate showed that this material also acts as a catalyst for the methanation reaction. In addition, the use of catalysts can reduce the amount of tar formed in the process. In the case of catalytic steam gasification of coal, carbon deposition reaction may affect catalyst life by fouling the catalyst active sites. This carbon deposition reaction is more likely to take place whenever the steam concentration is low.

Ruthenium-containing catalysts are used primarily in the production of ammonia. It has been shown that ruthenium catalysts provide five to 10 times higher reactivity rates than other catalysts. However, ruthenium quickly becomes inactive due to its necessary supporting material, such as activated carbon, which is used to achieve effective reactivity. However, during the process, the carbon is consumed, thereby reducing the effect of the ruthenium catalyst.

      Catalysts can also be used to favor or suppress the formation of certain components in the gaseous product by changing the chemistry of the reaction, the rate of reaction, and the thermodynamic balance of the reaction. For example, in the production of synthesis gas (mixtures of hydrogen and carbon monoxide), methane is also produced in small amounts. Catalytic gasification can be used to either promote methane formation or suppress it.

       2.5.5.3 Water Gas Shift Reaction

      The water gas shift reaction (shift conversion) is necessary because the gaseous product from a gasifier generally contains large amounts of carbon monoxide and hydrogen, plus lesser amounts of other gases. Carbon monoxide and hydrogen (if they are present in the mole ratio of 1:3) can be reacted in the presence of a catalyst to produce methane. However, some adjustment to the ideal (1:3) is usually required and, to accomplish this, all or part of the stream is treated according to the waste gas shift (shift conversion) reaction. This involves reacting carbon monoxide with steam to produce a carbon dioxide and hydrogen whereby the desired 1:3 mole ratio of carbon monoxide to hydrogen may be obtained:

      Even though the water gas shift reaction is not classified as one of the principal gasification reactions, it cannot be omitted in the analysis of chemical reaction systems that involve synthesis gas. Among all reactions involving synthesis gas, this reaction equilibrium is least sensitive to the temperature variation – the equilibrium constant is least strongly dependent on the temperature. Therefore, the reaction equilibrium can be reversed in a variety of practical process conditions over a wide range of temperature.

      The water gas shift reaction in its forward direction is mildly exothermic and although all of the participating chemical species are in gaseous form, the reaction is believed to be heterogeneous insofar as the chemistry occurs at the surface of the feedstock and the reaction is actually catalyzed by carbon surfaces. In addition, the reaction can also take place homogeneously as well as heterogeneously and a generalized understanding of the water gas shift reaction is difficult to achieve. Even the published kinetic rate information is not immediately useful or applicable to a practical reactor situation.

      Synthesis gas from a gasifier contains a variety of gaseous species other than carbon monoxide and hydrogen. Typically, they include carbon dioxide, methane, and water (steam). Depending on the objective of the ensuing process, the composition of synthesis gas may need to be preferentially readjusted. If the objective of the gasification process is to obtain a high yield of methane, it would be preferred to have the molar ratio of hydrogen to carbon monoxide at 3:1:

On the other hand, if the objective of generating synthesis gas is the synthesis of methanol via a vapor-phase low-pressure process, the stoichiometrically consistent ratio between hydrogen and carbon monoxide would be 2:1. In such cases, the stoichiometrically consistent synthesis gas mixture is often referred to as balanced gas, whereas a synthesis gas composition that is substantially deviated from the principal stoichiometry of the reaction is called unbalanced gas. If the objective of synthesis gas production is to obtain a high yield of hydrogen, it would be advantageous to increase the ratio of hydrogen to carbon monoxide by further converting carbon monoxide (and water) into hydrogen (and carbon dioxide) via the water gas shift reaction.

      The water gas shift reaction is one of the major reactions in the steam gasification process, where both water and carbon monoxide are present in ample amounts. Although the four chemical species involved in the water gas shift reaction are gaseous compounds at the reaction stage of most gas processing, the water gas shift reaction, in the case of steam gasification of feedstock, predominantly takes place on the solid surface of feedstock (hetero-geneous reaction). If the product synthesis gas from a gasifier needs to be reconditioned by the water gas shift reaction, this reaction can be catalyzed by a variety of metallic catalysts.

      Choice of specific kinds of catalysts has always depended on the desired outcome, the prevailing temperature conditions, composition of gas mixture, and process economics. Typical catalysts used for the reaction include catalysts containing iron, copper, zinc, nickel, chromium, and molybdenum.

       2.5.5.4 Carbon Dioxide Gasification

      The reaction of carbonaceous feedstocks with carbon dioxide produces carbon monoxide (Boudouard reaction) and (like the steam gasification reaction) is also an endothermic reaction:

      The reverse reaction results in carbon deposition (carbon fouling) on many surfaces including the catalysts and results in catalyst deactivation.

      This gasification reaction is thermodynamically favored at high temperatures (>680°C, >1255^oF), which is also quite similar to the steam gasification. If carried out alone, the reaction requires high temperature (for fast reaction) and high pressure (for higher reactant concentrations) for significant conversion but as a separate reaction a variety of factors come into play: (i) low conversion, (ii) slow kinetic rate, and (iii) low thermal efficiency.

      Also, the rate of the carbon dioxide gasification of a feedstock is different from the rate of the carbon dioxide gasification of carbon. Generally, the carbon-carbon dioxide reaction follows a reaction order based on the partial pressure of the carbon dioxide that is approximately 1.0 (or lower) whereas the feedstock-carbon dioxide reaction follows a reaction order based on the partial pressure of the carbon dioxide that is 1.0 (or higher). The observed higher reaction order for the feedstock reaction is also based on the relative reactivity of the feedstock in the gasification system.

       2.5.5.5 Hydrogasification

      Not all high heat-content (high-Btu) gasification technologies depend entirely on catalytic methanation and, in fact, a number of gasification processes use hydrogasification, that is, the direct addition of hydrogen to feedstock under pressure to form methane.

      The hydrogen-rich gas for hydrogasification can be manufactured from steam and char from the hydrogasifier. Appreciable quantities of methane are formed directly in the primary gasifier and the heat released by methane formation is at a sufficiently high temperature to be used in the steam-carbon reaction to produce hydrogen so that less oxygen is used to produce heat for