Coal Compositions for Catalytic Gasification

• US 20090217586A1
• Filed: 02/27/2009
• Published: 09/03/2009
• Est. Priority Date: 02/29/2008
• Status: Active Grant

• Current Assignee: Sure Champion Investments Limited
• Original Assignee: GreatPoint Energy, Inc.
• Inventors: Rappas, Alkis S., Salem, George Frederick
• Granted Patent: US 8,286,901 B2
• Time in Patent Office: Days
• US Class Current: 48/127.700
• CPC Class Codes: C10J 2300/0903 Feed preparation
• CPC Class Codes: C10J 2300/0916 Biomass
• CPC Class Codes: C10J 2300/0943 Coke
• CPC Class Codes: C10J 2300/0986 Catalysts
• CPC Class Codes: C10J 3/482 Gasifiers with stationary fluidised bed
• CPC Class Codes: C10J 3/54 Gasification of granular or pulverulent fuels by the Winkler technique, i.e. by fluidisation
• CPC Class Codes: C10L 1/326 Coal-water suspensions
• CPC Class Codes: C10L 5/04 Raw material of mineral origin to be used; Pretreatment thereof pretreatment of fuels of non-mineral origin C10L5/40
• CPC Class Codes: C10L 5/44 on vegetable substances
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 20/145 the feedstock being materials of biological origin

Abstract

Particulate compositions are described comprising an intimate mixture of a coal and a gasification catalyst. The particulate compositions are gasified in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons. 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 comprising an intimate mixture, the intimate mixture comprising:

(a) a petroleum coke particulate;

(b) a coal particulate;

(c) a transition metal gasification catalyst;

(d) an alkaline earth metal source; and

(e) an alkali metal gasification catalyst,

wherein;

(i) the petroleum coke particulate and the coal particulate have a size distribution suitable for gasification in a fluidized bed zone;

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

95 to about 95;

5;

(iii) the transition gasification catalyst, the alkaline earth metal source, and alkali metal gasification catalyst are loaded onto the coal particulate, the petroleum coke particulate, or both;

(iv) in the presence of steam and under suitable temperature and pressure, the particulate composition exhibits gasification activity whereby a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia, and other higher hydrocarbons are formed;

(v) the transition metal gasification catalyst is present in an amount sufficient to provide, in the particulate composition, a ratio of transition metal atoms to carbon atoms ranging from about 0.001 to about 0.10;

(vi) the alkaline earth metal source is present in an amount sufficient to provide, in the particulate composition, from about 0.1 wt % to about 3.0 wt % alkaline earth metal atoms on a dry basis; and

(vii) the alkali metal gasification catalyst is present in an amount sufficient to provide, in the particulate composition, a ratio of alkali metal atoms to carbon atoms ranging from about 0.01 to about 0.08.

2. The particulate composition according to claim 1, wherein at least one of the transition gasification catalyst, the alkaline earth metal source, or the alkali metal gasification catalyst are loaded onto the coal particulate and the others are loaded onto the petroleum coke particulate.

3. The particulate composition according to claim 1, wherein the transition gasification catalyst, the alkaline earth metal source, and the alkali metal gasification catalyst are loaded onto the coal particulate.

4. The particulate composition according to claim 1, wherein the alkali metal gasification catalyst comprises a source of potassium and/or sodium;

the alkaline earth metal source comprises a source of calcium, magnesium and/or barium; and

the transition metal gasification catalyst comprises Fe, Mn or mixtures thereof.

5. 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 gasification reactor;

(b) reacting the particulate composition in the gasification reactor in the presence of steam and under suitable temperature and pressure to form a plurality of gaseous products including methane and at least 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.

11. The process according to claim 6, wherein the particulate composition is as set forth in claim 1.

6. A process for preparing a particulate composition, the process comprising the steps of:

(a) providing a petroleum coke particulate;

(b) providing a first coal feedstock, a second coal feedstock and, optionally, a third coal feedstock, each in particulate form;

(c) contacting one of the petroleum coke particulate, the first coal feedstock, the second coal feedstock or the third coal feedstock, with a first aqueous solution comprising a transition metal gasification catalyst to form a first slurry;

(d) contacting one of petroleum coke particulate, the first coal feedstock, the second coal feedstock or the third coal feedstock, other than the one used for step (c), with a second aqueous solution comprising an alkaline earth metal source to form a second slurry;

(e) contacting one of the petroleum coke feedstock, the first coal feedstock, the second coal feedstock or the third coal feedstock, other than ones used for steps (c) and (d), with a third aqueous solution comprising an alkali metal gasification catalyst to form a third slurry; and

(f) dewatering the first slurry, the second slurry, and the third slurry to form a first wet cake, a second wet cake, and a third wet cake, respectively;

wherein the process comprises the further steps of (1) or (2);

(1) (g1) thermally treating the first wet cake, the second wet cake, and the third wet cake with a dry inert gas to provide a first particulate, a second particulate, and a third particulate; and

(h1) mixing at least a portion of each of the first particulate, the second particulate, and the third particulate to form a particulate composition,

wherein, in (1), if the petroleum coke particulate is not used in step (c), (d) or (e), the third coal feedstock is provided and is used in one of steps (c), (d) or (e), and the petroleum coke particulate is mixed with at least a portion of each of the first particulate, second particulate and third particulate to form a particulate composition;

or

(2) (g2) combining at least a portion of each of the first wet cake, the second wet cake, and the third wet cake to form a final wet cake; and

