Abstract: Disclosed in a pox process for producing hydrogen and carbon monoxide gaseous mixtures. The specific oxygen consumption is maintained between 212 to 235 employing a hydrocarbon feed gas while controlling soot production to 0.1 to 3 weight percent of the total feed carbon.

Abstract: Low sulfur, iron and calcium containing solid carbonaceous fuel having a high melting point ash is mixed with a sufficient amount of iron sulfide containing material or supplemental iron and sulfur containing reactant materials that react in the reaction zone to produce iron and sulfur containing compounds. The mixture of materials is reacted in a free-flow gasifier by partial oxidation to produce a raw gas stream of synthesis gas, reducing gas or fuel gas, containing entrained particulate matter including molten slag. By the process, sufficient iron and sulfur are in the reaction zone so that the melting point of the fuel ash is decreased, and the mole ratio H.sub.2 S/H.sub.2 +CO in the raw gas stream is greater than 0.01. Further, the amount of iron in the molten ash is greater than 10.0 wt. %, and preferably at least 14 wt. % of the molten ash. By this means, the fluid temperature of the molten ash entrained in the raw gas stream is reduced at least 100.degree. F.

Abstract: An aqueous dispersion of unreacted particulate petroleum coke substantially comprising carbon and containing a small amount of ash substantially comprising vanadium constituents and other materials from a process for the partial oxidation of petroleum coke to produce synthesis gas is mixed with C.sub.4 to C.sub.8 acyclic and/or cyclic alkanols and a frothing agent. After pH adjustment, if necessary, the mixture is subjected to aeration with or without mechanical agitation in a froth flotation zone. About 60 to 95 wt. % of the unconverted particulate petroleum coke (basis carbon) particles float in the froth layer that is formed. The remainder of the unconverted petroleum coke comprising coarser particles is suspended in a bottom aqueous dispersion on which the froth layer floats. In addition, selective separation of the vanadium constituents in the unconverted petroleum coke ash takes place.

Abstract: A method is provided for turning down from design conditions or below the output of raw product gas from a free-flow partial oxidation gas generator, or when operating below design conditions the output of raw product gas from the gas generator may be turned up while maintaining substantially constant the efficiency of the gas generation, or conversion of the fuel to gas, and the quality of the gas produced. The flow rates of the feedstreams to the burner are adjusted down or up a predetermined amount for each of the feedstreams to the burner to obtain a specified output of raw product gas while maintaining substantially constant in the reaction zone the levels of O/C atomic ratio and the H.sub.2 O/fuel weight ratio. Further, a pressure adjustment in the system is made which produces a corresponding adjustment to the pressure in the gas generator. The adjusted pressure is a direct function of the adjusted flow rate for the adjusted fuel or oxidant feedstream.

Abstract: Synthesis gas is produced by the partial oxidation of a fuel feedstock comprising sulfur-containing petroleum coke and/or heavy liquid hydrocarbonaceous fuel and having a nickel and iron-containing ash in a free-flow refractory lined partial oxidation reaction zone. The production of toxic nickel subsulfide (Ni.sub.3 S.sub.2) in said slag is prevented, and there is a substantial reduction in the concentration of H.sub.2 S+COS in the raw product gas stream by introducing an iron-containing additive into the reaction zone along with the feed. The weight ratio of iron-containing additive to ash in the fuel feedstock is in the range of about 0.5 to 10.0. The weight ratio of iron to nickel in said mixture of iron-containing additive and fuel feedstock is greater than 0.33. The additive combines with at least a portion of the nickel and iron constituents and sulfur found in the feedstock to produce a very fluid sulfide phase of iron and nickel, and an Fe, Ni alloy phase.

Abstract: Process for producing synthesis gas, reducing gas, or fuel gas substantially free-from volatile metal hydride impurities e.g. a hydride of arsenic, germanium, antimony, lead, tin, silicon, and mixtures thereof starting with the partial oxidation of liquid hydrocarbon fuel and/or solid carbonaceous fuel containing at least one mtal impurity from Group IV A and V A of the Periodic Table of Elements. At least one intermetallic reaction product of said metal impurity from Group IV A and V A leaves the gas generator in admixture with the hot raw process gas stream. A metal hydride forms when the gas stream is quench cooled and scrubbed with water. The metal hydride is then decomposed into its elements e.g. H.sub.2 and a Group IV A aor V A metal when the cooled and scrubbed gas stream contacts a solid sorbent material having a minimum surface area of 10 square meters per gram in a gas-solids contacting zone at a temperature in the range of about 0.degree. C. to 350.degree. C.

