Char Methanation Catalyst and its Use in Gasification Processes
First Claim
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1. A process for the production of a methane-enriched gas, comprising the steps of:
- (a) introducing a gaseous mixture comprising hydrogen and carbon monoxide into a reaction zone containing a carbon-alkali metal methanation catalyst,(b) reacting at least a portion of the hydrogen with at least a portion of the carbon monoxide in the reaction zone, under suitable temperature and pressure, in the presence of the carbon-alkali metal methanation catalyst, to produce a methane-enriched gaseous mixture, and(c) recovering a methane-enriched gas from the reaction zone,wherein the carbon-alkali metal methanation catalyst comprises a carbon char comprising a carbon content and an ash content, the carbon content being from about 25% to about 75% (by weight, dry basis), the carbon char further comprising;
(i) a total elemental oxide content of from about 65% to about 98% (based on the weight of the ash content, dry basis),(ii) a molar ratio of alkali metal to carbon (AIM/C) of from about 0.1 to about 0.6,(iii) a BET surface area of from about 10 to about 400 m2/g,(iv) an average particle size of from about 25 μ
m to about 2500 μ
m, and(v) an average particle density of from about 0.2 to about 1.75 g/cc.
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Abstract
The invention provides processes for generating a methane-enriched gas from a gas mixture comprising carbon monoxide and hydrogen such as gas streams generated by gasification of an alkali metal catalyst-loaded carbonaceous feedstock, and a char methanation catalyst useful in such processes.
188 Citations
16 Claims
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1. A process for the production of a methane-enriched gas, comprising the steps of:
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(a) introducing a gaseous mixture comprising hydrogen and carbon monoxide into a reaction zone containing a carbon-alkali metal methanation catalyst, (b) reacting at least a portion of the hydrogen with at least a portion of the carbon monoxide in the reaction zone, under suitable temperature and pressure, in the presence of the carbon-alkali metal methanation catalyst, to produce a methane-enriched gaseous mixture, and (c) recovering a methane-enriched gas from the reaction zone, wherein the carbon-alkali metal methanation catalyst comprises a carbon char comprising a carbon content and an ash content, the carbon content being from about 25% to about 75% (by weight, dry basis), the carbon char further comprising; (i) a total elemental oxide content of from about 65% to about 98% (based on the weight of the ash content, dry basis), (ii) a molar ratio of alkali metal to carbon (AIM/C) of from about 0.1 to about 0.6, (iii) a BET surface area of from about 10 to about 400 m2/g, (iv) an average particle size of from about 25 μ
m to about 2500 μ
m, and(v) an average particle density of from about 0.2 to about 1.75 g/cc. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A process for the production of a methane-enriched gaseous product, comprising the steps of:
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(a) gasifying a carbonaceous material in a gasifying reactor, in the presence of steam and an alkali metal gasification catalyst, to produce a gaseous product stream and an alkali metal-containing solid char product; (b) withdrawing the alkali metal-containing solid char product from the gasifying reactor; (c) introducing a gaseous mixture comprising hydrogen and carbon monoxide into a reaction zone containing at least a portion of the alkali metal-containing solid char product as a methanation catalyst, (d) reacting at least a portion of the hydrogen with at least a portion of the carbon monoxide in the reaction zone, under suitable temperature and pressure, in the presence of the alkali metal-containing solid char product to produce a methane-enriched gaseous product, and (e) recovering a methane-enriched gaseous product from the reaction zone. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16)
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Specification