Catalytic gasification process with recovery of alkali metal from char
First Claim
1. A process for extracting and recovering alkali metal from a char, the char comprising (i) one or more soluble alkali metal compounds and (ii) insoluble matter comprising one or more insoluble alkali metal compounds, the process comprising the steps of:
- (a) providing char at an elevated temperature ranging from 50°
C. to about 600°
C.;
(b) quenching the char in an aqueous medium to fracture the char and form a quenched char slurry;
(c) contacting the quenched char slurry with carbon dioxide under suitable pressure and temperature so as to convert at least a portion of the insoluble alkali metal compounds to one or more soluble alkali metal compounds, and produce a leached slurry comprising the soluble alkali metal compounds and residual insoluble matter;
(d) degassing the leached slurry under suitable pressure and temperature so as to remove a substantial portion of the excess carbon dioxide and hydrogen sulfide, if present, and produce a degassed leached slurry;
(e) separating the degassed leached slurry into a liquid stream and a residual insoluble matter stream, the liquid stream comprising a predominant portion of the soluble alkali metal compounds from the degassed leached slurry, and the residual insoluble matter stream comprising residual soluble alkali metal compounds and residual insoluble alkali metal compounds;
(f) recovering the liquid stream; and
(g) washing the extracted insoluble matter stream with an aqueous medium to produce a wash stream comprising substantially all of the residual soluble alkali metal compounds from the residual insoluble matter stream,wherein the quenching and contacting is performed in the substantial absence of gaseous oxygen.
2 Assignments
0 Petitions
Accused Products
Abstract
Processes are described for the extraction and recovery of alkali metal from the char that results from catalytic gasification of a carbonaceous material. Among other steps, the processes of the invention include a hydrothermal leaching step in which a slurry of insoluble particulate comprising insoluble alkali metal compounds is treated with carbon dioxide and steam at elevated temperatures and pressures to effect the conversion of insoluble alkali metal compounds to soluble alkali metal compounds. Further, processes are described for the catalytic gasification of a carbonaceous material where a substantial portion of alkali metal is extracted and recovered from the char that results from the catalytic gasification process.
-
Citations
21 Claims
-
1. A process for extracting and recovering alkali metal from a char, the char comprising (i) one or more soluble alkali metal compounds and (ii) insoluble matter comprising one or more insoluble alkali metal compounds, the process comprising the steps of:
-
(a) providing char at an elevated temperature ranging from 50°
C. to about 600°
C.;(b) quenching the char in an aqueous medium to fracture the char and form a quenched char slurry; (c) contacting the quenched char slurry with carbon dioxide under suitable pressure and temperature so as to convert at least a portion of the insoluble alkali metal compounds to one or more soluble alkali metal compounds, and produce a leached slurry comprising the soluble alkali metal compounds and residual insoluble matter; (d) degassing the leached slurry under suitable pressure and temperature so as to remove a substantial portion of the excess carbon dioxide and hydrogen sulfide, if present, and produce a degassed leached slurry; (e) separating the degassed leached slurry into a liquid stream and a residual insoluble matter stream, the liquid stream comprising a predominant portion of the soluble alkali metal compounds from the degassed leached slurry, and the residual insoluble matter stream comprising residual soluble alkali metal compounds and residual insoluble alkali metal compounds; (f) recovering the liquid stream; and (g) washing the extracted insoluble matter stream with an aqueous medium to produce a wash stream comprising substantially all of the residual soluble alkali metal compounds from the residual insoluble matter stream, wherein the quenching and contacting is performed in the substantial absence of gaseous oxygen. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
-
-
14. A process for catalytically converting a carbonaceous composition, in the presence of an alkali metal gasification catalyst, into a plurality of gaseous products, the process comprising the steps of:
-
(A) supplying a carbonaceous composition to a gasification reactor, the carbonaceous composition comprising an ash; (B) reacting the carbonaceous composition in the gasification reactor in the presence of steam and an alkali metal gasification catalyst under suitable temperature and pressure to form (i) a char comprising alkali metal from the alkali metal gasification catalyst in the form of one or more soluble alkali metal compounds and one or more insoluble alkali metal compounds, and (ii) a plurality of gaseous products comprising methane and one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia, and other higher hydrocarbons; (C) removing a portion of the char from the gasification reactor; (D) extracting and recovering a substantial portion of the alkali metal from the char; and (E) at least partially separating the plurality of gaseous products to produce a stream comprising a predominant amount of one of the gaseous products, wherein step (D) comprises the steps of; (a) providing the char at an elevated temperature ranging from 50°
C. to about 600°
C.;(b) quenching the char in an aqueous medium to fracture the char and form a quenched char slurry; (c) contacting the quenched char slurry with carbon dioxide under suitable pressure and temperature so as to convert at least a portion of the insoluble alkali metal compounds to one or more soluble alkali metal compounds, and produce a leached slurry comprising the soluble alkali metal compounds and residual insoluble matter; (d) degassing the leached slurry under suitable pressure and temperature so as to remove a substantial portion of the excess carbon dioxide and hydrogen sulfide, if present, and produce a degassed leached slurry; (e) separating the degassed leached slurry into a liquid stream and a residual insoluble matter stream, the liquid stream comprising a predominant portion of the soluble alkali metal compounds from the degassed leached slurry, and the residual insoluble matter stream comprising residual soluble alkali metal compounds and residual insoluble alkali metal compounds; (f) recovering the liquid stream; and (g) washing the extracted insoluble matter stream with an aqueous medium to produce a wash stream comprising substantially all of the residual soluble alkali metal compounds from the residual insoluble matter stream, wherein the quenching and contacting is performed in the substantial absence of gaseous oxygen. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21)
-
Specification