IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0094438
(2011-04-26)
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등록번호 |
US-8557878
(2013-10-15)
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발명자
/ 주소 |
- Rappas, Alkis S.
- Spitz, Robert A.
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출원인 / 주소 |
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대리인 / 주소 |
McDonell Boehnen Hulbert & Berghoff LLP
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인용정보 |
피인용 횟수 :
0 인용 특허 :
201 |
초록
The present invention relates to processes and apparatuses for hydromethanating a vanadium-containing carbonaceous feedstock while recovering at least a portion of the vanadium content originally present in the carbonaceous feedstock.
대표청구항
▼
1. A process for generating a methane-enriched raw product gas stream and a vanadium product stream from a non-gaseous vanadium-containing carbonaceous material, the process comprising the steps of: (a) preparing a catalyzed carbonaceous feedstock from the vanadium-containing carbonaceous material a
1. A process for generating a methane-enriched raw product gas stream and a vanadium product stream from a non-gaseous vanadium-containing carbonaceous material, the process comprising the steps of: (a) preparing a catalyzed carbonaceous feedstock from the vanadium-containing carbonaceous material and an alkali metal hydromethanation catalyst, wherein the alkali metal hydromethanation catalyst comprises a recycle catalyst and a makeup catalyst;(b) introducing the catalyzed carbonaceous feedstock into a hydromethanation reactor;(c) reacting the catalyzed carbonaceous feedstock in the hydromethanation reactor in the presence of carbon monoxide, hydrogen and steam to produce a methane-enriched raw gas and a solid by-product char;(d) withdrawing a stream of the methane-enriched raw product gas from the hydromethanation reactor as the methane-enriched raw product gas stream, wherein the methane-enriched raw product gas stream comprises methane, carbon monoxide, hydrogen, carbon dioxide, hydrogen sulfide, steam and heat energy;(e) withdrawing a stream of the solid by-product char from the hydromethanation reactor, wherein the withdrawn solid by-product char comprises carbon and an inorganic ash containing an alkali metal content and a vanadium content;(f) treating the withdrawn solid by-product char to generate (1) an alkali metal and vanadium-depleted char stream, and (2) an aqueous alkali metal and vanadium-enriched stream comprising one or more water-soluble alkali metal compounds and one or more water-soluble vanadium compounds, wherein the aqueous stream comprises at least a predominant portion of the alkali metal content and at least a predominant portion of the vanadium content of the withdrawn solid by-product char;(g) separating the aqueous stream into a bleed stream and a catalyst recycle stream, wherein the bleed stream comprises a bleed vanadium content;(h) recycling at least a portion of the catalyst recycle stream for use as the recycle catalyst;(i) treating the bleed stream to generate a vanadium-enriched stream and a vanadium-depleted stream, wherein the vanadium-enriched stream comprises at least a predominant portion of the bleed vanadium content;(j) contacting the vanadium-enriched stream with an ammonia stream to generate an ammonium vanadate; and(k) recovering at least a predominant portion of the ammonium vanadate generated in step (j) as the vanadium product stream. 2. The process of claim 1, wherein the methane-enriched raw product stream comprises at least about 20 mol % methane (based on the moles of methane, carbon dioxide, carbon monoxide and hydrogen in the methane-enriched raw product stream). 3. The process of claim 2, wherein the methane-enriched raw product stream comprises at least 50 mol % methane plus carbon dioxide (based on the moles of methane, carbon dioxide, carbon monoxide and hydrogen in the methane-enriched raw product stream). 4. The process of claim 1, wherein an oxygen-rich gas stream is fed into the hydromethanation reactor. 5. The process of claim 4, wherein the amount of oxygen provided is varied as a process control to assist control of the temperature in the hydromethanation reactor. 6. The process of claim 1, which is a continuous process in which steps (a), (b), (c) and (d) are performed in a continuous manner. 7. The process of claim 6, wherein steps (e), (f), (g), (h), (i), (j) and (k) are performed in a continuous manner. 8. The process of claim 1, wherein step (c) has a syngas demand, a steam demand and a heat demand, and the superheated hydromethanation gas feed stream comprises hydrogen, carbon monoxide, steam and heat energy sufficient to at least substantially satisfy the syngas demand, steam demand and heat demand. 9. The process of claim 1, wherein an oxygen-rich gas stream is supplied periodically or continuously to the hydromethanation reactor, and the amount of oxygen provided is varied as a process control. 10. The process of claim 1, wherein the char by-product is generated in step (c) is collected in the hydromethanation reactor in a collection zone, an oxygen-rich gas stream is supplied to the hydromethanation reactor, and the oxygen-rich gas stream is introduced into the char by-product collection zone of hydromethanation reactor. 11. The process of claim 1, wherein the vanadium-containing carbonaceous material is a petcoke. 12. The process of claim 1, wherein the alkali metal hydromethanation catalyst is a potassium hydromethanation catalyst. 13. The process of claim 1, wherein the char by-product withdrawn from the hydromethanation is quenched by contacting the char by-product with an aqueous quench stream. 14. The process of claim 13, wherein a quenched char slurry is generated by the quenching step, which is contacted with a stream of carbon dioxide, followed by a stream of an oxygen-containing gas, followed by solid/liquid separation, to generate the alkali metal and vanadium-depleted char stream and the aqueous alkali metal and vanadium enriched stream. 15. The process of claim 13, wherein a quenched char slurry is generated by the quenching step, which is contacted with a stream of an oxygen-containing gas, optionally followed by a stream of carbon dioxide with pressure let down, followed by solid/liquid separation, to generate the alkali metal and vanadium-depleted char stream and the aqueous alkali metal and vanadium enriched stream. 16. The process of claim 1, wherein the catalyst recycle stream split from the aqueous stream comprises from about 75 wt % to about 95 wt % of the aqueous stream. 17. The process of claim 1, wherein the bleed stream is subject to a solvent extraction step to generate the vanadium-enriched stream and the vanadium-depleted stream. 18. The process of claim 1, wherein the vanadium-depleted stream is contacted with carbon dioxide to recover alkali metal content from the vanadium-depleted stream, which can be recycled as a part of the catalyst recovery.
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