Mild catalytic steam gasification process

a gasification process and steam technology, applied in the field of low temperature catalytic gasification of carbonaceous materials, can solve the problems of coal gasification systems and designs, non-catalytic, and high cost of process operation, and achieve the effect of little additional treatment and greater carbon conversion

Inactive Publication Date: 2007-01-04
SURE CHAMPION INVESTMENT LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0020] It has been found that using calcium salts to remove or “trap” carbon dioxide and other oxidizing agents from a catalytic coal gasification environment can shift the kinetics towards greater carbon conversion to methane, and can also drive the conversion of CO to CO2 such that the process can yield a dry raw gaseous product comprised mainly of H2 and CH4 and substantially free of carbon oxides. The overall coal/carbon conversion can be

Problems solved by technology

Rapid economic, technological and industrial growth of populous countries such as China and India serves to increase this demand, making the need for alternative sources of energy even more severe.
Commercial, non-catalyzed, coal gasification systems and designs face a number of economic and technical challenges.
These processes are expensive to operate since, in order to drive the endothermic non-catalytic gasification of carbonaceous materials, they utilize severe temperatures (2400 to 2600° F.) and can consume high levels of oxygen.
Slagging and corrosion also can present operating and maintenance issues which reduce economic viability and increase product cost.
There is also no suggestion that the presence of calcium can improve catalyst recovery.
However, catalysts have not heretofore been identified that can catalyze mild temperature gasifi

Method used

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Examples

Experimental program
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example 1

Low Temperature Steam Gasification Results

[0052] Steam gasification of Illinois #6 coal was studied at elevated pressures and low temperatures. In the absence of a catalyst at 500° C. and elevated pressure (500-1000 psig—i.e. ˜34 to 68 atm), no coal conversion was observed. When the temperature was increased to 700° C., a significant amount of conversion was observed. Apparently the lower temperature is insufficient to overcome the activation energy barrier. Gas analyses at 700° C. showed no or substantially no methane formation for de-mineralized coal samples. A small amount of methane was detected for the raw coal gasification. These observations are in agreement with the findings that significant amounts of methane cannot be generated in the absence of catalysts, and that minerals in coal can contribute to catalysis.

[0053] The catalytic effects of iron, nickel and potassium in steam gasification were also studied. In the presence of these catalysts a substantial amount of Illin...

example 2

MCCG in Accordance with an Embodiment of the Invention

[0057] A process flow diagram for the envisioned low temperature steam gasification process, mild catalytic coal gasification (MCCG), is shown in FIG. 1. Among the advantages for this process is, as discussed above, that it is a simple process. Particulate coal or other carbonaceous material, particles of CO2 trap material and / or mineral binder material, and an alkali metal catalyst solution, can be combined and mixed in mixer 100 to form a feed stream and fed to one or more lock hoppers shown generally as lock hopper 200. Said particulate streams can be fed separately to mixer 100 or combined (not shown) before being fed to mixer 100. From lock hopper 200, the feed stream can be fed to gasifier 300 by a screw feeder 250, which alternatively can be a star feeder, or a mechanism that feeds the carbonaceous material as a liquid slurry, or any other feed mechanism known in the art which allows carbonaceous material to be fed to a g...

example 3

MCCG in Accordance with Another Embodiment

[0063] In other particular embodiments, coal or other carbonaceous material; a CO2 trap material such as CaO or Ca(OH)2 particles; and an alkali metal catalyst solution, are mixed in mixer 100, fed to lock hopper 200, and fed to gasifier 300 as described above. Mixer 100 can comprise an impeller and means to heat the contents such that the carbonaceous particles can become impregnated with alkali catalyst therein.

[0064] Gasifier 300 can be operated in a fluid bed 400A or a moving bed 400B mode, as described, and is operated at a temperature between about 300° C. about 700° C. and a pressure from about 12 to about 40 atm. As described in Example 2, CaO or Ca(OH)2 can be used as a trap for CO2 and sulfur gases, and CaO, Ca(OH)2, CaCO3, or other alkaline earth metal salts can react with alumina, silica, or other mineral constituents of the coal.

[0065] The remainder of the process follows that described for Example 2.

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Abstract

The present invention provides an improved alkali metal catalyzed steam gasification process that utilizes a CO2 trap material and/or a mineral binder material within the gasifier. The process optimally achieves over 90% carbon conversion with over 80% yield of methane. The raw gas product can be used directly as fuel. The catalyst can be recovered from the solid purge and recycled to the gasifier and/or the CO2 trap can be regenerated and recycled to the gasifier.

Description

[0001] This application claims priority under 35 U.S.C. 119(e) to provisional application 60 / 695,994 which is hereby incorporated by reference.FIELD OF THE INVENTION [0002] The present invention relates to low temperature catalytic gasification of carbonaceous material. More particularly, the present invention relates to an improved process for gasifying carbonaceous material that achieves high carbon conversion to methane at mild temperatures. BACKGROUND—DESCRIPTION OF RELATED ART [0003] The world-wide availability of petroleum is predicted to peak and then decline rapidly. Rapid economic, technological and industrial growth of populous countries such as China and India serves to increase this demand, making the need for alternative sources of energy even more severe. To meet this growing demand it has been suggested to convert coal into more useful and transportable forms. One such technique is to gasify coal into combustible gases. A coal gasification process for producing pipeli...

Claims

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Application Information

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IPC IPC(8): C10J3/00
CPCC10J3/06C10J3/463C10J2200/158C10J2300/0903Y02E20/18C10J2300/0969C10J2300/0983C10J2300/1807C10J2300/093C10J3/46C10J3/48C10J3/54
Inventor HIPPO, EDWIN J.SHETH, ATUL C.
Owner SURE CHAMPION INVESTMENT LTD
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