Method and system for oxidizing hydrogen- and carbon-containing feed in a molten bath of immiscible metals

• US 5,298,233 A
• Filed: 10/16/1992
• Issued: 03/29/1994
• Est. Priority Date: 07/24/1990
• Status: Expired due to Fees

• Current Assignee: Quantum Catalytics LLC
• Original Assignee: Molten Metal Technology Incorporated
• Inventors: Nagel, Christopher J.
• Primary Examiner(s): LANGEL, WAYNE A
• Application Number:
  US07/963,306
• Time in Patent Office: 529 Days
• Field of Search: 423/DIG. 12, 423/648.1, 423/580, 423/580.1, 588/201, 422/129, 422/189
• US Class Current: 423/580.1
• CPC Class Codes: A62D 2101/04 Pesticides, e.g. insecticides, herbicides, fungicides or nematocides
• CPC Class Codes: A62D 2101/06 Explosives, propellants or pyrotechnics, e.g. rocket fuel or napalm
• CPC Class Codes: A62D 2101/20 Organic substances
• CPC Class Codes: A62D 2101/22 containing halogen
• CPC Class Codes: A62D 2101/40 Inorganic substances
• CPC Class Codes: A62D 3/32 by treatment in molten chemical reagent, e.g. salts or metals
• CPC Class Codes: C10J 2300/0946 Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
• CPC Class Codes: C10J 2300/1269 by radiating device, e.g. radiant tubes
• CPC Class Codes: C10J 3/57 Gasification using molten salts or metals C10J3/02, C10J3/46 take precedence
• CPC Class Codes: F23G 5/085 High-temperature heating means, e.g. plasma, for partly melting the waste
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts
• CPC Class Codes: Y10S 423/12 Molten media

Abstract

A method and a system for catalytically converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolved hydrogen and for oxidizing the dissolved hydrogen to water is disclosed. Hydrogen- and carbon-containing feed, such as municipal garbage, low grade fuel oil and organic or inorganic sludge, is introduced to a molten bath system. The molten bath system includes first and second immiscible molten metal phases. Carbon and hydrogen component in the feed are converted to dissolved carbon and dissolved hydrogen, respectively. The dissolved carbon is oxidized in the first molten metal phase to carbon monoxide, which then migrates out of the first molten metal phase. As dissolved hydrogen accumulates in the first molten metal phase, it nucleates and migrates to the second molten metal phase, where it is oxidized and forms water vapor.

Claims

1. A method for converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolved hydrogen and for oxidizing the dissolved hydrogen to form water, comprising the steps of:

a) introducing the feed to a molten bath system having,

1) a first molten metal phase for converting hydrogen and carbon components in the feed to dissolved hydrogen and dissolved carbon, said first molten metal phase comprising a first metal having a free energy of oxidation, at the molten bath system conditions, which is less than that of the oxidation of hydrogen to form water and greater than that of the oxidation of carbon to form a carbon oxide, and

2) a second molten metal phase for oxidizing the dissolved hydrogen formed in the first molten metal phase to form water, the second molten metal phase being substantially immiscible in the first molten metal phase and in contact with the first molten metal phase, the second molten metal phase being distributed, relative to the first molten metal phase, to cause a substantial portion of the dissolved hydrogen formed in the first molten metal phase to migrate to the second molten metal phase, said second molten metal phase comprising a second metal having a free energy of oxidation, at the molten bath system conditions, which is greater than that of the oxidation of hydrogen to form water, and in which the solubility of carbon is lower than in the first molten metal phase,

wherein the first molten metal phase causes a greater amount of the carbon component in the feed to be converted to dissolved carbon in the molten bath system than in a molten bath of about equal volume to that of the molten bath system, but which includes only the second molten metal phase, said conversion of the carbon in the first molten metal phase increasing the rate of conversion of hydrogen in the molten bath system to dissolved hydrogen; and

