Carbonaceous Fuels and Processes for Making and Using Them
First Claim
1. A carbonaceous fuel comprising (a) unconverted fines of a carbonaceous feedstock, the carbonaceous feedstock having an ash content of greater than about 1 wt % (based on the weight of the carbonaceous feedstock), the fines having an average particle size less than about 45 μ
- m; and
(b) a char residue formed by catalytic gasification of the carbonaceous feedstock, the char residue having an ash content of greater than about 30 wt % (based on the weight of the char residue), wherein the ash includes at least one aluminum-containing compound or silicon-containing compound; and
having a weight ratio of fines to char residue in the range of from about 4;
1 to about 1;
4, and a total dry basis wt % of carbon of least about 40 wt % (based on the weight of the carbonaceous fuel).
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Accused Products
Abstract
The present invention provides carbonaceous fuels and processes for making them. Moreover, the invention also relates to processes using the carbonaceous fuels in the production of cement products. One embodiment of the invention is a carbonaceous fuel comprising (a) unconverted fines of a carbonaceous feedstock, the carbonaceous feedstock having an ash content of greater than 1%, the fines having an average particle size less than about 45 μm; and (b) a char residue formed by catalytic gasification of the carbonaceous feedstock, the char residue having an ash content of greater than about 30%, wherein the ash includes at least one aluminum-containing compound or silicon-containing compound; and having a weight ratio of fines to char residue in the range of about 4:1 to about 1:4, and a total dry basis wt % of carbon of least about 40%. Another embodiment of the invention is a process of making a cement product comprising: (a) providing a carbonaceous fuel as described above; (b) passing the carbonaceous fuel into a cement-making zone; and (c) at least partially combusting the carbonaceous fuel to provide heat for a cement producing reaction within the cement-making zone.
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Citations
19 Claims
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1. A carbonaceous fuel comprising (a) unconverted fines of a carbonaceous feedstock, the carbonaceous feedstock having an ash content of greater than about 1 wt % (based on the weight of the carbonaceous feedstock), the fines having an average particle size less than about 45 μ
- m; and
(b) a char residue formed by catalytic gasification of the carbonaceous feedstock, the char residue having an ash content of greater than about 30 wt % (based on the weight of the char residue), wherein the ash includes at least one aluminum-containing compound or silicon-containing compound; and
having a weight ratio of fines to char residue in the range of from about 4;
1 to about 1;
4, and a total dry basis wt % of carbon of least about 40 wt % (based on the weight of the carbonaceous fuel). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 17, 18, 19)
- m; and
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12. A process for making one or more gaseous products and a carbonaceous fuel, the process comprising the steps of:
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(a) providing (1) unconverted fines of a carbonaceous feedstock, the carbonaceous feedstock having an ash content of greater than about 1 wt % (based on the weight of the carbonaceous feedstock), the fines having an average particle size less than about 45 μ
m, and (2) particulates of the carbonaceous feedstock suitable for gasification in a reactor;(b) reacting the particulates in the reactor in the presence of steam and a gasification catalyst under suitable temperature and pressure to form the one or more gaseous products and a char residue having an ash content greater than about 30 wt % (based on the weight of the char residue), wherein the ash includes at least one aluminum-containing compound or silicon-containing compound; and (c) combining the fines with the char residue in a weight ratio in the range of from about 4;
1 to about 1;
4 to form the carbonaceous fuel,wherein the carbonaceous fuel has a dry basis wt % carbon of at least about 40%. - View Dependent Claims (13, 14, 15, 16)
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Specification