(h2) optionally thermally treating the final wet cake with a dry inert gas as needed to form a particulate composition,

wherein, in (2), if the petroleum coke particulate is not used in step (c), (d) or (e), the third coal feedstock is provided and is used in one of steps (c), (d) or (e); and

(i) the petroleum coke particulate is mixed with at least a portion of each of the first wet cake, the second wet cake and the third wet cake to form the final wet cake, which is optionally thermally treated with a dry inert gas as needed to form a particulate composition;

(ii) the petroleum coke particulate is mixed with at least a portion of the final wet cake, which is optionally thermally treated with a dry inert gas as needed to form a particulate composition;

or (iii) the petroleum coke particulate is mixed with at least a portion of the particulate composition from step (h2).

7. The process according to claim 6, wherein the process comprises the steps of:

(a) providing a petroleum coke particulate;

(b) providing a first coal feedstock, a second coal feedstock, and a third coal feedstock, all in particulate form;

(c) contacting the first coal feedstock with a first aqueous solution comprising a transition metal gasification catalyst to form a first slurry;

(d) contacting the second coal feedstock with a second aqueous solution comprising an alkaline earth metal source to form a second slurry;

(e) contacting the third coal feedstock with a third aqueous solution comprising an alkali metal gasification catalyst to form a third slurry;

(f) dewatering the first slurry, the second slurry, and the third slurry to form a first wet cake, a second wet cake, and a third wet cake, respectively;

(g) thermally treating the first wet cake, the second wet cake, and the third wet cake with a dry inert gas to provide a first particulate, a second particulate, and a third particulate; and

(h) mixing the petroleum coke particulate with at least a portion of the first particulate, at least a portion of the second particulate, and at least a portion of the third particulate to form a particulate composition.

8. The process of claim 6, wherein the process comprises the steps of:

(a) providing a petroleum coke particulate;

(b) providing a first coal feedstock and a second coal feedstock, both in particulate form;

(c) contacting one of the petroleum coke particulate, first coal feedstock or second coal feedstock with a first aqueous solution comprising a transition metal gasification catalyst to form a first slurry;

(d) contacting one of petroleum coke particulate, the first coal feedstock or the second coal feedstock, other than the one used for step (c), with a second aqueous solution comprising an alkaline earth metal source to form a second slurry;

(e) contacting one of the petroleum coke feedstock, the first coal feedstock or the second coal feedstock, other than ones used for steps (c) and (d), with a third aqueous solution comprising an alkali metal gasification catalyst to form a third slurry;

(f) dewatering the first slurry, the second slurry, and the third slurry to form a first wet cake, a second wet cake, and a third wet cake, respectively;

(g) thermally treating the first wet cake, the second wet cake, and the third wet cake with a dry inert gas to provide a first particulate, a second particulate, and a third particulate; and

(h) mixing at least a portion of the first particulate, at least a portion of the second particulate, and at least a portion of the third particulate to form a particulate composition.

9. The process according to claim 6, wherein the process comprises the steps of:

(a) providing a petroleum coke particulate;

(b) providing a first coal feedstock, a second coal feedstock, and a third coal feedstock, all in particulate form;

(c) contacting the first coal feedstock with a first aqueous solution comprising a transition metal gasification catalyst to form a first slurry;

(d) contacting the second coal feedstock with a second aqueous solution comprising an alkaline earth metal source to form a second slurry;

(e) contacting the third coal feedstock with a third aqueous solution comprising an alkali metal gasification catalyst to form a third slurry;

(f) dewatering the first slurry, the second slurry, and the third slurry to form a first wet cake, a second wet cake, and a third wet cake, respectively;

(g) combining at least a portion of the first wet cake, at least a portion of the second wet cake, and at least a portion of the third wet cake to form a final wet cake; and

(h) mixing the petroleum coke particulate with at least a portion of the final wet cake to provide a particulate composition.

10. The process according to claim 6, wherein the process comprises the steps of:

(a) providing a petroleum coke particulate;

(b) providing a first coal feedstock and a second coal feedstock, both in particulate form;

(c) contacting one of the petroleum coke particulate, first coal feedstock or second coal feedstock with a first aqueous solution comprising a transition metal gasification catalyst to form a first slurry;

(d) contacting one of petroleum coke particulate, the first coal feedstock or the second coal feedstock, other than the one used for step (c), with a second aqueous solution comprising an alkaline earth metal source to form a second slurry;

(e) contacting one of the petroleum coke feedstock, the first coal feedstock or the second coal feedstock, other than ones used for steps (c) and (d), with a third aqueous solution comprising an alkali metal gasification catalyst to form a third slurry;

(f) dewatering the first slurry, the second slurry, and the third slurry to form a first wet cake, a second wet cake, and a third wet cake, respectively;

(g) combining at least a portion of the first wet cake, at least a portion of the second wet cake, and at least a portion of the third wet cake to form a final wet cake; and

(h) thermally treating the final wet cake with a dry inert gas to form a particulate composition.

12. The process according to claim 6, wherein the alkali metal gasification catalyst comprises a source of potassium and/or sodium;

the alkaline earth metal source comprises a source of calcium, magnesium and/or barium; and

the transition metal gasification catalyst comprises Fe, Mn or mixtures thereof.