b) introducing an oxidant to the first molten metal phase and the second molten metal phase of the molten bath system at a rate which is sufficient to cause the dissolved carbon in the first molten metal phase to be oxidized to form a carbon oxide gas, whereby at least a substantial portion of the carbon component in subsequent feed converts to dissolved carbon in the first molten metal phase, and which rate is also sufficient to cause dissolved hydrogen in the second molten metal phase to oxidize and form water, whereby dissolved hydrogen in the first molten metal phase will migrate to the second molten metal phase for subsequent oxidation, thereby converting hydrogen in the hydrogen- and carbon-containing feed to dissolved hydrogen and oxidizing the dissolved hydrogen to form water.

2. The method of claim 1 wherein the molten bath system further includes a vitreous layer.

3. The method of claim 2 wherein the solubility of hydrogen in the vitreous layer is less than that of the first molten metal phase.

4. The method of claim 3 wherein the vitreous layer has a lower thermal conductivity than that of the first molten metal phase and the second molten metal phase.

5. The method of claim 4 wherein the hydrogen- and carbon-containing feed is exposed in the molten bath system to conditions sufficient to cause catalytic extraction of substantially all soluble reducible atomic constituents from the feed, whereby the atomic constituents are converted to dissolved species in the molten bath system.

6. The method of claim 5 wherein the feed is exposed in the molten bath system to at least a portion of the dissolved species, whereby the atomic constituents of subsequent hydrogen- and carbon-containing feed are at least partially extracted from the feed and are thereby converted to additional dissolved species.

7. The method of claim 6 wherein the dissolved species formed by extraction of atomic constituents from the feed include carbon.

8. The method of claim 7 wherein the dissolved species formed by extraction of atomic constituents from the feed further include dissolved halide species.

9. The method of claim 8 wherein the water formed by oxidation of dissolved hydrogen in the molten bath system generates sufficient heat to cause exposure of the feed in the first molten metal phase and the second molten metal phase to convert the feed to dissolved species, including dissolved hydrogen.

10. The method of claim 9 further including the steps of introducing an oxidant above the vitreous layer in an amount sufficient to substantially oxidize nucleated species leaving the molten bath system and to form a gas layer above the vitreous layer.

11. The method of claim 10 wherein the molten bath system is disposed in a vessel and wherein the feed is introduced to the molten bath system at the vitreous layer.

12. The method of claim 9 wherein an oxidant is introduced to the molten bath system through a bottom portion of the vessel.

13. The method of claim 12 wherein the first molten metal phase forms a first layer and wherein the second molten metal phase forms a second layer disposed adjacent to the first layer and above the first layer.

14. The method of claim 13 wherein the oxidant is introduced to the system through the bottom portion of the vessel is directed into the first molten metal phase.

15. The method of claim 12 wherein the second molten metal phase forms a continuous phase and wherein the first molten metal phase is dispersed within the second molten metal phase.

16. The method of claim 15 wherein the first metal is iron.

17. A method for catalytically converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolve hydrogen and for oxidizing the dissolved hydrogen to form water, comprising the steps of:

a) introducing the feed to a molten bath system having,

1) a first molten metal phase for catalytically converting hydrogen and carbon components in the feed to dissolved hydrogen and dissolved carbon, said first molten metal phase comprising a first metal having a free energy of oxidation, at the molten bath system conditions, which is less than that of the oxidation of hydrogen to form water and greater than that of the oxidation of carbon to form a carbon oxide, and

