Method and composition for decreasing emissions of sulfur oxides and nitrogen oxides

• US 4,824,441 A
• Filed: 11/30/1987
• Issued: 04/25/1989
• Est. Priority Date: 11/30/1987
• Status: Expired due to Fees

• Current Assignee: General Research Corporation
• Original Assignee: General Research Corporation
• Inventors: Kindig, James K.
• Primary Examiner(s): DEES, CARL
• Application Number:
  US07/126,409
• Time in Patent Office: 512 Days
• Field of Search: 44/1 R, 44/1 SR, 44/26, 44/603, 44/641, 44/604, 44/905, 110/344, 110/347, 431/4
• US Class Current: 44/604
• CPC Class Codes: C10L 9/10 by using additives
• CPC Class Codes: F23K 1/00 Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
• CPC Class Codes: F23K 2201/505 with additives

Abstract

A method and composition are provided for decreasing emissions of sulfur oxides and nitrogen oxides upon combustion of carbonaceous fuel material. In particular, the composition comprises a refined coal, having low ash-forming material and inorganic sulfur content, a sulfur sorbent, a sulfation promoter, and a catalyst for the reaction of sulfur dioxide to sulfur trioxide. Reduced emissions of sulfur oxides are achieved by combusting the composition in an oxygen restricted burner to lessen the effect of sorbent sintering while obtaining other advantages associated with mixing a sulfur sorbent with the carbonaceous material prior to combustion. Nitrogen oxides emissions are reduced by use of an oxygen restricted burner which lowers the flame temperature. Nitrogen oxides emissions are also reduced by lower flame temperatures resulting from endothermic reactions which are undergone by the sulfur sorbent and promoter.

Claims

1. A carbonaceous fuel composition, said composition capable of providing reduced emissions of sulfur oxides and nitrogen oxides upon combustion, said composition comprising:

(a) at least about sixty percent by weight refined particulate coal;

(b) a sulfur sorbent which comprises a calcium and a magnesium component, said sulfur sorbent being present in an amount effective to reduce sulfur oxides emissions upon combustion of said fuel composition;

(c) a sulfation promoter in an amount effective to increase reduction of sulfur oxides emissions by said sulfur sorbent; and

(d) a catalyst for converting sulfur dioxide to sulfur trioxide, said catalyst being present in an amount effective to increase sulfur oxides reduction by said magnesium component of said sorbent.

2. A fuel composition as claimed in claim 1, wherein said pyritic sulfur content of said refined coal is less than about one percent by weight of said refined coal.

3. A fuel composition as claimed in claim 1, wherein an ash content of said refined coal is less than about five percent by weight of said refined coal.

4. A fuel composition as claimed in claim 1, wherein said sorbent is present in an amount sufficient to provide a calcium to total sulfur content molar ratio of at least about 1.

5. A fuel composition, as claimed in claim 1, wherein said sulfur sorbent comprises material selected from the group consisting of lime, limestone, hydrated lime, dolomite, burnt dolomite, pressure hydrated burnt dolomite, and mixtures thereof.

6. A fuel composition, as claimed in claim 1, wherein said sulfur sorbent comprises material selected from the group consisting of dolomite, burnt dolomite, pressure hydrated burnt dolomite, and mixtures thereof.

7. A fuel composition, as claimed in claim 1, wherein said sulfation promoter comprises material selected from the group consisting of Cr₂ O₃, Na₂ CO₃, NaHCO₃, K₂ CO₃, KHCO₃, Li₂ CO₃, Na₂ SO₄, MoO₃, V₂ O₅, TiO₂, Pt, P₂ O₅, NaCl and mixtures thereof.

8. A fuel composition, as claimed in claim 1, wherein said catalyst comprises material selected from the group consisting of platinum, nickel sulfate, cobalt sulfate, vanadium oxides, tungsten oxides, chromium oxides, molybdenum oxides, iron oxides, and mixtures thereof.

9. A fuel composition, as claimed in claim 1, wherein said promoter is present in amounts equal to at least about 1 percent by weight of said sulfur sorbent.

10. A fuel composition, as claimed in claim 1, said composition further comprising a binder and wherein said composition is agglomerated.

11. A fuel composition, as claimed in claim 10, in the form of a pellet.

12. A fuel composition, as claimed in claim 1, further comprising carbonaceous material selected from the group consisting of residual petroleum bottoms, oil, bitumen, kerogen, and mixtures thereof.

13. A fuel composition as claimed in claim 1, further comprising weatherproofing material.

14. A process for reducing emissions of sulfur oxides and nitrogen oxides from the combustion of coal, comprising:

(a) forming a fuel material comprising refined particulate coal;

a sulfur sorbent comprising calcium and magnesium, said sulfur sorbent present in an amount effective to reduce sulfur oxides emissions upon combustion of said fuel material;

a sulfation promoter being present in an amount effective to increase reductions of sulfur oxides emissions by said sulfur sorbent; and

a catalyst for converting sulfur dioxide to sulfur trioxide, said catalyst being present in an amount effective to increase sulfur oxides reduction by said magnesium component of said sorbent;

(b) providing an oxygen restricted combustion zone;

(c) introducing said fuel material into said combustion zone; and

(d) combusting said fuel material at a combustion temperature to produce combustion products.

15. A process, as claimed in claim 14, wherein said combustion temperature is less than about 2700°

F.

16. A process, as claimed in claim 14, further comprising confining said combustion products in an exhaust zone to allow for reaction of sulfur oxides with said sulfur sorbent until said combustion products cool to a temperature below about 700°

F.

17. A process, as claimed in claim 14, wherein said fuel material is agglomerated prior to introduction into said combustion zone.

18. A self-scrubbing carbonaceous fuel composition, said composition producing reduced emissions of sulfur oxides and nitrogen oxides on combustion, said composition comprising:

(a) at least about sixty percent by weight refined particulate coal having a pyritic sulfur content, wherein said pyritic sulfur content is less than about one percent by weight of said coal;

(b) a sulfur sorbent comprising a calcium and a magnesium component, wherein said calcium component includes material selected from the group consisting of lime, limestone, hydrated lime, dolomite, burnt dolomite, pressure hydrated burnt dolomite, and mixtures thereof, and wherein said sulfur sorbent is present in an amount sufficient to provide a calcium to total sulfur content molar ratio of at least about 1;

(c) a sulfation promoter present in amounts equal to at least about one percent by weight of said sulfur sorbent, wherein said sulfation promoter comprises material selected from the group consisting of Cr₂ O₃, Na₂ CO₃, NaHCO₃, K₂ CO₃, Li₂ CO₃, Na₂ SO₄, MoO₃, V₂ O₅, TiO₂, Pt, P₂ O₅, NaCl, KHCO₃, K₂ SO₄ and mixtures thereof; and

(d) a catalyst for converting sulfur dioxide to sulfur trioxide in an amount effective to increase sulfur oxides reduction by said magnesium component of said sorbent, wherein said catalyst comprises material selected from the group consisting of platinum, nickel sulfate, cobalt sulfate, vanadium oxides, tungsten oxides, chromium oxides, molybdenum oxides, iron oxides, and mixtures thereof.

19. A fuel composition, as claimed in claim 18, said composition further comprising a binder and wherein said composition is agglomerated.

20. A fuel composition, as claimed in claim 18, said composition further comprising carbonaceous material selected from the group consisting of residual petroleum bottoms, oil, bitumen, kerogen, and mixtures thereof.

21. A fuel composition, as claimed in claim 18, wherein an ash content of said refined coal is less than about five percent by weight of said refined coal.