Catalyst-Loaded Carbonaceous Particulate Preparation
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Solution Overview
Problem
Existing methods for loading catalysts onto carbonaceous feedstocks, such as coal, result in inefficient gasification due to non-uniform catalyst distribution and high energy consumption, particularly in methods like spraying or soaking, which do not achieve optimal gasification efficiency.
Innovation Solution
A process involving grinding and classifying carbonaceous feedstock to a specific particle size, followed by contacting with an alkali metal gasification catalyst solution under controlled conditions to create a substantially free-flowing catalyst-loaded particulate, which is then thermally treated to reduce moisture content, ensuring even catalyst distribution and minimizing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spraying or soaking methods are used to load catalyst onto carbonaceous feedstock, then catalyst loading is achieved, but uniform catalyst distribution is not achieved and gasification efficiency is reduced
Solution Approach 1:
The carbonaceous feedstock is ground and classified to a specific particle size range (d50: 75-350 microns, d95: ≤1000 microns) before catalyst loading. This preliminary size preparation ensures uniform surface area and porosity characteristics, enabling even catalyst distribution when the aqueous catalyst solution is added, thereby resolving the contradiction between achieving catalyst loading and maintaining uniform distribution for efficient gasification
2Loss of energy
If conventional catalyst loading methods are used, then catalyst is applied to carbonaceous material, but energy consumption is high due to multiple heating steps for moisture reduction
Solution Approach 1:
The process controls the moisture content of the carbonaceous feedstock within a specific range (5-20 wt%) before catalyst loading, and maintains the catalyst solution concentration at 1-10 wt%. These optimized parameter ranges allow for effective catalyst distribution while minimizing the energy required for subsequent moisture reduction, thus reducing energy loss while maintaining reliable gasification performance
Solution Approach 2:
The carbonaceous feedstock is pre-dried to a controlled moisture range rather than complete dryness, and the catalyst solution is applied at optimized concentrations. This partial action approach avoids excessive energy input for complete moisture removal while ensuring sufficient catalyst distribution, thereby reducing overall energy consumption without compromising gasification reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enhances gasification efficiency by achieving uniform catalyst distribution and reducing energy consumption, leading to improved production of value-added gases like methane from carbonaceous materials.
Implementation Method 1
grinding the carbonaceous feedstock; classifying the carbonaceous feedstock from step (B) to a specified particle size profile
Implementation Method 2
contacting the carbonaceous particulate with an amount of an aqueous solution comprising a concentration of an alkali metal gasification catalyst, to form an alkali metal gasification catalyst-loaded carbonaceous particulate wet cake
Implementation Method 3
thermally treating the alkali metal gasification catalyst-loaded carbonaceous particulate wet cake as required to reduce the second moisture content
Implementation Method 4
catalytic gasification of the catalyst-loaded carbonaceous particulate in the presence of steam
Implementation Method 5
converting a particulate composition into a plurality of gaseous products comprising the steps of: (a) supplying a particulate composition, prepared according to the present invention, to a gasifying reactor; (b) reacting the particulate composition in the presence of steam
Data Source
AI summary
Processes are provided for preparing a substantially free-flowing alkali metal gasification catalyst-loaded carbonaceous particulate suitable for use as a feedstock for the production of gaseous products, and in particular methane, via the catalytic gasification of the catalyst-loaded carbonaceous particulate in the presence of steam.