2) a second molten metal phase for oxidizing the dissolved hydrogen formed in the first molten metal phase to form water, the second molten metal phase being substantially immiscible in the first molten metal phase and in contact with the first molten metal phase, the second molten metal phase being distributed, relative to the first molten metal phase, to cause a substantial portion of the dissolved hydrogen formed in the first molten metal phase to migrate to the second molten metal phase, said second molten metal phase comprising a second metal having a free energy of oxidation, at the molten bath system conditions, which is greater than that of the oxidation of hydrogen to form water, and in which the solubility of carbon is lower than in the first molten metal phase,

whereby the first molten metal phase causes a greater amount of the carbon component in the feed to be catalytically converted to dissolved carbon in the molten bath system than in a molten bath of about equal volume to that of the molten bath system, but which includes only the second molten metal phase, said catalytic conversion of the carbon in the first molten metal phase increasing the rate of catalytic conversion of hydrogen component of the feed in the molten bath system to dissolved hydrogen; and

b) introducing an oxidant to the first molten metal phase and the second molten metal phase of the molten bath system at a rate which is sufficient to cause the carbon in the first molten metal phase to be oxidized to form a carbon oxide gas, whereby at least a substantial portion of the carbon component in subsequent feed is catalytically converted to dissolved carbon in the first molten metal phase, and which rate is also sufficient to cause hydrogen in the second molten metal phase to oxidize and form water, whereby dissolved hydrogen in the first molten metal phase will migrate to the second molten metal phase for subsequent oxidation, thereby catalytically converting the hydrogen component in the hydrogen- and carbon-containing feed to dissolved hydrogen and oxidizing the dissolved hydrogen to form water.

18. In a method for converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolved hydrogen, wherein the feed and an oxidant are introduced to a molten bath, and wherein the feed is exposed in the molten bath to conditions sufficient to cause the molten bath to convert the hydrogen component to dissolved hydrogen:

The improvement comprising introducing the feed into a molten bath system having a first molten metal phase for converting the hydrogen and carbon components in the feed to dissolved hydrogen and dissolved carbon, said first molten metal phase comprising a first metal having a free energy of oxidation, at the molten bath system conditions, which is less than that of the oxidation of hydrogen to form water and greater than that of oxidation of carbon to form a carbon oxide, and a second molten metal phase for oxidizing the dissolved hydrogen formed in the first molten metal phase to form water, the second molten metal phase being substantially immiscible in the first molten metal phase and in contact with the first molten metal phase, the second molten metal phase being distributed, relative to the first molten metal phase, to cause a substantial portion of the hydrogen dissolved in the first molten metal phase to migrate to the second molten metal phase, said second molten metal phase comprising a second metal having a free energy of oxidation, at the molten bath system conditions, which is greater than that of the oxidation of hydrogen to form water, and in which the solubility of carbon is lower than in the first molten metal phase, whereby the first molten metal phase causes a greater amount of the carbon component in the feed to be converted to dissolved carbon in the molten bath system than in a molten bath of about equal volume to that of the molten bath system, but which includes only the second molten metal phase, said conversion of the carbon in the first molten metal phase increasing the rate of conversion of the hydrogen component in the feed to dissolved hydrogen, and introducing an oxidant to the first molten metal phase and the second molten metal phase of the molten bath system at a rate which is sufficient to cause the dissolved carbon in the first molten metal phase to be oxidized to form a carbon oxide gas, whereby at least a substantial portion of the carbon component in subsequent feed converts to dissolved carbon in the first molten metal phase, and which rate is also sufficient to cause hydrogen in the second molten metal phase to oxidize and form water, whereby dissolved hydrogen in the first molten metal phase will migrate to the second molten metal phase for subsequent oxidation, thereby converting the hydrogen component in the hydrogen- and carbon-containing feed to dissolved hydrogen and oxidizing the dissolved hydrogen to form water.

