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Catalytic Gasification Process with Recovery of Alkali Metal from Char

a gasification process and alkali metal technology, applied in the field of catalytic gasification process, can solve the problems of substantially insoluble alkali metal compound in water and has little effect as gasification catalyst, and achieve the effect of reducing the amount of makeup catalyst required

Inactive Publication Date: 2009-07-02
SURE CHAMPION INVESTMENT LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0010]The process can be run continuously, and the recovered alkali metal can be recycled back into the process to minimize the amount of makeup catalyst required.

Problems solved by technology

As an aluminosilicate, the alkali metal compound is substantially insoluble in water and has little effectiveness as a gasification catalyst.

Method used

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  • Catalytic Gasification Process with Recovery of Alkali Metal from Char
  • Catalytic Gasification Process with Recovery of Alkali Metal from Char

Examples

Experimental program
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Effect test

example 1

Extraction of Soluble Potassium from High-KAlSiO4 Ash Sample

[0098]An agglomerate char material was provided having a composition especially concentrated in kaliophilite. By weight, the sample was approximately 90% ash (including soluble and insoluble potassium) and about 10% carbon. The material was ground to a particle size (Dp80) of 68.5 microns. The sample was subjected to water at 95° C. in a nitrogen atmosphere. The sample was filtered and dried. Analysis of the resulting sample indicated that the amount of water-soluble potassium removed from the sample amounted to 40.08 wt % (dry basis) of the original sample.

example 2

Extraction of Insoluble Potassium from High-KAlSiO4 Ash Sample

[0099]he post-treatment sample from Example 1 was used. The hot-water-washed sample consisted of 78.20 wt % of ash and 8.99 wt % fixed carbon. Analysis of the ash portion determined that the ash contained 36.42 wt % of silica, 15.72 wt % of alumina, 18.48 wt % of insoluble potassium oxide, 12.56 wt % of calcium oxide, 9.13 wt % of ferric oxide, and trace quantities of other inorganic oxides. SEM data confirmed that most of the insoluble potassium oxide in the ash is tied up in KAlSiO4, primarily as kaliophilite and kalsilite.

[0100]The post-treatment sample from Example 1 was provided to a 450 ml autoclave. KOH was added and supplemented with an amount of potassium carbonate to simulate a recycle stream from washing, the autoclave pressurized by the addition of CO2, and the system was heated to 200° C. for 3 hours. The leached slurries were filtered, the solids washed, and the solutions and solids analyzed to provide a mat...

example 3

Extraction of Insoluble Potassium from Typical Char Sample

[0101]A char sample was provided from the gasification (87-89% carbon conversion) of Class B catalyzed Powder River Basin coal. The dry sample was determined to contain 34.4 wt % potassium. The char sample was crushed and added to water to form a slurry in a nitrogen atmosphere. The slurry sample was added to an autoclave with KOH and additional water. The system was pressurized with CO2 and heated for 90 minutes at 160° C. The autoclave was cooled to ambient temperature. The solid was filtered and washed three times with water. Thus, the soluble potassium was largely removed from the sample. The total potassium extraction was 92.0%.

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Abstract

Processes for extracting and recycling alkali metal compounds present in the char produced from the catalytic gasification of carbonaceous materials are provided involving at least contacting the char with and alkali metal hydroxide followed by carbon dioxide. Both the alkali metal hydroxide and carbon dioxide treatments serve to convert at least a portion of the insoluble alkali metal compounds in the char into soluble species which can be recovered and recycled.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001]This application claims priority under 35 U.S.C. §119 from U.S. Provisional Application Ser. No. 61 / 017,312 (filed Dec. 28, 2007), the disclosure of which is incorporated by reference herein for all purposes as if fully set forth.[0002]This application is related to commonly owned U.S. application Ser. No. 11 / 421,511, filed Jun. 1, 2006, entitled “CATALYTIC STEAM GASIFICATION PROCESS WITH RECOVERY AND RECYCLE OF ALKALI METAL COMPOUNDS”; U.S. application Ser. No. ______, (filed concurrently herewith), entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR” (attorney docket no. FN-0007 US NP1); U.S. application Ser. No. ______, (filed concurrently herewith), entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR” (attorney docket no. FN-0015 US NP1); and U.S. application Ser. No. ______, (filed concurrently herewith), entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL ...

Claims

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Application Information

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IPC IPC(8): C10J3/00C22B26/10
CPCC10J3/00C10K1/165C10J2300/0903C10J2300/093C10J2300/0943C10J2300/0973C10J2300/0986C10J2300/16C10J2300/1631C10J2300/169C10J2300/1807C10J2300/1853C10K1/004C10K1/101C10K1/122C10K1/143C10K1/146C10K1/16C10J3/463
Inventor RAPPAS, ALKIS S.SPITZ, ROBERT A.
Owner SURE CHAMPION INVESTMENT LTD
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