Coal-Coke Catalyst Blend for Gasification Reactivity
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Solution Overview
Problem
Petroleum coke has poor gasification reactivity due to its highly crystalline carbon and elevated organic sulfur content, requiring catalysts to improve reactivity, but these catalysts can be poisoned by sulfur-containing compounds, and conventional catalyst impregnation methods are hindered by petroleum coke's low moisture content and poor water soaking capacity.
Innovation Solution
A particulate composition comprising a blend of petroleum coke and coal, loaded with a transition metal gasification catalyst, an alkaline earth metal source, and an alkali metal gasification catalyst, which are mixed in specific ratios and treated to form a gasification-ready blend that can be efficiently processed in a fluidized bed reactor to produce methane and other gaseous products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If catalysts are used to improve gasification reactivity of petroleum coke, then gasification activity is improved, but catalysts can be poisoned by sulfur-containing compounds
Solution Approach 1:
Coal acts as an intermediary carrier that protects the catalyst from direct contact with sulfur-containing compounds in petroleum coke. The catalyst is impregnated onto the coal surface, which serves as a protective barrier while still enabling catalytic activity during gasification.
Solution Approach 2:
The invention creates a composite particulate composition combining petroleum coke, coal, and catalyst. This composite structure allows the catalyst to function effectively while the coal component protects against sulfur poisoning and provides structural support.
2Quantity of substance
If conventional catalyst impregnation methods are used, then catalyst can be loaded, but petroleum coke's low moisture content and poor water soaking capacity hinder effective loading
Solution Approach 1:
Coal serves as an intermediary substrate for catalyst impregnation. Since coal has better water soaking capacity than petroleum coke, the catalyst can be effectively loaded onto the coal component, which then distributes the catalyst throughout the particulate composition.
Solution Approach 2:
The invention changes the moisture content parameter of the overall particulate composition by blending petroleum coke with moisture-containing coal. This provides sufficient moisture for effective catalyst impregnation while maintaining the desired properties of the final gasification feedstock.
3Productivity
If petroleum coke is treated alone to achieve high carbon conversion, then theoretical carbon conversion reaches 98%, but bed composition control and fluidization become difficult
Solution Approach 1:
The invention changes the physical and chemical parameters of the gasification feedstock by blending petroleum coke with coal. This modification maintains high carbon conversion while improving bed fluidization characteristics and composition control through the complementary properties of coal.
Solution Approach 2:
The particulate composition is a composite material combining petroleum coke and coal in specific ratios. This composite structure provides both the high carbon conversion of petroleum coke and the operational advantages of coal for bed fluidization and composition control.
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
The composition enhances gasification activity, overcoming reactivity challenges and catalyst poisoning issues, while allowing for effective catalyst loading and efficient gas production, including methane, hydrogen, and other hydrocarbons, with improved bed composition and fluidization control.
Implementation Method 1
a transition metal gasification catalyst, an alkaline earth metal source, and an alkali metal gasification catalyst, wherein the transition gasification catalyst, the alkaline earth metal source, and alkali metal gasification catalyst are loaded onto the coal particulate, the petroleum coke particulate, or both
Implementation Method 2
reacting the particulate composition in the gasification reactor in the presence of steam and under suitable temperature and pressure to form a plurality of gaseous products including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide
Data Source
AI summary
Particulate compositions are described comprising an intimate mixture of a coal and a gasification catalyst. The particulate compositions are gasified in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.