19. An apparatus for converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolved hydrogen and for oxidizing the dissolved hydrogen to form water, comprising:

a) a vessel;

b) a molten bath system disposed in the vessel having,

1) a first molten metal phase for converting hydrogen and carbon components in the feed to dissolved hydrogen and dissolved carbon, said first molten metal phase comprising a first metal having a free energy of oxidation, at the molten bath system conditions, which is less than that of the oxidation of hydrogen to form water and greater than that of oxidation of carbon to form a carbon oxide, and

2) a second molten metal phase for oxidizing the dissolved hydrogen formed in the first molten metal phase to form water, the second molten metal phase being substantially immiscible in the first molten metal phase and in contact with the first molten metal phase, the second molten metal phase being distributed, relative to the first molten metal phase, to cause a substantial portion of the dissolved hydrogen formed in the first molten metal phase to migrate to the second molten metal phase, said second molten metal phase comprising a second metal having a free energy of oxidation, at the molten bath system conditions, greater than that of the oxidation of hydrogen to form water, and in which the solubility of carbon is lower than in the first molten metal phase,

whereby the first molten metal phase causes a greater amount of the carbon component in the feed to be converted to dissolved carbon in the molten bath system than in a molten bath of about equal volume to that of the molten bath system, but which includes only the second molten metal phase, said conversion of the carbon in the first molten metal phase increasing the rate of conversion of hydrogen in the molten bath system to dissolved hydrogen; and

c) means for introducing an oxidant to the first molten metal phase and the second molten metal phase of the molten bath system at a rate which is sufficient to cause the carbon in the first molten metal phase to be oxidized to form a carbon oxide gas, whereby at least a substantial portion of the carbon component in subsequent feed converts to dissolved carbon in the first molten metal phase, and which rate is also sufficient to cause hydrogen in the second molten metal phase to oxidize and form water, whereby hydrogen in the first molten metal phase will migrate to the second molten metal phase for subsequent oxidation, thereby converting the hydrogen component in the hydrogen- and carbon-containing feed to dissolved hydrogen and oxidizing the hydrogen to form water; and

d) means for removing water formed in the molten bath system from the vessel.

20. An apparatus for catalytically converting a hydrogen component in a hydrogen- and carbon-containing feed to dissolved hydrogen and for oxidizing the dissolved hydrogen to form water, comprising:

a) a vessel;

b) a molten bath system disposed in the vessel having,

1) a first molten metal phase for catalytically converting hydrogen and carbon in the feed to dissolved hydrogen and dissolved carbon, said first molten metal phase comprising a first metal having a free energy of oxidation, at the molten bath system conditions, which is less than that of the oxidation of hydrogen to form water and greater than that of oxidation of carbon to form a carbon oxide, and

2) a second molten metal phase for oxidizing the hydrogen in the first molten metal phase to form water, the second molten metal phase being substantially immiscible in the first molten metal phase and in contact with the first molten metal phase, the second molten metal phase being distributed, relative to the first molten metal phase, to cause a substantial portion of the dissolved hydrogen formed in the first molten metal phase to migrate to the second molten metal phase, said second molten metal phase comprising a second metal having a free energy of oxidation, at the molten bath system conditions, greater than that of the oxidation of hydrogen to form water, and in which the solubility of carbon is lower than in the first molten metal phase. whereby the first molten metal phase causes a greater amount of the carbon component in the feed to be catalytically converted to dissolved carbon in the molten bath system than in a molten bath of about equal volume to that of the molten bath system, but which includes only the second molten metal phase, said catalytic conversion of the carbon component of feed in the first molten metal phase increasing the rate of conversion of hydrogen component of feed in the molten bath system to dissolved hydrogen; and

means for introducing an oxidant to the first molten metal phase and the second molten metal phase of the molten bath system at a rate which is sufficient to cause the carbon in the first molten metal phase to be oxidized to form a carbon oxide gas, whereby at least a substantial portion of the carbon component of subsequent feed is catalytically converted to dissolved carbon in the first molten metal phase, and which rate is also sufficient to cause hydrogen in the second molten metal phase to oxidize and form water, whereby dissolved hydrogen in the first molten metal phase will migrate to the second molten metal phase for subsequent oxidation, thereby catalytically converting the hydrogen component in the hydrogen- and carbon-containing feed to dissolved hydrogen and oxidizing the dissolved hydrogen to form water; and

d) means for removing water formed in the molten bath system from the vessel.