Abstract: Synthesis gas is produced by the partial oxidation of a feedstock comprising petroleum coke and/or heavy liquid hydrocarbonaceous fuel containing sulfur and having an ash that contains nickel, vanadium and a comparatively high level of silicon. An iron and calcium-containing additive is introduced into the reaction zone along wth the feed. Separate portions of the additive (i) combine with a portion of the nickel, calcium and sulfur to generate a liquid phase washing agent that collects and transports out of the gas generator a portion of the vanadium-containing oxide laths and spinels and other ash components; and (ii) combine with a portion of the nickel, calcium and silicon to generate a liquid oxide-silicate phase that fluxes e.g. dissolves substantially all of the remaining portion of said vanadium-containing oxide laths and spinels and other ash components.

Abstract: Aqueous slurries of solid carbonaceous fuel having an increased reactivity of the solid material are produced by maintaining the solid carbonaceous fuel-water slurry at a temperature in the range of about 300.degree. to 650.degree. F. and a pressure in the range of about 100 to 3500 psia and sufficient to maintain the H.sub.2 O in the slurry in liquid phase; at substantially constant temperature depressurizing said slurry to a pressure in the range of about above atmospheric to 250 psia above that in the reaction zone of a partial oxidation gas generator, thereby partially vaporizing the water in the slurry and producing steam. After depressurizing, the slurry is cooled so that the solid particles drop in temperature about 2.degree. F. to 10.degree. F. and the water in the slurry drops in temperature about 100.degree. F. to about 200.degree. F.

Abstract: Control process for producing an aqueous slurry of solid carbonaceous fuel having a desired solids concentration for feed to a partial oxidation gas generator by grinding together in a size reduction zone a recycle aqueous slurry stream comprising carbon-containing particulate solids, a stream of solid carbonaceous fuel, and a specific amount of make-up water. No valves are in the line or path between the size reduction zone and the feed tanks for the solid carbonaceous fuel and recycle aqueous slurry. A system control unit automatically calculates the amount of make-up water and provides a corresponding signal to control the flow rate. Input signals that are provided to the system control unit include those corresponding to the weigh belt feeder speed and moisture content for the solid carbonaceous fuel; and pump speed, weight fraction, temperature, and density of the solids for the slurry of recycle particulate solids.

Abstract: The temperature of a burner in the reaction zone of a partial oxidation gas generator is controlled so that there is substantially no condensation of H.sub.2 O from the hot raw product gas on the surface of the burner. Burner corrosion is thereby reduced. In the method, burner coolant is introduced into the burner at a pressure greater than that in the reaction zone and at a temperature in the range of about 5.degree. to 50.degree. F. higher than the dew point of the raw product gas contacting the burner in the reaction zone. The heated water coolant leaving the burner flows to a pressurized receiving vessel and its temperature is reduced by expansion into a feed vessel. Saturated steam is produced from a portion of the flashed water and is separated in the feed vessel for use as a heat source. Steam condensate is thereby produced and recycled to the feed vessel as make-up. The cooled liquid water coolant is then pumped into the inlet to the burner at a higher pressure than that in the feed vessel.

Abstract: An ash fusion temperature reducing agent comprising a mixture of about 70-97 wt. % of an iron compound and the remainder comprising a silicon compound is mixed with an ash-containing fuel comprising liquid hydrocarbonaceous material and/or petroleum coke. The comminuted mixture is reacted in a free-flow partial oxidation reaction zone with a free-oxygen containing gas in the presence of a temperature moderator to produce a hot raw effluent gas stream comprising H.sub.2 +CO along with molten ash having a reduced initial deformation temperature. The weight ratio of ash fusion temperature reducing agent to ash in said ash-containing fuel is in the range of about 0.5 to 10, and the weight ratio of iron oxide to SiO.sub.2 in said molten ash is about 1.5, or more. The molten ash is then separated from the hot raw effluent gas stream.

Abstract: An aqueous dispersion of unreacted particulate petroleum coke substantially comprising carbon and containing a small amount of ash substantially comprising vanadium constituents and other materials from a process for the partial oxidation of petroleum coke to produce synthesis gas is mixed with a K.sup.+ amyl xanthate vanadium collection agent and a frothing agent. After pH adjustment, if necessary, the mixture is subjected to aeration with or without mechanical agitation in a froth flotation zone. About 70 to 95 wt. % of the unconverted particulate petroleum coke particles (basis carbon) float in the froth layer that is formed. The remainder of the unconverted petroleum coke comprising coarser particles is suspended in a bottom aqueous dispersion on which the froth layer floats. In addition, selective separation of the vanadium constituents in the unconverted petroleum coke ash takes place.

Abstract: An ash fusion temperature reducing agent comprising a comminuted ore mixture of the silicates of iron, calcium, magnesium and aluminum is mixed with an ash containing pumpable liquid hydrocarbonaceous material to produce Mixture A. Mixture A is reacted with a free-oxygen containing gas in a partial oxidation gas generator. A hot raw effluent gas stream comprising H.sub.2 +CO along with molten ash having a reduced ash fusion temperature are produced at a lower temperature. Alternatively, Mixture A may be first introduced into a coking zone and converted into petroleum coke in which the ash fusion temperature reducing agent is dispersed throughout. The petroleum coke is then introduced into the partial oxidation gas generator where the hot raw effluent gas stream comprising H.sub.2 +CO is produced along with molten petroleum coke ash having a reduced ash fusion temperature.

