Catalyst-loaded coal compositions, methods of making and use
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01J-023/04
C07C-004/00
출원번호
US-0178380
(2008-07-23)
등록번호
US-8163048
(2012-04-24)
발명자
/ 주소
Rappas, Alkis S.
Salem, George Frederick
Hippo, Edwin J.
출원인 / 주소
Greatpoint Energy, Inc.
대리인 / 주소
McDonnell Boehnen Hulbert & Berghoff LLP
인용정보
피인용 횟수 :
15인용 특허 :
139
초록▼
The present invention relates to catalyst-loaded coal compositions having a moisture content of less than about 6 wt %, a process for the preparation of catalyst-loaded coal compositions, and an integrated process for the gasification of the catalyst-loaded coal compositions. The catalyst-loaded coa
The present invention relates to catalyst-loaded coal compositions having a moisture content of less than about 6 wt %, a process for the preparation of catalyst-loaded coal compositions, and an integrated process for the gasification of the catalyst-loaded coal compositions. The catalyst-loaded coal compositions can be prepared by a diffusive catalyst loading process that provides for a highly dispersed catalyst that is predominantly associated with the coal matrix, such as by ion-exchange.
대표청구항▼
1. An integrated process for the steady-state gasification of an optimized reactor feed catalyst-loaded coal composition, comprising the steps of: (a) providing a ground raw coal solid stream into a diffuse catalyst loading contactor, wherein the coal comprises a matrix containing ion exchange sites
1. An integrated process for the steady-state gasification of an optimized reactor feed catalyst-loaded coal composition, comprising the steps of: (a) providing a ground raw coal solid stream into a diffuse catalyst loading contactor, wherein the coal comprises a matrix containing ion exchange sites comprising acidic functional groups;(b) introducing an influent stream comprising a salt of a Group I alkali metal catalyst into the diffuse catalyst loading contactor to create a slurry, wherein the influent stream is comprised of a raffinate stream, a recycle stream and a makeup stream;(c) controlling the amount of catalyst in the influent stream such that the amount of Group I alkali metal catalyst in the influent stream is equal to or greater than the amount to achieve saturation ion-exchange loading of the coal;(d) holding the slurry at a contact temperature and for a contact time so as to provide ample opportunity to achieve substantial and uniform catalyst loading such that the Group I alkali metal catalyst is highly dispersed throughout the coal matrix;(e) dewatering the slurry by filtration to form a catalyst-loaded wet coal cake and the raffinate solution;(f) recycling the raffinate solution into the influent stream;(g) thermally-treating the catalyst-loaded wet coal cake under a flow of inert dry gas to reduce the moisture content to less than about 6 wt %, such that greater than about 50% of the total amount of the catalyst loaded is Group I alkali metal catalyst associated with the coal matrix;(h) gasifying the catalyst-loaded thermally-treated coal composition in a fluidized bed reactor in the presence of steam, CO and H2 at a temperature ranging from about 450° C. to about 750° C. and a pressure ranging from about 50 psig and about 1000 psig, to produce a char and a raw gas stream comprising methane;(i) withdrawing the raw gas stream from the fluidized bed reactor;(j) withdrawing the char from the fluidized bed reactor;(k) extracting catalyst from the char; and(l) recycling extracted catalyst into the influent stream as the recycle stream. 2. The integrated process according to claim 1, wherein the amount of Group I alkali metal catalyst in the influent stream is controlled by a method comprising the steps of: (a) monitoring the amount of Group I alkali metal catalyst in the raffinate stream;(b) monitoring the amount of Group I alkali metal catalyst in the recycle stream; and(c) adjusting the amount of Group I alkali metal catalyst in the makeup stream. 3. The integrated process according to claim 1, wherein the concentration of Group I alkali metal catalyst in the influent stream is sufficient to provide the catalyst-loaded coal composition having a ratio of Group I alkali metal catalyst atoms to carbon atoms in the range of about 0.01 to about 0.1. 4. The integrated process according to claim 1, wherein the amount of Group I alkali metal catalyst in the influent stream ranges from about 0.3 mol/kg to about 3.0 mol/kg. 5. The integrated process according to claim 1, wherein the coal is sub-bituminous, bituminous, lignite, anthracite or mixtures thereof. 6. The integrated process according to claim 1, wherein the ground raw coal is sub-bituminous, the catalyst is potassium cation, the salt of said catalyst is potassium carbonate, and the influent solution comprises a concentration of the catalyst salt sufficient to provide the catalyst-loaded coal composition having a ratio of catalyst atoms to carbon atoms in the range of about 0.03 to about 0.05. 7. The integrated process according to claim 1, wherein greater than about 70% of the total amount of catalyst loaded is Group I alkali metal catalyst associated with the coal matrix. 8. The integrated process according to claim 1, wherein greater than about 50% of the total amount of the catalyst loaded is Group I alkali metal catalyst associated with the coal matrix by ion exchange on the acidic functional groups of the coal. 9. The integrated process according to claim 1, wherein greater than about 70% of the total amount of the catalyst loaded is Group I alkali metal catalyst associated with the coal matrix by ion exchange on the acidic functional groups of the coal. 10. The integrated process according to claim 1, wherein the slurry is held at a contact temperature ranging from about 20° C. to about 95° C. for a contact time ranging from about 1 hours to about 48 hours. 11. The integrated process according to claim 1, wherein the thermally-treating step is performed at a temperature ranging from about 90° C. to about 250° C. 12. The integrated process of claim 1, wherein the Group I alkali metal is potassium. 13. The integrated process of claim 2, wherein the Group I alkali metal is potassium. 14. The integrated process of claim 3, wherein the Group I alkali metal is potassium. 15. The integrated process of claim 4, wherein the Group I alkali metal is potassium. 16. The integrated process of claim 7, wherein the Group I alkali metal is potassium. 17. The integrated process of claim 8, wherein the Group I alkali metal is potassium. 18. The integrated process of claim 9, wherein the Group I alkali metal is potassium. 19. The integrated process of claim 10, wherein the Group I alkali metal is potassium. 20. The integrated process of claim 11, wherein the Group I alkali metal is potassium.
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이 특허에 인용된 특허 (139)
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