×

Processes for Preparing a Catalyzed Coal Particulate

  • US 20100168494A1
  • Filed: 12/29/2009
  • Published: 07/01/2010
  • Est. Priority Date: 12/30/2008
  • Status: Active Grant
First Claim
Patent Images

1. A process for preparing a substantially free-flowing alkali metal gasification catalyst-loaded coal particulate from a coal feedstock, the process comprising the steps of:

  • (A) providing a coal feedstock having an initial moisture content and an initial concentration of acidic functional groups;

    (B) grinding the coal feedstock;

    (C) classifying the coal feedstock from step (B) to a specified particle size profile to produce a coal particulate having a matrix, and comprising a second concentration of acidic functional groups;

    (D) contacting the coal particulate with an amount of an aqueous solution comprising a concentration of an alkali metal gasification catalyst, to form an alkali metal gasification catalyst-loaded coal particulate wet cake having a specified ratio of alkali metal atoms to carbon atoms and a second moisture content; and

    (E) thermally treating the alkali metal gasification catalyst-loaded coal particulate wet cake as required to reduce the second moisture content to produce the alkali metal gasification catalyst-loaded coal particulate as a substantially free-flowing particulate,wherein;

    (a) the second concentration of acidic functional groups is at least about 50% of the initial concentration;

    (b) the specified particle size profile has a d5 particle size of at least about 20 microns, a d95 particle size of about 1000 microns or less, and a d50 particle size ranging from about 75 to about 350 microns;

    (c) the specified ratio of alkali metal atoms to carbon atoms of step (D) is sufficient to provide an alkali metal atoms to carbon atoms ratio in the substantially free-flowing alkali metal gasification catalyst-loaded coal particulate of from about 0.01 to about 0.10;

    (d) the alkali metal gasification catalyst-loaded coal particulate wet cake from step (D) is substantially non-draining;

    (e) the amount of aqueous solution and the concentration of the alkali metal gasification catalyst in step (D) are sufficient to provide the specified ratio of alkali metal atoms to carbon atoms in the alkali metal gasification catalyst-loaded coal particulate wet cake;

    (f) the contacting in step (D) takes place at substantially atmospheric pressure, and at an elevated temperature substantially at or below the boiling point of the aqueous solution, under agitation and for a specified amount of time, each which is in an amount sufficient in combination to allow substantially even distribution of the alkali metal gasification catalyst within the non-draining alkali metal gasification catalyst-loaded coal particulate wet cake;

    (g) the non-draining alkali metal gasification catalyst loaded carbonaceous particulate wet cake exits step (D) at a first temperature, and is passed into the thermal treating step (E) at substantially the same temperature; and

    (h) the substantially free-flowing alkali metal gasification catalyst-loaded coal particulate comprises a content of alkali metal atoms, wherein greater than about 50% of the content of alkali metal atoms are associated with the coal particulate matrix by ion exchange on acidic functional groups.

View all claims
  • 2 Assignments
Timeline View
Assignment View
    ×
    ×