Carbonaceous Fines Recycle
First Claim
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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 carbonaceous fines material having an average particle size of less than about 45 microns;
(b) a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; 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 from the particulate composition,wherein;
(1) the carbonaceous fines material and particulate carbonaceous feedstock are present in the particulate composition at a weight ratio of from about 1;
99 to about 99;
1;
(2) the carbonaceous fines material is physically associated with the particulate carbonaceous feedstock;
(3) the carbonaceous fines material and the particulate carbonaceous feedstock each comprise a gasification catalyst; and
(4) 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.
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Abstract
Processes are provided for capturing and recycling carbonaceous fines generated during a gasification process. In particular, the recycled fines are processed into a particulate composition which is useable as a carbonaceous feedstock and is conversion into a gas stream comprising methane.
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Citations
11 Claims
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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:
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(a) a carbonaceous fines material having an average particle size of less than about 45 microns; (b) a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; 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 from the particulate composition, wherein; (1) the carbonaceous fines material and particulate carbonaceous feedstock are present in the particulate composition at a weight ratio of from about 1;
99 to about 99;
1;(2) the carbonaceous fines material is physically associated with the particulate carbonaceous feedstock; (3) the carbonaceous fines material and the particulate carbonaceous feedstock each comprise a gasification catalyst; and (4) 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. - View Dependent Claims (2, 3, 4, 5, 9, 10, 11)
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6. A process for preparing a particulate composition having a particle distribution size suitable for gasification in a fluidized bed zone, the process comprising the steps of:
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(a) providing a particulate carbonaceous fines material having an average particle size of less than about 45 microns and comprising a gasification catalyst; (b) providing a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; (c) contacting the particulate carbonaceous feedstock material with an aqueous medium comprising a gasification catalyst to form a slurry; (d) dewatering the slurry to form a wet cake; (e) mixing the particulate carbonaceous fines material with the wet cake to form a wet particulate composition; and (f) thermally treating the wet particulate composition to form a particulate composition, wherein 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. - View Dependent Claims (7, 8)
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Specification