Petroleum Coke Compositions for Catalytic Gasification

• US 20090166588A1
• Filed: 12/23/2008
• Published: 07/02/2009
• Est. Priority Date: 12/28/2007
• Status: Abandoned Application

• Current Assignee: Sure Champion Investments Limited
• Original Assignee: GreatPoint Energy, Inc.
• Inventors: Rappas, Alkis S., Spitz, Robert A.
• Application Number:
  US12/342,565
• Publication Number:
  US 20090166588A1
• Time in Patent Office: Days
• US Class Current: 252/363.500
• CPC Class Codes: C10J 2300/0903 Feed preparation
• CPC Class Codes: C10J 2300/0909 Drying
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/0943 Coke
• CPC Class Codes: C10J 2300/0973 Water
• CPC Class Codes: C10J 2300/0976 as steam
• CPC Class Codes: C10J 2300/0986 Catalysts
• CPC Class Codes: C10J 2300/1603 with gas treatment gas cleaning C10K1/00
• CPC Class Codes: C10J 2300/1662 to methane (SNG) production of synthetic natural gas C10L3/08
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 2300/1823 for synthesis gas
• CPC Class Codes: C10J 2300/1853 Steam reforming, i.e. injection of steam only
• CPC Class Codes: C10J 3/00 Production of combustible gases containing carbon monoxide from solid carbonaceous fuels destructive distillation processes C10B
• CPC Class Codes: C10J 3/463 in stationary fluidised beds
• CPC Class Codes: C10J 3/72 Other features
• CPC Class Codes: C10L 2290/04 Gasification
• CPC Class Codes: C10L 2290/10 Recycling of a stream within the process or apparatus to reuse elsewhere therein
• CPC Class Codes: C10L 2290/54 Specific separation steps for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: C10L 3/08 Production of synthetic natural gas
• CPC Class Codes: C10L 5/00 Solid fuels produced by solidifying fluid fuels C10L7/00
• CPC Class Codes: C10L 5/366 : Powders
• CPC Class Codes: C10L 9/00 : Treating solid fuels to improve their combustion
• CPC Class Codes: C10L 9/10 : by using additives

Abstract

Particulate compositions are described comprising an intimate mixture of a petroleum coke, coal and a gasification catalyst, where the gasification catalyst is loaded onto at least the coal for gasification in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Claims

1. A particulate composition having a particle distribution size suitable for gasification in a fluidized bed zone, the particulate composition comprising an intimate mixture of (a) a petroleum coke;

(b) a coal; and

(c) a gasification catalyst which, in the presence of steam and under suitable temperature and pressure, exhibits gasification activity whereby a plurality of gases comprising methane and one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons are formed, wherein;

(i) the petroleum coke and the coal are present in the particulate composition at a weight ratio of from about 5;

95 to about 95;

5;

(ii) the gasification catalyst is loaded onto at least the coal;

(iii) the gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the particulate composition, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08; and

(iv) the particulate composition comprises a total ash content of less than about 20 wt %, based on the weight of the particulate composition.

2. The particulate composition according to claim 1, where in the alkali metal comprises potassium, sodium or both.

3. The particulate composition according to claim 2, wherein the alkali metal is potassium.

4. The particulate composition according to claim 1, wherein the source of alkali metal is an alkali metal salt selected from the group consisting of carbonate, hydroxide, acetate, halide and nitrate salts.

5. The particulate composition according to claim 1, having a particle size ranging from about 25 microns to about 2500 microns.

6. The particulate composition according to claim 1, wherein the gasification catalyst is loaded only onto the coal.

7. The particulate composition according to claim 1, wherein the gasification catalyst is loaded onto both the coal and the petroleum coke.

8. The particulate composition according to claim 1, wherein the ash content of the particulate composition comprises less than about 20 wt % alumina, based on the weight of the ash.

9. A process for converting a particulate composition into a plurality of gaseous products, the process comprising the steps of:

(a) supplying a particulate composition according to claim 1 to a gasifying reactor;

(b) reacting the particulate composition in the gasifying reactor in the presence of steam and under suitable temperature and pressure to form a plurality of gaseous including methane and one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons; and

(c) at least partially separating the plurality of gaseous products to produce a stream comprising a predominant amount of one of the gaseous products.

10. The process according to claim 9, wherein the stream comprises a predominant amount of methane.

11. The process according to claim 9, wherein a char is formed in step (b), and the char is removed from the gasifying reactor and sent to a catalyst recovery and recycle process.

12. The process according to claim 11, wherein the gasification catalyst comprises gasification catalyst recycled from the catalyst recovery and recycle process.

13. A process for preparing a particulate composition according to claim 1, the process comprising the steps of:

(a) providing petroleum coke particulates, coal particulates and gasification catalyst;

(b) contacting the coal particulates with an aqueous solution comprising gasification catalyst to form a slurry; and

(c) dewatering the slurry to form a catalyst-loaded wet coal cake; and

(d) kneading the wet coal cake and the petroleum coke particulates to form the particulate composition.