Abstract: Synthesis gas is produced by the partial oxidation of a fuel feedstock comprising a heavy liquid and/or petroleum coke having a nickel, iron, and vanadium-containing ash. A copper-containing additive is introduced into the reaction zone along with the feed. The additive combines with at least a portion of the nickel and iron constituents and the sulfur found in the feedstock to produce a liquid phase washing agent that collects and transports at least a portion of the vanadium-containing oxide laths and spinels and other ash components out of the reaction zone. In another embodiment, a minor amount of a second additive comprising a compound of an element selected from the group consisting of iron, calcium, magnesium, chromium, and mixtures thereof is introduced into the partial oxidation reaction zone along with the fuel feedstock and the copper-containing additive.

Abstract: An apparatus is provided for the partial oxidation of a high metals or ash containing liquid hydrocarbonaceous fuel or a slurry of solid carbonaceous fuel to simultaneously produce saturated and unsaturated raw streams of synthesis gas, reducing gas, or fuel gas. Two continuous partial oxidation reactions in two separate reaction zones go on simultaneously. The fuel feed to the first partial oxidation zone is said fresh high metals or ash containing fuel. The raw product gas stream from the first partial oxidation zone is split into first and second split gas streams. The first split gas stream may be cooled in a radiant and/or convection type gas cooler without fouling heat exchange surfaces. The fuel feed to the second partial oxidation zone is a pumpable slurry which is prepared from the entrained matter that is separated from said gas streams during quench cooling and cleaning operations and which contains a comparatively high amount of metals and/or ash.

Abstract: A partial oxidation process for the production of a stream of mixed gases comprising H.sub.2 and CO. An aqueous particulate solid carbonaceous fuel slurry feedstream is preheated by indirect heat exchange with a process-derived stream of skimmed gases substantially comprising H.sub.2 O. The aqueous carrier of the slurry is vaporized by introducing superheated steam directly into the slurry pipeline. A suspension of particulate solid carbonaceous fuel entrained in a gaseous mixture substantially comprising steam e.g. about 90 to 99.9 wt. % H.sub.2 O and about 0.1 to 10 wt. % of a CO.sub.2 -containing gas mixture is produced. The suspension of solid fuel in the gaseous mixture is then separated in a skimming operation into an overhead gas stream substantially comprising steam, as previously described, and a bottom stream comprising particulate solid carbonaceous fuel with the remainder of said gaseous mixture.

Abstract: Aqueous slurries of solid carbonaceous fuel that include a novel highly converted sulfonated surfactant derived from a suspension of low rank coal and coal derived creosote oil for reducing the viscosity and increasing the solids content of the aqueous slurry.

Abstract: A clear stable motor fuel composition having an improved octane rating which comprises about 2.0 to 10.0 volume percent of an alcohol selected from the group consisting of methanol, ethanol, tertiary butyl alcohol, isopropanol, and mixtures thereof; about 0.10 to 0.50 weight percent water; about 0.10 to 3.0 weight percent of a nonionic adduct of alkylphenol and ethylene oxide surfactant having 9 to 24 carbon atoms in the alkyl group and 6-10.0 ethylene oxide groups; and the remainder of said clear stable motor fuel composition is gasoline.

Abstract: The soot-water dispersion that is produced by quenching and/or scrubbing the raw effluent gas stream from a partial oxidation gas generator in a gas quench cooling and/or scrubbing zone is resolved in a decanter using two different liquid organic extractants. Advantageously, liquid organic by-products from an oxo or oxyl process which may contain harmful water soluble constituents may be used as a major portion of the liquid organic extractant. The dispersion of soot and co-extractants that is produced may be safely disposed of as a portion of the feed to the gas generator without polluting the environment. A novel vertical decanter is provided comprising a vertical cylindrical vessel with separate inner and outer coaxial concentric conduits that pass down through the central axial flanged inlet in the upper head of the vessel. The mixture of soot-water dispersion and first liquid organic extractant i.e.

Abstract: A clear stable motor fuel composition having an improved octane rating comprising alcohol selected from the group consisting of methanol in the amount of about 2.0 to 5.0 vol. %, ethanol in the amount of about 2.0 to 10.0 vol. %, and mixtures thereof in the amount of about 3 to 9.0 vol. %; about 2.0 to 10 vol. % of a cosolvent alcohol selected from the group consisting of tertiary butyl alcohol, isopropanol, and mixtures thereof; water to provide a total water concentration of about 0.1 to 0.5 wt. % (basis weight of motor fuel composition); about 0.01 to 3.0 weight percent (basis weight of motor fuel composition) of a nonionic ethoxylated bisphenol surfactant; and the balance of said motor fuel composition comprising gasoline.