IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0402022
(2012-02-22)
|
등록번호 |
US-8648121
(2014-02-11)
|
발명자
/ 주소 |
- Rappas, Alkis S.
- Spitz, Robert A.
|
출원인 / 주소 |
|
대리인 / 주소 |
McDonnell Boehnen Hulbert & Berghoff LLP
|
인용정보 |
피인용 횟수 :
0 인용 특허 :
202 |
초록
The present invention relates to processes for hydromethanating a nickel-containing (and optionally vanadium-containing) carbonaceous feedstock while recovering at least a portion of the nickel content (and optionally vanadium content) originally present in the carbonaceous feedstock.
대표청구항
▼
1. A process for generating a methane-enriched raw product gas stream and a nickel product stream from a non-gaseous nickel-containing carbonaceous material, the process comprising the steps of: (a) preparing a catalyzed carbonaceous feedstock from the nickel-containing carbonaceous material and an
1. A process for generating a methane-enriched raw product gas stream and a nickel product stream from a non-gaseous nickel-containing carbonaceous material, the process comprising the steps of: (a) preparing a catalyzed carbonaceous feedstock from the nickel-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 product 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and heat energy;(e) withdrawing a stream of the solid by-product char from the hydromethanation reactor, wherein the withdrawn solid by-product char comprises carbon and an inorganic ash containing an alkali metal content and a nickel content;(f) treating the withdrawn solid by-product char to generate (1) an alkali metal-depleted char stream comprising a substantial portion of the nickel content, and (2) an aqueous alkali metal-enriched stream comprising one or more water-soluble alkali metal compounds, wherein the aqueous alkali metal-enriched stream comprises at least a predominant portion of the alkali metal content of the withdrawn solid by-product char;(g) recycling at least a portion of the aqueous alkali-metal enriched stream for use as the recycle catalyst;(h) treating the alkali metal-depleted char stream to generate a nickel-enriched stream and a nickel-depleted char stream, wherein the nickel-enriched stream comprises at least a predominant portion of the nickel content;(i) recovering at least a predominant portion of the nickel from the nickel-enriched stream in step (h) as the nickel product stream. 2. 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. 3. The process of claim 2, 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-depleted char stream and the aqueous alkali metal-enriched stream. 4. The process of claim 2, 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-depleted char stream and the aqueous alkali metal-enriched stream. 5. The process of claim 1, wherein the alkali metal-depleted char stream is treated by acid extraction to generate the nickel-enriched stream and the nickel-depleted char. 6. The process of claim 5, wherein the nickel-enriched stream is treated by electrodeposition to generate the nickel product stream. 7. The process of claim 1, wherein the alkali metal-depleted char stream is treated by ammonia extraction to generate the nickel-enriched stream and the nickel-depleted char. 8. The process of claim 7, wherein the nickel-enriched stream is treated by steam stripping to generate the nickel product stream. 9. The process of claim 1, wherein the nickel-containing carbonaceous material is also a vanadium-containing carbonaceous material, and wherein the methane-enriched raw product gas stream, the nickel product stream and a vanadium product stream are produced by a process comprising the steps of: (A) preparing the catalyzed carbonaceous feedstock from the vanadium and nickel-containing carbonaceous material and the alkali metal hydromethanation catalyst;(B) introducing the catalyzed carbonaceous feedstock into the hydromethanation reactor;(C) reacting the catalyzed carbonaceous feedstock in the hydromethanation reactor in the presence of carbon monoxide, hydrogen and steam to produce the methane-enriched raw product gas and the solid by-product char;(D) withdrawing the stream of the methane-enriched raw product gas from the hydromethanation reactor as the methane-enriched raw product gas stream;(E) withdrawing the 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 the alkali metal content, the nickel 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 alkali metal and vanadium-enriched 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, and the alkali metal and vanadium-depleted char steam comprises a predominant portion of the nickel content of the withdrawn solid by-product char;(G) separating the aqueous alkali metal and vanadium-enriched 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;(K) recovering at least a predominant portion of the ammonium vanadate generated in step (J) as the vanadium product stream;(L) treating the alkali metal and vanadium-depleted char stream to generate the nickel-enriched stream and the nickel-depleted char stream; and(M) recovering at least a predominant portion of the nickel from the nickel-enriched stream in step (L) as the nickel product stream. 10. The process of claim 9, wherein the char by-product withdrawn from the hydromethanation is quenched by contacting the char by-product with an aqueous quench stream. 11. The process of claim 10, 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. 12. The process of claim 10, 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. 13. The process of claim 9, wherein the catalyst recycle stream split from the aqueous alkali metal and vanadium-enriched stream comprises from about 75 wt % to about 95 wt % of the aqueous alkali metal and vanadium-enriched stream. 14. The process of claim 9, wherein the bleed stream is subject to a solvent extraction step to generate the vanadium-enriched stream and the vanadium-depleted stream. 15. The process of claim 9, wherein the vanadium-depleted stream is contacted with carbon dioxide to recover alkali metal content from the vanadium-depleted stream. 16. The process of claim 15, wherein at least a part of the recovered alkali metal content is used as recycle catalyst. 17. The process of claim 9, wherein the alkali metal and vanadium-depleted char stream is treated by acid extraction to generate the nickel-enriched stream and the nickel-depleted char. 18. The process of claim 17, wherein the nickel-enriched stream is treated by electrodeposition to generate the nickel product stream. 19. The process of claim 9, wherein the alkali metal and vanadium-depleted char stream is treated by ammonia extraction to generate the nickel-enriched stream and the nickel-depleted char. 20. The process of claim 19, wherein the nickel-enriched stream is treated by steam stripping to generate the nickel product stream. 21. The process of claim 1, wherein the carbonaceous material is a petcoke. 22. The process of claim 1, wherein the alkali metal hydromethanation catalyst is a potassium hydromethanation catalyst.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.