Abstract: The present invention is an integrated process and apparatus for supplying at least a portion of the reducing gas feedstock to a reduction reactor, such as a reactor for the direct reduction of iron, wherein the reducing gas contacts a feed material at a mean operating gas pressure and effects reduction of the feed material to provide a reduced product. The integrated process includes gasifying a hydrocarbonaceous feedstock in a partial oxidation reaction to produce a synthesis gas which comprises hydrogen, and carbon monoxide at a pressure substantially greater than the mean operating gas pressure in the reduction reactor. The synthesis gas is expanded to lower its pressure to substantially the mean operating gas pressure in the DRI reduction reactor to thereby form the reducing gas feedstock at the pressure conditions used for the DRI reaction.

Abstract: A method facilitating the deslagging of a partial oxidation reactor used to produce syngas is disclosed. The slag comprises vanadium trioxide and a siliceous material that accumulate on the interior walls of the partial oxidation reactor as a byproduct of the syngas production. The deslagging is accomplished by controlled oxidation, wherein the vanadium to glass weight ratio is maintained to at least about 3:2, operating the reactor at a temperature of at least about 2000.degree. F, and maintaining controlled oxidation conditions sufficient to convert the vanadium trioxide in the slag to vanadium pentoxide.

Abstract: Method and apparatus for deslagging a gasifier's combustion chamber which has accumulated a residual solidified slag as a result of the fuel being combusted. The gasifier is provided with means for liquefying the slag into a flowable state by heating the combustion chamber to a temperature of which the slag will flow. To epitomize the gasifiers' deslagging mode, the combustion chamber is provided with an array of strain monitoring or measuring load cells which are located to detect and collectively respond to movement at the combustion chamber floor whereby to control the slag removing procedure.

Abstract: The progress and completion of slag removal from the quench chamber of a partial oxidation reactor during controlled oxidation can be monitored by measuring such quench water parameters as pH, conductivity, total dissolved solids, and sulfate concentration.

Abstract: A selective deslagging operation is conducted in a partial oxidation reactor wherein a first predetermined portion of the reactor is selectively deslagged by derivatization while limiting derivatizing slag conditions in a second predetermined portion of the reactor. Selective deslagging can be accomplished by controlled oxidation conditions in the reactor that vary from one predetermined portion of the reactor to another. Thus, the slag present in one predetermined portion is derivatized and fluidized for removal from the reactor at a faster rate than the slag present in another portion of the reactor, which is not derivatized or is subjected to more limited derivatizing slag conditions. Derivatized slag can be differentiated from non-derivatized slag that does not flow or more limited derivatized slag that has a lower mass flow rate then the derivatized slag at conditions of controlled oxidation. The derivatized slag can then be selectively removed because it has attained a lower fluidizing temperature.

Abstract: A gasifier for partially combusting a carbonaceous fuel mixture in the combustion chamber of the gasifier. The latter includes a water bath into which the hot effluent or products of combustion are immersed, including a synthetic gas. The products of combustion are directed into the bath by way of a constricted throat section. To avoid excessive erosion action and/or thermal shock to the throat section as a result of exposure to the effluent's high temperatures, the throat section is structured with an internal framework of pipes. The framework is communicated with a pressurized source of a cooling fluid, preferably water, whereby to cool the throat section sufficiently to counteract the ill effects of exposure to contact with the high temperature effluent.