Nano-dispersions of carbonaceous material in water as the basis of fuel related technologies and methods of making same

Abstract

Colloidal carbonaceous material-in-water slurries having nano-particles of carbonaceous material creating a pseudo-fluid. The colloidal carbonaceous material-in-water slurry generally includes from about fifty to about seventy two weight percent of carbonaceous material, with about 20 to about 80 percent of the carbonaceous material having a particle size of about one micron or less with a mode particle size of about 250 nanometers. The carbonaceous material-in-water slurry can also include a surfactant system containing one surfactant or mixtures of two or more surfactants, or mixtures of one or more surfactants and an inorganic or organic salt. The carbonaceous material-in-water slurry can be used in low NOx burner applications as the main fuel and / or the reburn fuel, in gasification processes as the input fuel either alone, or in combination with organic materials, in gas turbine applications, and in diesel engine applications.

Description

RELATED APPLICATION[0001]The present application claims the benefit of U.S. Provisional Application No. 61 / 473,017 filed Apr. 7, 2011, which is incorporated herein in its entirety by reference, and the present application is a continuation-in-part of application Ser. No. 12 / 495,151 filed Jun. 30, 2009, which claims the benefit of U.S. Provisional Application No. 61 / 077,009 filed Jun. 30, 2008, and U.S. Provisional Application No. 61 / 157,089 filed Mar. 3, 2009, each of which is hereby fully incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention relates generally to a nano-dispersion of carbonaceous material, such as coal, asphaltite, or the like, in water that is essentially a pseudo-fluid, and optionally other additives. The present invention also relates to the methods of making the nano-dispersion of carbonaceous material in water, which can be used in several applications such as a fuel in boilers, secondary fuel for re-burning applications, as a feed ...

AI Technical Summary

Benefits of technology

[0021]In another embodiment of the invention, the heat of combustion can also be increased by adding to the carbonaceous material in water slurry a volatile or water-soluble fuel such as methanol, ethanol, propanol, butanol and glycerol. The component can also be an organic immiscible phase such as spent oil engine, hydrocarbons as heavy crude oils and bitumens such as asphaltite including gilsonite (uintaite), glance pitch, and grahamite, diesel, petroleum coke, biodiesel and biomass. The organic immiscible phase is preferably dispersed into nanodroplets or nanoparticles that enhance the heat of combustion of the carbonaceous material(s).

Problems solved by technology

When coal burns, it mainly produces water and carbon dioxide, however it also produces harmful sulfur dioxide, carbon monoxide, hydrocarbons, particulate matter and soot, and oxides of nitrogen (hereinafter “NOx”).

Under such conditions, the amount of unburned fuel normally was below two percent, although NOx levels generated by such burners reached levels that are now unacceptable according to current emission standards.

The disposal of boiler ash with increased carbon content is becoming a pressing issue within the power utilities markets and will continue to be more so in the future, as the cost of coal and other fuels continue to rise.

However, because the pulverized or micronized coal is only available at the particle sizes described above, the pulverized coal does not completely burn, and therefore the coal in water slurry does not solve the issues of high carbon content in boiler ash as described above.

However, commercially available coal-in-water slurries are not conducive to gas turbine applications.

When the pulverized or micronized coal is combined with the compressed air and burned, the presence of unburned coal particles can damage the turbine blades, resulting in a less efficient process, and significant expense in replacing the turbine blades.

As the piston approaches top dead centre (TDC), fuel oil is injected into the cylinder at high pressure, causing the fuel charge to be nebulized.

Owing to the high air temperature in the cylinder, ignition instantly occurs, causing a rapid and considerable increase in cylinder temperature and pressure.

If commercially available coal-in-water slurries are used as the fuel, the presence of unburned coal particles after combustion of these fuels can cause damage to the cylinders, such as damaging the tolerances between the piston and the cylinder.

This in turn may cause damage or failure to the seal of the cylinder, resulting in a lack of pressure to increase the temperature to ignite the fuel, for example.

However, commercially available coal-in-water slurries produce a lower quality or contaminated syngas because of the presence of unburned coal particles, as well as clogging of the particulates in the input stream.

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