Carbonaceous fines recycle
First Claim
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1. A particulate composition having a particle distribution size suitable for gasification in a fluidized bed zone, the particulate composition comprising an intimate mixture of:
- (a) a carbonaceous fines material having an average particle size of less than about 45 microns;
(b) a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; and
(c) a gasification catalyst which, in the presence of steam and under suitable temperature and pressure, exhibits gasification activity such that a plurality of gases comprising methane and one or more gases selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons are formed from the particulate composition,wherein;
(1) the carbonaceous fines material and particulate carbonaceous feedstock are present in the particulate composition at a weight ratio of from about 1;
99 to about 99;
1;
(2) the carbonaceous fines material is physically associated with the particulate carbonaceous feedstock;
(3) the carbonaceous fines material and the particulate carbonaceous feedstock each comprise a gasification catalyst;
(4) the gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the particulate composition, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08; and
(5) the particulate composition has a particle size ranging from about 10 microns to about 2500 microns.
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Abstract
Processes are provided for capturing and recycling carbonaceous fines generated during a gasification process. In particular, the recycled fines are processed into a particulate composition which is useable as a carbonaceous feedstock and is conversion into a gas stream comprising methane.
346 Citations
11 Claims
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1. A particulate composition having a particle distribution size suitable for gasification in a fluidized bed zone, the particulate composition comprising an intimate mixture of:
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(a) a carbonaceous fines material having an average particle size of less than about 45 microns; (b) a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; and (c) a gasification catalyst which, in the presence of steam and under suitable temperature and pressure, exhibits gasification activity such that a plurality of gases comprising methane and one or more gases selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons are formed from the particulate composition, wherein; (1) the carbonaceous fines material and particulate carbonaceous feedstock are present in the particulate composition at a weight ratio of from about 1;
99 to about 99;
1;(2) the carbonaceous fines material is physically associated with the particulate carbonaceous feedstock; (3) the carbonaceous fines material and the particulate carbonaceous feedstock each comprise a gasification catalyst; (4) the gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the particulate composition, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08; and (5) the particulate composition has a particle size ranging from about 10 microns to about 2500 microns. - View Dependent Claims (2, 3, 4, 8, 9, 10, 11)
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5. A process for preparing a particulate composition having a particle distribution size suitable for gasification in a fluidized bed zone, the process comprising the steps of:
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(a) providing a particulate carbonaceous fines material having an average particle size of less than about 45 microns and comprising a gasification catalyst; (b) providing a particulate carbonaceous feedstock material having a particle distribution size suitable for gasification in a fluidized bed zone; (c) contacting the particulate carbonaceous feedstock material with an aqueous medium comprising a gasification catalyst to form a slurry; (d) dewatering the slurry to form a wet cake; (e) mixing the particulate carbonaceous fines material with the wet cake to form a wet particulate composition; and (f) thermally treating the wet particulate composition to form a particulate composition, wherein the gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the particulate composition, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08, and wherein the particulate composition has a particle size ranging from about 10 microns to about 2500 microns. - View Dependent Claims (6, 7)
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Specification